Critical DesignReviewSPECTRE

Solar-sail Pitch Enabling Controller Through Root Excitation

Michael Andrews Brendon Barela Austin Cerny Corinne Desroches Kyle Edson Conrad Gabel Chris Riesco Justin Yong

Intr

oduc

tion

2

Briefing Overview and Context

bull SPECTRE seeks to design and prototype a sail blade damping augmentation controller for flapping and twisting blade oscillations for a proposed heliogyro CubeSat mission

bull SPECTRE is a continuation of last yearrsquos GHOST senior design project which focused on sail blade deployment and a blade pitching controller

Customer

Dr Keats Wilkie

NASA Langley

Advisor

Dr Xinlin Li

LASP

Department of Aerospace Engineering Sciences CU

Content Breakdown

Introduction

Design Solutions

Verification and Validation

Project Risk

Project Planning

Intr

oduc

tion

3

Heliogyro Backgroundbull Propulsion system using solar radiation

pressure

bull Solar sail ldquobladesrdquo are held in place with centripetal forces

bull Spins similarly to a helicopter

bull Solar pressure instead of air

bull Proposed heliogyros have long blades (gt1 km) but no heliogyro mission has ever flown

bull NASA would like a CubeSat demonstrator

bull GHOST developed a deployment system

bull Pitching was not completed

bull SPECTRE demonstrates the ability to pitch the solar-sail blades and damp oscillations in the blades

Illustration of proposed heliogyro solar sail rendezvous with Halleyrsquos Comet (source NASAJPL)

GHOST 2 Blade CubeSat DesignDimensions 10cm x 20cm x 30cm Blade Dimensions 15cm x ~30m

Housing

Bus

Intr

oduc

tion

4

Solar Sail Blade MaterialProperties

bull Constructed from Aluminum coated Mylar total thickness of 264 m

bull Maximum areal density of 60 g allows for 23 g of support materialbull Blades are stiffened by edge loading the sail with Kapton tapebull Further stiffened by adding tip mass equal to 10 of the total blade mass

Thrust

bull Blades provide 4510-6 N of thrust per based on solar pressure at 1 AU

bull Solar sail will need to accelerate the spacecraft at least 01 mmto be usefulbull For a 6U cubesat weighing approximately 8 kg ~45 deployed area neededbull Two bladed CubeSat with 2U width needs ~350 m blade lengthbull Aspect Ratio of 23331

Tip Mass

KaptonTape

15 cm

Intr

oduc

tion

5

Orbital Operationsbull Blade can pitched in and out of solar

flux to modulate the moment for attitude control and the thrust for orbit control

bull To increasedecrease spacecraft orbit velocity blades must pitch over a 90 degree range

bull Two 90deg pitch maneuvers are performed during 1 LEO orbit to maximize a change in velocity

Blade dynamics need be sensed while in the Earthrsquos shadow

Sun

Blades pitched 90deg parallel to solar pressure

Earth

Blades pitched 90deg perpendicular to solar pressure

Blades hit by solar flux and generate thrust

orbital velocity increases

Blades parallel to solar flux orbital

velocity unchanged

119889119881

120596

120596

120596

120596

Intr

oduc

tion

6

Blade Oscillationsbull A major concern of heliogyro designs is blade oscillation

bull Pitching manuvers and moving blades in and out of solar flux induces twisting and flapping oscillationsbull First modes of these oscillations behave similarly to swinging pendulums

bull Mode shapes are known deflection measurements made at the root can be used to calculate tip deflections

Blade RootBlade Root

Blade TipBlade Tip

Housing

θflapNominalBlade

DeflectedBlade

Flapping

θtwist

Blade Root

Blade Tip

Twisting

>

>

Intr

oduc

tion

7

Mode FrequenciesEarth Behavior

bull Flapping Mode Frequenecy can be approximated as a pendulum

bull Period Depends on the bladersquos mass (M) moment of inertia (I) and center of gravity (R) measured from the blade root g remains constant for Earth testing

bull

bull The torsional mode is best estimated from the flapping mode

bull

Space Behaviorbull Frequencies directly tied to spacecraft angular

velocity

bull Angular velocities of proposed heliogyro missions typically ~13 RPM

120596

Based on the expected mode frequencies for space operations and the constraints of Heliogyro missions the controller is required to demonstrate a damping ratio of 00136

Intr

oduc

tion

8

Testing Constraintsbull Full scale blade cannot be built or tested

bull 22 meter blade analog will be used to simulate space environment

bull Controller can still be validated by showing it can function with blade conditions similar to those seen in space

bull Graviational forces will be present during testing

bull Centripetal force of the spinning spacecraft will be simulated with these gravitational forces

bull Air viscosity will contribute to damping

bull Damping provided by the controller will need to be distinguishable from damping provided by air

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

2

Briefing Overview and Context

bull SPECTRE seeks to design and prototype a sail blade damping augmentation controller for flapping and twisting blade oscillations for a proposed heliogyro CubeSat mission

bull SPECTRE is a continuation of last yearrsquos GHOST senior design project which focused on sail blade deployment and a blade pitching controller

Customer

Dr Keats Wilkie

NASA Langley

Advisor

Dr Xinlin Li

LASP

Department of Aerospace Engineering Sciences CU

Content Breakdown

Introduction

Design Solutions

Verification and Validation

Project Risk

Project Planning

Intr

oduc

tion

3

Heliogyro Backgroundbull Propulsion system using solar radiation

pressure

bull Solar sail ldquobladesrdquo are held in place with centripetal forces

bull Spins similarly to a helicopter

bull Solar pressure instead of air

bull Proposed heliogyros have long blades (gt1 km) but no heliogyro mission has ever flown

bull NASA would like a CubeSat demonstrator

bull GHOST developed a deployment system

bull Pitching was not completed

bull SPECTRE demonstrates the ability to pitch the solar-sail blades and damp oscillations in the blades

Illustration of proposed heliogyro solar sail rendezvous with Halleyrsquos Comet (source NASAJPL)

GHOST 2 Blade CubeSat DesignDimensions 10cm x 20cm x 30cm Blade Dimensions 15cm x ~30m

Housing

Bus

Intr

oduc

tion

4

Solar Sail Blade MaterialProperties

bull Constructed from Aluminum coated Mylar total thickness of 264 m

bull Maximum areal density of 60 g allows for 23 g of support materialbull Blades are stiffened by edge loading the sail with Kapton tapebull Further stiffened by adding tip mass equal to 10 of the total blade mass

Thrust

bull Blades provide 4510-6 N of thrust per based on solar pressure at 1 AU

bull Solar sail will need to accelerate the spacecraft at least 01 mmto be usefulbull For a 6U cubesat weighing approximately 8 kg ~45 deployed area neededbull Two bladed CubeSat with 2U width needs ~350 m blade lengthbull Aspect Ratio of 23331

Tip Mass

KaptonTape

15 cm

Intr

oduc

tion

5

Orbital Operationsbull Blade can pitched in and out of solar

flux to modulate the moment for attitude control and the thrust for orbit control

bull To increasedecrease spacecraft orbit velocity blades must pitch over a 90 degree range

bull Two 90deg pitch maneuvers are performed during 1 LEO orbit to maximize a change in velocity

Blade dynamics need be sensed while in the Earthrsquos shadow

Sun

Blades pitched 90deg parallel to solar pressure

Earth

Blades pitched 90deg perpendicular to solar pressure

Blades hit by solar flux and generate thrust

orbital velocity increases

Blades parallel to solar flux orbital

velocity unchanged

119889119881

120596

120596

120596

120596

Intr

oduc

tion

6

Blade Oscillationsbull A major concern of heliogyro designs is blade oscillation

bull Pitching manuvers and moving blades in and out of solar flux induces twisting and flapping oscillationsbull First modes of these oscillations behave similarly to swinging pendulums

bull Mode shapes are known deflection measurements made at the root can be used to calculate tip deflections

Blade RootBlade Root

Blade TipBlade Tip

Housing

θflapNominalBlade

DeflectedBlade

Flapping

θtwist

Blade Root

Blade Tip

Twisting

>

>

Intr

oduc

tion

7

Mode FrequenciesEarth Behavior

bull Flapping Mode Frequenecy can be approximated as a pendulum

bull Period Depends on the bladersquos mass (M) moment of inertia (I) and center of gravity (R) measured from the blade root g remains constant for Earth testing

bull

bull The torsional mode is best estimated from the flapping mode

bull

Space Behaviorbull Frequencies directly tied to spacecraft angular

velocity

bull Angular velocities of proposed heliogyro missions typically ~13 RPM

120596

Based on the expected mode frequencies for space operations and the constraints of Heliogyro missions the controller is required to demonstrate a damping ratio of 00136

Intr

oduc

tion

8

Testing Constraintsbull Full scale blade cannot be built or tested

bull 22 meter blade analog will be used to simulate space environment

bull Controller can still be validated by showing it can function with blade conditions similar to those seen in space

bull Graviational forces will be present during testing

bull Centripetal force of the spinning spacecraft will be simulated with these gravitational forces

bull Air viscosity will contribute to damping

bull Damping provided by the controller will need to be distinguishable from damping provided by air

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

3

Heliogyro Backgroundbull Propulsion system using solar radiation

pressure

bull Solar sail ldquobladesrdquo are held in place with centripetal forces

bull Spins similarly to a helicopter

bull Solar pressure instead of air

bull Proposed heliogyros have long blades (gt1 km) but no heliogyro mission has ever flown

bull NASA would like a CubeSat demonstrator

bull GHOST developed a deployment system

bull Pitching was not completed

bull SPECTRE demonstrates the ability to pitch the solar-sail blades and damp oscillations in the blades

Illustration of proposed heliogyro solar sail rendezvous with Halleyrsquos Comet (source NASAJPL)

GHOST 2 Blade CubeSat DesignDimensions 10cm x 20cm x 30cm Blade Dimensions 15cm x ~30m

Housing

Bus

Intr

oduc

tion

4

Solar Sail Blade MaterialProperties

bull Constructed from Aluminum coated Mylar total thickness of 264 m

bull Maximum areal density of 60 g allows for 23 g of support materialbull Blades are stiffened by edge loading the sail with Kapton tapebull Further stiffened by adding tip mass equal to 10 of the total blade mass

Thrust

bull Blades provide 4510-6 N of thrust per based on solar pressure at 1 AU

bull Solar sail will need to accelerate the spacecraft at least 01 mmto be usefulbull For a 6U cubesat weighing approximately 8 kg ~45 deployed area neededbull Two bladed CubeSat with 2U width needs ~350 m blade lengthbull Aspect Ratio of 23331

Tip Mass

KaptonTape

15 cm

Intr

oduc

tion

5

Orbital Operationsbull Blade can pitched in and out of solar

flux to modulate the moment for attitude control and the thrust for orbit control

bull To increasedecrease spacecraft orbit velocity blades must pitch over a 90 degree range

bull Two 90deg pitch maneuvers are performed during 1 LEO orbit to maximize a change in velocity

Blade dynamics need be sensed while in the Earthrsquos shadow

Sun

Blades pitched 90deg parallel to solar pressure

Earth

Blades pitched 90deg perpendicular to solar pressure

Blades hit by solar flux and generate thrust

orbital velocity increases

Blades parallel to solar flux orbital

velocity unchanged

119889119881

120596

120596

120596

120596

Intr

oduc

tion

6

Blade Oscillationsbull A major concern of heliogyro designs is blade oscillation

bull Pitching manuvers and moving blades in and out of solar flux induces twisting and flapping oscillationsbull First modes of these oscillations behave similarly to swinging pendulums

bull Mode shapes are known deflection measurements made at the root can be used to calculate tip deflections

Blade RootBlade Root

Blade TipBlade Tip

Housing

θflapNominalBlade

DeflectedBlade

Flapping

θtwist

Blade Root

Blade Tip

Twisting

>

>

Intr

oduc

tion

7

Mode FrequenciesEarth Behavior

bull Flapping Mode Frequenecy can be approximated as a pendulum

bull Period Depends on the bladersquos mass (M) moment of inertia (I) and center of gravity (R) measured from the blade root g remains constant for Earth testing

bull

bull The torsional mode is best estimated from the flapping mode

bull

Space Behaviorbull Frequencies directly tied to spacecraft angular

velocity

bull Angular velocities of proposed heliogyro missions typically ~13 RPM

120596

Based on the expected mode frequencies for space operations and the constraints of Heliogyro missions the controller is required to demonstrate a damping ratio of 00136

Intr

oduc

tion

8

Testing Constraintsbull Full scale blade cannot be built or tested

bull 22 meter blade analog will be used to simulate space environment

bull Controller can still be validated by showing it can function with blade conditions similar to those seen in space

bull Graviational forces will be present during testing

bull Centripetal force of the spinning spacecraft will be simulated with these gravitational forces

bull Air viscosity will contribute to damping

bull Damping provided by the controller will need to be distinguishable from damping provided by air

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

4

Solar Sail Blade MaterialProperties

bull Constructed from Aluminum coated Mylar total thickness of 264 m

bull Maximum areal density of 60 g allows for 23 g of support materialbull Blades are stiffened by edge loading the sail with Kapton tapebull Further stiffened by adding tip mass equal to 10 of the total blade mass

Thrust

bull Blades provide 4510-6 N of thrust per based on solar pressure at 1 AU

bull Solar sail will need to accelerate the spacecraft at least 01 mmto be usefulbull For a 6U cubesat weighing approximately 8 kg ~45 deployed area neededbull Two bladed CubeSat with 2U width needs ~350 m blade lengthbull Aspect Ratio of 23331

Tip Mass

KaptonTape

15 cm

Intr

oduc

tion

5

Orbital Operationsbull Blade can pitched in and out of solar

flux to modulate the moment for attitude control and the thrust for orbit control

bull To increasedecrease spacecraft orbit velocity blades must pitch over a 90 degree range

bull Two 90deg pitch maneuvers are performed during 1 LEO orbit to maximize a change in velocity

Blade dynamics need be sensed while in the Earthrsquos shadow

Sun

Blades pitched 90deg parallel to solar pressure

Earth

Blades pitched 90deg perpendicular to solar pressure

Blades hit by solar flux and generate thrust

orbital velocity increases

Blades parallel to solar flux orbital

velocity unchanged

119889119881

120596

120596

120596

120596

Intr

oduc

tion

6

Blade Oscillationsbull A major concern of heliogyro designs is blade oscillation

bull Pitching manuvers and moving blades in and out of solar flux induces twisting and flapping oscillationsbull First modes of these oscillations behave similarly to swinging pendulums

bull Mode shapes are known deflection measurements made at the root can be used to calculate tip deflections

Blade RootBlade Root

Blade TipBlade Tip

Housing

θflapNominalBlade

DeflectedBlade

Flapping

θtwist

Blade Root

Blade Tip

Twisting

>

>

Intr

oduc

tion

7

Mode FrequenciesEarth Behavior

bull Flapping Mode Frequenecy can be approximated as a pendulum

bull Period Depends on the bladersquos mass (M) moment of inertia (I) and center of gravity (R) measured from the blade root g remains constant for Earth testing

bull

bull The torsional mode is best estimated from the flapping mode

bull

Space Behaviorbull Frequencies directly tied to spacecraft angular

velocity

bull Angular velocities of proposed heliogyro missions typically ~13 RPM

120596

Based on the expected mode frequencies for space operations and the constraints of Heliogyro missions the controller is required to demonstrate a damping ratio of 00136

Intr

oduc

tion

8

Testing Constraintsbull Full scale blade cannot be built or tested

bull 22 meter blade analog will be used to simulate space environment

bull Controller can still be validated by showing it can function with blade conditions similar to those seen in space

bull Graviational forces will be present during testing

bull Centripetal force of the spinning spacecraft will be simulated with these gravitational forces

bull Air viscosity will contribute to damping

bull Damping provided by the controller will need to be distinguishable from damping provided by air

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

5

Orbital Operationsbull Blade can pitched in and out of solar

flux to modulate the moment for attitude control and the thrust for orbit control

bull To increasedecrease spacecraft orbit velocity blades must pitch over a 90 degree range

bull Two 90deg pitch maneuvers are performed during 1 LEO orbit to maximize a change in velocity

Blade dynamics need be sensed while in the Earthrsquos shadow

Sun

Blades pitched 90deg parallel to solar pressure

Earth

Blades pitched 90deg perpendicular to solar pressure

Blades hit by solar flux and generate thrust

orbital velocity increases

Blades parallel to solar flux orbital

velocity unchanged

119889119881

120596

120596

120596

120596

Intr

oduc

tion

6

Blade Oscillationsbull A major concern of heliogyro designs is blade oscillation

bull Pitching manuvers and moving blades in and out of solar flux induces twisting and flapping oscillationsbull First modes of these oscillations behave similarly to swinging pendulums

bull Mode shapes are known deflection measurements made at the root can be used to calculate tip deflections

Blade RootBlade Root

Blade TipBlade Tip

Housing

θflapNominalBlade

DeflectedBlade

Flapping

θtwist

Blade Root

Blade Tip

Twisting

>

>

Intr

oduc

tion

7

Mode FrequenciesEarth Behavior

bull Flapping Mode Frequenecy can be approximated as a pendulum

bull Period Depends on the bladersquos mass (M) moment of inertia (I) and center of gravity (R) measured from the blade root g remains constant for Earth testing

bull

bull The torsional mode is best estimated from the flapping mode

bull

Space Behaviorbull Frequencies directly tied to spacecraft angular

velocity

bull Angular velocities of proposed heliogyro missions typically ~13 RPM

120596

Based on the expected mode frequencies for space operations and the constraints of Heliogyro missions the controller is required to demonstrate a damping ratio of 00136

Intr

oduc

tion

8

Testing Constraintsbull Full scale blade cannot be built or tested

bull 22 meter blade analog will be used to simulate space environment

bull Controller can still be validated by showing it can function with blade conditions similar to those seen in space

bull Graviational forces will be present during testing

bull Centripetal force of the spinning spacecraft will be simulated with these gravitational forces

bull Air viscosity will contribute to damping

bull Damping provided by the controller will need to be distinguishable from damping provided by air

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

6

Blade Oscillationsbull A major concern of heliogyro designs is blade oscillation

bull Pitching manuvers and moving blades in and out of solar flux induces twisting and flapping oscillationsbull First modes of these oscillations behave similarly to swinging pendulums

bull Mode shapes are known deflection measurements made at the root can be used to calculate tip deflections

Blade RootBlade Root

Blade TipBlade Tip

Housing

θflapNominalBlade

DeflectedBlade

Flapping

θtwist

Blade Root

Blade Tip

Twisting

>

>

Intr

oduc

tion

7

Mode FrequenciesEarth Behavior

bull Flapping Mode Frequenecy can be approximated as a pendulum

bull Period Depends on the bladersquos mass (M) moment of inertia (I) and center of gravity (R) measured from the blade root g remains constant for Earth testing

bull

bull The torsional mode is best estimated from the flapping mode

bull

Space Behaviorbull Frequencies directly tied to spacecraft angular

velocity

bull Angular velocities of proposed heliogyro missions typically ~13 RPM

120596

Based on the expected mode frequencies for space operations and the constraints of Heliogyro missions the controller is required to demonstrate a damping ratio of 00136

Intr

oduc

tion

8

Testing Constraintsbull Full scale blade cannot be built or tested

bull 22 meter blade analog will be used to simulate space environment

bull Controller can still be validated by showing it can function with blade conditions similar to those seen in space

bull Graviational forces will be present during testing

bull Centripetal force of the spinning spacecraft will be simulated with these gravitational forces

bull Air viscosity will contribute to damping

bull Damping provided by the controller will need to be distinguishable from damping provided by air

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

7

Mode FrequenciesEarth Behavior

bull Flapping Mode Frequenecy can be approximated as a pendulum

bull Period Depends on the bladersquos mass (M) moment of inertia (I) and center of gravity (R) measured from the blade root g remains constant for Earth testing

bull

bull The torsional mode is best estimated from the flapping mode

bull

Space Behaviorbull Frequencies directly tied to spacecraft angular

velocity

bull Angular velocities of proposed heliogyro missions typically ~13 RPM

120596

Based on the expected mode frequencies for space operations and the constraints of Heliogyro missions the controller is required to demonstrate a damping ratio of 00136

Intr

oduc

tion

8

Testing Constraintsbull Full scale blade cannot be built or tested

bull 22 meter blade analog will be used to simulate space environment

bull Controller can still be validated by showing it can function with blade conditions similar to those seen in space

bull Graviational forces will be present during testing

bull Centripetal force of the spinning spacecraft will be simulated with these gravitational forces

bull Air viscosity will contribute to damping

bull Damping provided by the controller will need to be distinguishable from damping provided by air

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

8

Testing Constraintsbull Full scale blade cannot be built or tested

bull 22 meter blade analog will be used to simulate space environment

bull Controller can still be validated by showing it can function with blade conditions similar to those seen in space

bull Graviational forces will be present during testing

bull Centripetal force of the spinning spacecraft will be simulated with these gravitational forces

bull Air viscosity will contribute to damping

bull Damping provided by the controller will need to be distinguishable from damping provided by air

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

9

Blade Controller RequirementsController housing must be able to accommodate one blade capable of providing useful acceleration (~350 m in length)

Controller must be able to pitch blades to plusmn 90deg with plusmn 5deg of accuracy

Controller must demonstrate a damping ratios for flapping and twisting modes of

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 ~13 kgU total of 26 kg

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

10

Design Solutionbull Blade housing can accommodate a

blade of 15 cm by 350 mbull Rotational actuator with a range of

motion of 360degbull Camera senses motion of blade

bull Closed loop controller damps oscillations

bull Linear actuator provides damping ratio of 00077 for flapping mode

bull Rotational actuator provides damping ratio of 0015 for twisting mode

bull LED near camera for low light conditionsbull Blade housing has 14U volume

electronics require 04U in CubeSat busbull Total of 18U

bull System requires 20 Wbull Total mass of 2 kg

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

11

Blade Housing

Linear Actuator

Camera

Image Processor

Blade Analogue

7 cm

10 cm

20 cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

12

CubeSat Bus

Microcontroller

Actuator Drivers

Rotational Actuator

Dimensions in cm

Intr

oduc

tion

13

Rope Ladder Analogbull Current heliogyro reseach uses a rope ladder assumption to

investigate blade dynamicsbull Extremely thin sail material (264 thickness) has negligible internal forcesbull Assumes the sail blade material has no stiffness or internal damping

bull Rope ladder assumption allows for blades to be constructed from support materials alone for blade testingbull Reduction in surface area results in less damping being provided by airbull 22 meters in length

Rope Ladder Blade Diagram Regular Sail Blade KaptonTape

Tip Mass

15 cm

Tip Mass

15 cm

StringWireBlade Skeleton

Intr

oduc

tion

14

FBDBlade Housing

CubeSat Bus

Power Supply

LabVIEW VI(CubeSat processor)

Rotational Actuator

Linear Actuator

Camera

LED

Gum

stix

Arduino Due

Actuator Drivers

Mode Angle Rate (UART)Images

Voltage

Voltage

RS232 instructions

Angle Logic (UART)

Blade

Linear Motion

Pitching Motion

Legend

- Power

- Data

- Command

s

- Motion6 V

6 V

6 V

5 V

9 V

gt1 V

18 V

Intr

oduc

tion

15

Intr

oduc

tion

16

CPEs

bull Control Law

bull Actuators

bull Sensing

bull Electronics

Intr

oduc

tion

14

FBDBlade Housing

CubeSat Bus

Power Supply

LabVIEW VI(CubeSat processor)

Rotational Actuator

Linear Actuator

Camera

LED

Gum

stix

Arduino Due

Actuator Drivers

Mode Angle Rate (UART)Images

Voltage

Voltage

RS232 instructions

Angle Logic (UART)

Blade

Linear Motion

Pitching Motion

Legend

- Power

- Data

- Command

s

- Motion6 V

6 V

6 V

5 V

9 V

gt1 V

18 V

Intr

oduc

tion

15

Intr

oduc

tion

16

CPEs

bull Control Law

bull Actuators

bull Sensing

bull Electronics

Intr

oduc

tion

15

Intr

oduc

tion

16

CPEs

bull Control Law

bull Actuators

bull Sensing

bull Electronics

Intr

oduc

tion

16

CPEs

bull Control Law

bull Actuators

bull Sensing

bull Electronics

Control Law

Con

trol

Law

18

Control Law Introduction

bull Control Law adds damping by moving the root based on movements at the tip of the solar sail

bull Control Law sets the requirements for the system Minimum resolution of the cameras Minimum range of motion (linearrotary) Minimum resolution of the actuators (linearrotary) Maximum computational time Minimum required acceleration

Con

trol

Law

19

Requirements For SensorsLinear sensor Rotary sensor

Minimum Sampling Rate

frac12 second frac12 second

Resolution gt5 degree gt5 degree

Con

trol

Law

20

Requirements For ActuatorsLinear Actuator Rotary

Actuator

Range of Motion +- 13 cm +- 90 degrees

Resolution 15 mm 3 degrees

Maximum acceleration

08 ms^2 10 rads^2

Con

trol

Law

21

Requirements For Computational Time

Twisting mode Flapping Mode

Max Computational Time frac14 second frac14 second

Con

trol

Law

22

Summary of the Control Law Flapping (Linear Motion)

Twisting(Angular Motion)

Sensor resolution frac12 second frac12 second

Actuator range of motion

+- 13 cm +- 90 degrees

Actuator resolution 15 mm 3 degrees

Maximum Acceleration

08 ms^2 126 rads^2

Max computational Time

frac14 second frac14 second

Actuators

Act

uato

rs

24

Actuation Design Front View Deployed Blade

Top View Deployed Blade Back View

3-D View

LinearActuator

RotaryActuator

Act

uato

rs

25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

uato

rs

26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

uato

rs

27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

uato

rs

28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Con

trol

Law

18

Control Law Introduction

bull Control Law adds damping by moving the root based on movements at the tip of the solar sail

bull Control Law sets the requirements for the system Minimum resolution of the cameras Minimum range of motion (linearrotary) Minimum resolution of the actuators (linearrotary) Maximum computational time Minimum required acceleration

Con

trol

Law

19

Requirements For SensorsLinear sensor Rotary sensor

Minimum Sampling Rate

frac12 second frac12 second

Resolution gt5 degree gt5 degree

Con

trol

Law

20

Requirements For ActuatorsLinear Actuator Rotary

Actuator

Range of Motion +- 13 cm +- 90 degrees

Resolution 15 mm 3 degrees

Maximum acceleration

08 ms^2 10 rads^2

Con

trol

Law

21

Requirements For Computational Time

Twisting mode Flapping Mode

Max Computational Time frac14 second frac14 second

Con

trol

Law

22

Summary of the Control Law Flapping (Linear Motion)

Twisting(Angular Motion)

Sensor resolution frac12 second frac12 second

Actuator range of motion

+- 13 cm +- 90 degrees

Actuator resolution 15 mm 3 degrees

Maximum Acceleration

08 ms^2 126 rads^2

Max computational Time

frac14 second frac14 second

Actuators

Act

uato

rs

24

Actuation Design Front View Deployed Blade

Top View Deployed Blade Back View

3-D View

LinearActuator

RotaryActuator

Act

uato

rs

25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

uato

rs

26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

uato

rs

27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

uato

rs

28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Con

trol

Law

19

Requirements For SensorsLinear sensor Rotary sensor

Minimum Sampling Rate

frac12 second frac12 second

Resolution gt5 degree gt5 degree

Con

trol

Law

20

Requirements For ActuatorsLinear Actuator Rotary

Actuator

Range of Motion +- 13 cm +- 90 degrees

Resolution 15 mm 3 degrees

Maximum acceleration

08 ms^2 10 rads^2

Con

trol

Law

21

Requirements For Computational Time

Twisting mode Flapping Mode

Max Computational Time frac14 second frac14 second

Con

trol

Law

22

Summary of the Control Law Flapping (Linear Motion)

Twisting(Angular Motion)

Sensor resolution frac12 second frac12 second

Actuator range of motion

+- 13 cm +- 90 degrees

Actuator resolution 15 mm 3 degrees

Maximum Acceleration

08 ms^2 126 rads^2

Max computational Time

frac14 second frac14 second

Actuators

Act

uato

rs

24

Actuation Design Front View Deployed Blade

Top View Deployed Blade Back View

3-D View

LinearActuator

RotaryActuator

Act

uato

rs

25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

uato

rs

26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

uato

rs

27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

uato

rs

28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Con

trol

Law

20

Requirements For ActuatorsLinear Actuator Rotary

Actuator

Range of Motion +- 13 cm +- 90 degrees

Resolution 15 mm 3 degrees

Maximum acceleration

08 ms^2 10 rads^2

Con

trol

Law

21

Requirements For Computational Time

Twisting mode Flapping Mode

Max Computational Time frac14 second frac14 second

Con

trol

Law

22

Summary of the Control Law Flapping (Linear Motion)

Twisting(Angular Motion)

Sensor resolution frac12 second frac12 second

Actuator range of motion

+- 13 cm +- 90 degrees

Actuator resolution 15 mm 3 degrees

Maximum Acceleration

08 ms^2 126 rads^2

Max computational Time

frac14 second frac14 second

Actuators

Act

uato

rs

24

Actuation Design Front View Deployed Blade

Top View Deployed Blade Back View

3-D View

LinearActuator

RotaryActuator

Act

uato

rs

25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

uato

rs

26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

uato

rs

27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

uato

rs

28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Con

trol

Law

21

Requirements For Computational Time

Twisting mode Flapping Mode

Max Computational Time frac14 second frac14 second

Con

trol

Law

22

Summary of the Control Law Flapping (Linear Motion)

Twisting(Angular Motion)

Sensor resolution frac12 second frac12 second

Actuator range of motion

+- 13 cm +- 90 degrees

Actuator resolution 15 mm 3 degrees

Maximum Acceleration

08 ms^2 126 rads^2

Max computational Time

frac14 second frac14 second

Actuators

Act

uato

rs

24

Actuation Design Front View Deployed Blade

Top View Deployed Blade Back View

3-D View

LinearActuator

RotaryActuator

Act

uato

rs

25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

uato

rs

26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

uato

rs

27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

uato

rs

28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Con

trol

Law

22

Summary of the Control Law Flapping (Linear Motion)

Twisting(Angular Motion)

Sensor resolution frac12 second frac12 second

Actuator range of motion

+- 13 cm +- 90 degrees

Actuator resolution 15 mm 3 degrees

Maximum Acceleration

08 ms^2 126 rads^2

Max computational Time

frac14 second frac14 second

Actuators

Act

uato

rs

24

Actuation Design Front View Deployed Blade

Top View Deployed Blade Back View

3-D View

LinearActuator

RotaryActuator

Act

uato

rs

25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

uato

rs

26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

uato

rs

27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

uato

rs

28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Actuators

Act

uato

rs

24

Actuation Design Front View Deployed Blade

Top View Deployed Blade Back View

3-D View

LinearActuator

RotaryActuator

Act

uato

rs

25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

uato

rs

26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

uato

rs

27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

uato

rs

28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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Image Processor Code

Bac

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Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Act

uato

rs

24

Actuation Design Front View Deployed Blade

Top View Deployed Blade Back View

3-D View

LinearActuator

RotaryActuator

Act

uato

rs

25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

uato

rs

26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

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27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

uato

rs

28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

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36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

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nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

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nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

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nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

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nics

42

Software

Ele

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nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

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79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Act

uato

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25

Mass Budget

Subsystem

Components Mass

Structural 5 ndash 18rdquo Aluminum plates (Machined)

330g

Electronics -2 drivers- Arduino

30g35g35g

Actuators -Rotary motor w Encoder 50g

Mechanical -Bevel Gear-Mounting components

30g75g

Total Mass 585g

Full Assembly

Rear unit

65 cm

3 cm

05 cm

Rear Housing Back View

Motor Drivers

Arduino

Aluminum Plates

Bevel Gear

Electrical Wiring

Rotary Motor

3 cm 3 cm

10 cm

Rear Housing Side View

20 cm

10 cm

Rotary Motor w Encoder Bevel Gear

Mounting Components

Electrical Wiring

Wiring Through Hollow Rod

Act

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26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

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27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

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28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

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29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

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36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

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nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

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nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

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nics

42

Software

Ele

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nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

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79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

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RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Act

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26

Rotary Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionServo Motor w Encoder

+- 90o rotation Customer 360o motion reversible

Torque gt 16 mNm Control Law Continuous torque w 21 Gear Ratio 22 mNm

Minimum Resolution lt 3o

Control Law Encoder 036o

Fit within rear housing unit lt 5 cm axial length lt 3 cm diameter

Design 35 cm axial length22 cm diameter

Act

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27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

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28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

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29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

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nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

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79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Act

uato

rs

27

Mass Budget

Subsystem

Components Mass

Structural 5ndash 18rdquo Aluminum plates (Machined)

360g

Electronics -Image Processor

-Expansion Board

-Camera

15g

30g

30g

Actuators -Linear motor 20g

Mechanical -Linear Guide System

-Mounting Components

-Spool and Rolled Blade

60g

50g

300g

Total Mass 820g

Full Assembly

Front unit65 cm

3 cm

05 cm

Front View Undeployed Blade

Image ProcessorExpansion Board Camera

Linear Guide System

Linear Actuator

Spool and Rolled Blade

10 cm

20 cm

1 cm

3 cm

3 cm

1 cm

3 cm

3 cm

25 cm

Electrical WiringTo ArduinoElectrical Wiring to Image Processor

Electrical Wiring to DriverFront View Deployed Blade

Deployed Blade

Act

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28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

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29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

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31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

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36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

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37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

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39

Connection Diagram

Ele

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40

Power

Ele

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41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

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Software

Ele

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43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

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g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

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Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

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Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

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Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

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Requirements for Actuators

Linear accelerationAngular Acceleration

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Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

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Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

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Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

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State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

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Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

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Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

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Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

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Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

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Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

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Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

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Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

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Linear Motion Requirement

θ

bull

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82

Binding Ratio

L

D

a

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Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

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Gear Ratio bull

r

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Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

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Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

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Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

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Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

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Camera Requirements Geometry

Bac

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Encoder Wiring

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Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

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RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

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LED Light intensity 7000mcd Powered separately Alkaline battery

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include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

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Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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Motor Controller Code

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Image Processor Code

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Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Act

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28

Linear Actuator Requirements and Solution

Actuator Requirement

Parent Requirement

SolutionLinear Servo Motor

Range of Motion +- 25 cm

Control Law Range of Motion +- 40 cm

Precision 45 mm Control Law Precision 004 mm

Velocity 31 cms Control Law Velocity 80 cms continuous

Force gt 053Nm Control Law Force 103 N continuous

Horizontal Length lt 25 mmAxial Length lt 93 mm

Design Horizontal Length 8 mmAxial Length 82 mm

Act

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29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

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31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

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32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

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Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

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34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

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36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

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nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

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nics

39

Connection Diagram

Ele

ctro

nics

40

Power

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41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

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42

Software

Ele

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43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

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Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

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Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

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Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

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Requirements for Actuators

Linear accelerationAngular Acceleration

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Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

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Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

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State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

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Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

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Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

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Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

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Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

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Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

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Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

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Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

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Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

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Gear Ratio bull

r

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Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

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Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

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Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

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Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

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Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

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Camera Requirements Geometry

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Encoder Wiring

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Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

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RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

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LED Light intensity 7000mcd Powered separately Alkaline battery

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include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

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Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

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Motor Controller Code

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Image Processor Code

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Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Act

uato

rs

29

Mass Budget Housing Interface Assembly

Subsystem Components Mass

Mechanical -Hollow Precision Rod-Radial Bearing

-Turntable Bearing

-Mounting Components(Machined)

10 g

20g

30g

50g

Total Mass 110g

Requirement Design

Mass less than 26 kg

Total Mass 17 kg

Volume gt= 2U Total Volume 2U

Design Requirements

50 cm

318 cm

318 cm

1111 cm 4695 cm

75 cm

Electrical wires

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

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36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

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37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

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39

Connection Diagram

Ele

ctro

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40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

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43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

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79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Sensing

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

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79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Sen

sing

31

Sensor Design

Camera is mounted inside the blade housing pointed towards one surface of the blade

Reflective tape will be placed on the blade facing the camera and will be illuminated via LEDs mounted to blade housing

Image processing algorithm will locate the center of the reflective tape within the camera frame and compare the location against the known position of the sensing point at no deflection

Blade will move between +- 20 degress for flapping oscillation and between +- 90 degrees for twsiting oscillation

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Sen

sing

32

Camera Requirements and Selection

θmin= 5deg

θrange= 40deg

Camera Requirement Parent Requirement

Caspa VL

Field of View gt 436deg x 10deg

Blade Range of Motion

786deg x 593deg(752x480 Pixels)

Pixel Density gt 2 pixelsdegFOV

Blade Range of Motion

95 pixelsdegFOV

Frame Rate gt 2 fps Control Law 60 fps

Width = 257 cm

Length = 39 cm

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Sen

sing

33

Range of Motion - Markers

ProcessedImage

Flap ModeMarkers movesame direction

Nominal marker

positions

Marker position at 20deg flap

ProcessedImage

Twist ModeMarkers move

opposite directions

Nominal marker

positions

Marker position at 90deg twist

The green box outlines the section of the image that needs to be processed It encompases a total area of 015 Megapixels

Deflection Angles

θtwist= +- 90deg θtwist per pixel= 106deg

θflap = +- 20deg θflap per pixel= 011deg

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

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nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

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nics

39

Connection Diagram

Ele

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nics

40

Power

Ele

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nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

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nics

42

Software

Ele

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43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

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Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

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Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

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Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

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Requirements for Actuators

Linear accelerationAngular Acceleration

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

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Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

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Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

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State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

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Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

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79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

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Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

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81

Linear Motion Requirement

θ

bull

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82

Binding Ratio

L

D

a

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Sen

sing

34

Sensor Deflection Calculations

Raw Image Filtered Binary Image

50 lt L lt 255 0 lt Cr lt 125 0 lt Cb lt 255

Marker 1328 626

Marker 2396 624

Marker Centroid Locations In

Pixels

Flap angle ~0 degrees

Twist angle ~0 degrees

Deflection Angles Calculated1cm x 1cm teflon tape

markers located 2 meters from the camera

Electronics

Ele

ctro

nics

36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

ctro

nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Electronics

Ele

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36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

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nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

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57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

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g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

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87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

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36

Motor Controller

To Bus

To Gumstix From Gumstix

From Bus

84 MHz Processor

Requirements Arduino DUE

2 Receive and 2 Transmit Pins

4 Receive and 4 Transmit Pins

2 USB Ports 2 USB Ports

Fit in 2U CubeSat Volume

1016 cm x 5334 cm

Serial Receive and Transmit Pins(TTL)

1016 cm

5334 cm

Language based on C

Ele

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37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

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41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

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43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

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96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

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nics

37

Image Processor Overo

Ribbon Connection

Mini SD Card Slot

1 GHz Processor

Ribbon Connection built to be compatible with selected camera (Caspa VL)

1 GHz processor512 MB RAM (81 MB in imagessec)Mini SD Card slot for additional storage

Requirements Overo

Interface with camera Ribbon Connection

Provide angular rate and mode at least 2 times a second

Predicted to give angular rate and mode 7 times a second

Store up to 48 Gigabytes in images from camera

Mini SD Card slot allows up to 64 GB SD Card

Fit in 2U CubeSat Volume 58 cm x 17 cm x 042 cm

1 USB Port No USB Port Need Expansion Board

17 cm

58 cm

042 cm

Runs Linux (Ubuntu) code written in C image processing library is OpenCV

Ele

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nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

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nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

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nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

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nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

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nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

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75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

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80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

ctro

nics

38

Expansion Board Pinto

762 cm

23 cm

USB Port

Requirements Pinto

1 USB Port 1 USB Port

Interface with Overo Connects directly to Overo

Overo Connector

Overo Connector

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

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78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

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81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

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84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

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86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

ctro

nics

39

Connection Diagram

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

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62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

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82

Binding Ratio

L

D

a

Bac

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83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

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85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

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88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

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89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

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95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

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98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

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99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

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100

Motor Controller Code

Bac

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101

Image Processor Code

Bac

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102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

ctro

nics

40

Power

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

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90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

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91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

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92

Camera Requirements Geometry

Bac

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93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

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97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

ctro

nics

41

Power BudgetDevice Source Voltage

RequirementsCurrent Draw Continuously

PoweredPower

Encoder Faulhaber 45-55 V 9 mA Yes 004-005 W

Linear Motor and controller

Faulhaber 5 V 278 mA No 139 W

Rotary Motor and controller

Faulhaber 5 V 27 A No 134 W

Pinto-TH Gumstix Overo 5 V 250 mA Yes 125 W

Airstorm-P Gumstix Overo 4 V 250 mA Yes 1 W

Arduino Due SparkFun 7-12 V 50 mA Yes 035 - 06 W

(2x TTL-RS232 converters)

SparkFun 33 V 10 mA Yes 007 W

LED Thumb Lite 15 V 400 mA Yes 06 W

Peak Power 185 - 188 W

Continuous Power 41 - 44 W

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

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63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

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64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

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65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

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66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

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67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

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68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

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69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

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70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

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71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

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72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

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73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

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74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

ctro

nics

42

Software

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

ctro

nics

43

Image Processor

Component What it Does Time

Receive Image Enable 91 bits at 9600 baud 00095 sec

Camera ActuationStore Takes picturestores picture

00167 sec

Image Processing Function Calculates Angle Rate Mode

00200 sec

Send Angle Rate Mode 91 bits at 9600 baud 00095 sec

Receive Image Enable From

Motor Controller

Perform Logic Check

Give Camera

Actuation Command

Store Image

Call Image Processing Function (written

by SPECTRE)

Send Angular Rate Mode to

Motor Controller

00095 sec002 sec 00095 sec

00167 sec

TOTAL TIME = 00462 sec 216 Hz

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ele

ctro

nics

44

Motor Controller

Component What it Does Time

Receive Pitch Command 91 bits at 9600 baud 00095 sec

Send Command to Pitch Motor Pause to transfer command receive feedback angle 00200 sec

Enable Image Capture Turn on Image Capture 00095 sec

Waiting on Image Processor Allows time for Image Processing Code to run 00462 sec

Receive Angle Rate Mode 91 bits at 9600 baud 00095 sec

Check Mode Implement Control Law

Logic check on mode scales anglular rate by appropriate Kd

00000 sec

Send Damping Command Pause to transfer command receive feedback angle 00200 sec

Receive Pitch Command Control Law Enable From Labview VI

Enable Image

Capture Relative Angle

Send Command to Pitch

Motor

Check Mode

Implement Control Law

Send Damping

Command to Appropriate

Actuator

Wait on Image

Processor

00095 sec00095 sec

00095 sec00462 sec

0020 sec0020 sec

TOTAL TIME = 01147 sec 87 Hz 4 Hz Required

Receive Angular

Rate Mode

0000 sec

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Verification and Validation

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ver

ific

atio

n an

d V

alid

atio

n

46

Test SetupA scaled rope ladder blade analog will be tested with to validate the controller

bull Blade Dimensions 22 meters by 15 centimeters

Blade testible indoors = ~13 Hz = ~715 Hz Frequences are approximately 60 times faster than those expected

from the blade in space

bull Markers placed 2 meters down the blade Tip not being measuredfilmed directly Direct tip measurement not possible for full scale blade

bull Modes will be excited manually

Markers

015 m

Blade Tip

2m

Contoller Blade Housing

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ver

ific

atio

n an

d V

alid

atio

n

47

Manual Mode Excitation

Flapp Mode Twist Mode

>

>

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ver

ific

atio

n an

d V

alid

atio

n

48

Test Setup Air DampingTwisting Oscillation

Flapping Oscillation

Elasped Time (s)Elasped Time (s)

Fla

p A

ngle

(de

g)

Twis

t Ang

le (

deg)

120577 cong 000 50 120577 cong 00055

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

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94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ver

ific

atio

n an

d V

alid

atio

n

49

Flapping mode Control Law

Sensor resolution 110 degree

Resolution ⅙ framessecond

Actuator resolution 25 millimeter

Computational Time

160 seconds

Air damping ~0050

Damping ratio 0137

Control Law 0077

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ver

ific

atio

n an

d V

alid

atio

n

50

Twisting Mode Control Law

Sensor resolution 1 degree

Resolution ⅙ framessecond

Actuator resolution 36 degree

Computational Time 160 seconds

Air damping ~0055

Damping ratio 0205

Control Law 0150

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Project Risk

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ris

k

52

Risk Assessment

1

5 6 23

4

Consequence

Like

liho

od

Very High

Very Low

Minimal Catastrophic

1) Controller cannot measure defection angles accurately enough

2) Controller requires faster sampling than the sensors can provide

3) Mode coupling disrupts controller operations

4) Project is over budget

5) Components brokenneed replacements

6) HousingBus cannot be assembled on schedule

AcceptableRisk

Risk Acceptable with Contingency Plans

Unacceptable Risk

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Ris

k

53

Risk ManagementRisk 1 Controller cannot measure deflection angles accurately enough

Contingency Plan Testing can be performed in a lighted environment Cameras can be moved to closer to the markers

Risk 2 Controller requires faster sampling than the sensors can provide

Contingency Plan Larger blades (~4m) can be tested decreasing mode frequencies and sampling rate requirments by (~50) Electronic baud rates can be increased from 9600 to 57600 Baud

Risk 3 Mode coupling disrupts operation of the Controller

Contingency Plan Smaller gains can be applied to the controller Modes of the blade can be excited mechanically Larger tip masses can be used to give the blade more in

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Project Planning

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Pla

nnin

g

55

Organizational Chart

SPECTRE

Micheal Andrews

Software Lead

Financial Coordinator

Brendon Barela

Manufacturing Lead

Austin Cerny

Testing Lead

Project Manager

Corinne Desroches

Electronics Lead

Kyle Edson

Systems Lead

Safety Lead

Conrad Gabel

Mechanical Lead

Chris Riesco

Sensing Lead

Justin Yong

Controls Lead

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Pla

nnin

g

56

Work Breakdown Structure

SPECTRE

ManufacturingTesting

Bus Assembly

Blade Root Housing Assembly

Test Blade Analog

Mechanical

Installed Linear Actuator

Installed Rotary Actuator

Installed Gearbox Connection

Software

C++ Image Processing Algorithm

C++ Control Law Algorithm

Controls

Torsional Mode Model

Flapping Mode Model

Electronics

Installed Motor Controller

Installed Image Processor

Systems

Power Connection to all Electronic

Components

ControllerDriver Interface

Connection

Image ProcessorControlle

r Interface Connection

Sensing

Installed Cameras

Image Processing Subsystem

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Pla

nnin

g

57

Work Plan

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Pla

nnin

g

58

Work Plan Critical Path

Sp

rin

g B

reak

Classes Start MSR TRR Spring Final Report Symposium

ManufacturingSoftwareMechanicalElectricalSystems

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Pla

nnin

g

59

Cost Plan

Component Number Needed

Lead Times (Weeks)

Cost per Component

Total Price

Overo Firestorm-P 1 3 $15900 $ 15900

Pinto 1 3 $ 2750 $ 2750

Power Adapters 2 3 $ 1000 $ 2000

Caspa VL 1 3 $ 7500 $ 7500

Micro SD 1 0 $ 5000 $ 5000

Arduino DUE 1 6-8 $ 5000 $ 5000

USB Cable 3 0 $ 300 $ 900

Linear Motor 1 3 $69000 $ 69000

Linear Motor Driver 1 8 $22600 $ 22600

Rotary Motor 1 3 $22000 $ 22000

Rotary Motor Driver 1 6-8 $22600 $ 22600

LEDs 2 0 $ 1000 $ 1000

Aluminum Sheet 1 1 $ 5000 $ 5000

Misc Wires 0 $10000 $ 10000

Misc Screws 0 $10000 $ 10000

Rotary Encoder 1 3 $ 5000 $ 5000

Hardened Steel Shaft 1 1 $ 2400 $ 2400

Linear Bearing with Pillow Block 1 1 $ 4000 $ 4000

Shaft Support 2 1 $ 4400 $ 4400

Bevel Gear 1 1 $ 5000 $ 5000

Turntable Bearing 1 1 $ 500 $ 500

Radial Berings 1 1 $ 500 $ 500

Precision Shaft (hollow) 1 1 $ 4000 $ 4000

Mounting Components 1 1 $ 4000 $ 4000

TOTAL $ 230050

Margin=$269950

gt50 Total Budget

enough to repurchase every component in case of failure

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Pla

nnin

g

60

Test Plan

TestApproxima

te DateDescription Purpose

Sensors Collecting Data

EquipmentFacilities Needed

1 Feb 2 -9Camera Takes Image of

Test BladeMarkers

Ensure markers are visible and Image Processesing

Filter is accurateOvero Camera

Dark 1 Story Room 1-4 wall outlets

1-4 power supplies

2 March 2-9

Blade Flapping and Pitching Modes are

Excited and Filmed With Camera

Confirm sensors are installed correctly and angle measurement

sampling rate is sufficent

Overo Camera

3March 9 -

16Blade Is Commanded to

Pitch 90 degrees

Confirm actuatorsdrivers are correctly installed controller has required

range of motion

Rotary Encoder

4 April 6-20Blade Flapping and Pitching Modes are

Excited and Damped

VerficationValidation of Controller

Rotary Encoder Overo Camera

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Backup Slides

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

62

Frequency Testing Tested Bladesbull Several ldquoRope Ladderrdquo blades with similar masses to sail blades of the same area were built to

test the accuracy of the frequency estimatesbull Modes were excited manually and filmed to observe frequenciesbull Blade Frequencies matched predicted frequencies lt 3 error

Blade Length (m)Width (m) AR Mblade(g) Mtip(g)

1 15 01 15 0034 012

2 15 01 15 0034 204

3 1 01 10 0023 013

4 15 02 75 0034 024

Blade

Predicte

d

Observe

d

Error

Predicted

Observe

d

Error

1 0420 0428 200 0588 0600 204

2 0407 0400 171 0571 0577 105

3 0509 0508 004 07122 0732 273

4 0414 0417 072 0579 0588 115

Scaled Test Blade Being Filmed

MarkerCameraMotion of

Blade

Blade Tip

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

63

Damping RatiosBlades oscillations need to be small enough to preserve 95 of the

surface area of the blade exposed to the solar flux

TwistingMaximum amplitude of 125 minute window (18 orbital period in LEO) for blades to settle201 radminute oscillation frequency

FlappingMaximum amplitudes (~1-2) always less than50 damping in frac12 orbital period (45 minutes)293 radminute oscillation frequency

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

64

Time Requirements

The Controller Continues to act like a controller at 91 seconds

At 1 second the controller does not display the desired characteristics

1 second Time step91 Second Time step

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

65

Requirement for Actuators

Linear Actuator Position Rotary Actuator Position

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

66

Requirements for Rotary Actuators

Resolution of 3 degreeResolution of 4 degree

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

67

Requirements for Linear Actuators

Resolution of 14mmResolution of 3mm

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

68

Requirements for Actuators

Linear accelerationAngular Acceleration

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

69

Requirements for damping system

Addition of ⅓ computation time

Flapping ModeTwisting Mode

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

70

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

71

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

72

State Space model Twisting Mode Kgyro is non existent in

the earth setting only 2-DOF were used

for the model

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

73

Membrane-Ladder Assumption

Assumes no materialstructural damping

The membrane in between the elements are mass-less

Experimental results have shown good correlation with this FEM theory

Can accurately predict the motion of the pitching mode

Gyroscopic stiffness is not included on earth

Centripetal stiffness is now sitffness by gravity

SourceHeliogyro Solar Sail Blade Twist Stability Analysis of Root and Reflectivity Controllers

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

74

Control Law Assumptions

The Solar Sail material has almost no material damping

Without the Control Law the flapping mode of the solar sail acts like an air damped pendulum

The twisting and flapping mode are considered uncoupled and can not influence each other

Root

Tip

Solar Sail

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

75

Control Law Design

Takes in the error in the deflection angle from the reference angle

Outputs the Moment produced at the root

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

76

Control Law Design

Takes in the moment needed to damp the solar sail

Exports the deflection of the solar sail

u = Mroot

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

77

Key Elements to be PurchasedElement Manufacturer

SupplierModel Number Cost Lead Time

Rotary Motor FaulhaberMicromo BLDC 0824D $22000 1-3 weeks

Rotary Motor Driver

FaulhaberMicromo MCBL 3002RS $226 6-8 weeks max

Rotary Encoder FaulhaberMicromo AESM ndash 4096 $5000 1-3 weeks

Linear Actuator FaulhaberMicromo LM ndash 0830 $69000 1-3 weeks

Linear Motor Driver

FaulhaberMicromo MCLM 3002RS $226 6-8 weeks max

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

78

Mechanical Components to be Purchased

Component Material Tolerance

Structural Plating Aluminum 18rdquo +- 0005rdquo

Mounting Components Aluminum +- 0001rdquo

Components to be Manufactured

Element ManufacturerSupplier Tolerence Cost Lead Time

Hardened Steel Shaft (14rdquo)

McMaster Carr Diameter 00002rdquoStraigtness 00048rdquofoot

$2400 1 week

Linear Bearing with Pillow Block Housing

McMaster Carr Self Aligning ball bearings

$4000 1 week

Shaft Support (2) McMaster Carr Diameter+-0003rdquo $2200 1 week

Bevel Gear Stock Drive Products Backlash 0002rdquo $5000 1 week

Turntable Bearing McMaster Carr Diameter 0005rdquo $500 1 week

Radial Bearings McMaster Carr Diameter 0005rdquo $500 1 week

Precision shaft (hollow) McMaster Carr Diameter 0001rdquo Straightness 0001rdquofoot

$4000 1 week

Mounting Components McMaster Carr Diameter +- 0003rdquo $4000 1 week

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

79

Parallel Shaft Misalignment MitigationProblem Shafts are misaligned from shaft support tolerancemisalignmentSolutionReduce Size of spool rod by expect misalignment dx total

dx2dx1

dxtotal =dx1+dx2

bearings

Spool rod

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

80

Linear actuation Tolerancing

dx1

θ1

θ2

L

θ

1

θ1 = θ2

dx = Lsin(θ1 )θ1max = 1o

dx1max allowable = 01108 mm

dx2

dx2 = tolerance in shaft support s= 0003rdquo=0076 mm (worst case)

Shaft Hardness = 015192 mmfootdx3 = 008 mm

dx3

Max Possible Error = dx2 + dx3 = 0156 mm = 17o

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

81

Linear Motion Requirement

θ

bull

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

82

Binding Ratio

L

D

a

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

83

Binding Preventionbull Lever arm distance = 15cm

bull Can prevent binding by increasing length between bearings or by decreasing μs

bull For typical ball bearing μs = 0005 need L gt15 mm

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

84

Gear Ratio bull

r

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

85

Gear Backlashbull 21 Gear Ratio with 2cm

radius gear translates into 0350 mm (0014 in) backlash for a 1o error

bull Backlash = Rθ

bull Diametral Pitch of 24-48 gives accuracy of 015o

R = 2cm

Θmax=1oBacklash

Average stock Gear Backlash(Bevel Gear)

httpwwwbostongearcompdfgear_theorypdf

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

86

Image Processing in Space

Image processing methods are similar for space applications

Oscillations seen at any point along the blade can be used to extrapolate the state of the 350m blade

Sensing the blade at a location 2m from the root will require similar camera characteristics for the flapping mode

The twisting mode will require a smaller field of view and higher specific resolution

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

87

Expected Deflections (Flapping)

In the flapping mode the flap angle of the blade is constant over the entire length of the blade (simple pendulum assumption)

Sensing a point at 2m from the root will have identical requirements to our testing case The same camera can be used to detect the full range of flapping motion

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

88

Expected Deflections (Twisting)

In the twisting mode the twist angle increases along the length of the blade

Deflections seen at a location 2m from the root will have a displacement of ~1 times that of the tip

This narrows the required field of view of the camera to sense the small motions of the sensing point

The resolution requirement (pixelsdegFOV) is unchanged

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

89

Camera Requirements (Space)

To accommodate small twisting mode deflections the field of view must be changed from 437deg to 023deg

This can be done through optical zoom requiring a focusing lens being added to the camera system

The lens must supply 190x optical zoom

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

90

Camera Setup (Space)

The flapping mode requires an unchanged field of view and the twisting mode requires a significantly smaller field of view

It is proposed that two separate cameras are used Each is mounted within the blade housing on separate sides of the blade

Integrating the 190x focusing lens with one of the two cameras will allow the sensing of both modes independently

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

91

Camera Requirements Geometry

α = Vertical angle from camera axis to sensing location

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

92

Camera Requirements Geometry

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

93

Encoder Wiring

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

94

Motor PowerRotary motor Back-EMF constant 0624 mVrmp Current constant 0168 AmNm 03 mNm maximum 96 rpm 595 mV at 27 A (minimum 5V for driverhall sensors)

Linear Motor Back-EMF constant 158 V(ms) Force constant 194 NA Maximum force 054 N maximum speed 5 cms 0079 V at 278 mA (minimum 5V for driverhall sensors)

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

95

RS232 Level Shifter

TTL Serial interface and supply(Rx Tx GndUcc)

DB9 female connector (RS232)

Max baud rate 115200 bpsVariable voltage level depends on TTL level able to run on 33 V

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

96

LED Light intensity 7000mcd Powered separately Alkaline battery

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

97

include ltstdiohgt include ltstdlibhgt include ltusrlocalopencv-249includeopencvcvhgt include ltmathhgt

void main(int argc char argv[])

int mat[752][480]int sz1=752int sz2=480int fnd1[4]int fnd2[4]int count=0int iter1=1int iter2=1int r1=rand() 751int r2=rand() 479int r3=rand() 751int r4=rand() 479int r5=rand() 751int r6=rand() 479int r7=rand() 751int r8=rand() 479int sz3=1int iter3=1int a=0int b=0int c=sz1+1int d=sz2+1int avg1=1int avg2=1int image=0int iter4=0

image=cvLoadImage(Sample1_pbmpbm)

for (iter4=0 iter4ltsizeof image iter4++) printf(inimage[iter4])

memset(mat 0 sizeof mat)mat[r1][r2]=1mat[r3][r4]=1mat[r5][r6]=1mat[r7][r8]=1

for (iter1=0 iter1ltsz1 iter1++)

for (iter2=0 iter2ltsz2 iter2++)

if (mat[iter1][iter2]=0)

fnd1[count]=iter1

fnd2[count]=iter2

count=count+1

sz3=sizeof fnd1

for (iter3=0 iter3ltsz3 iter3++) a=fmax(fnd1[iter3]a)b=fmax(fnd2[iter3]b)c=fmin(fnd1[iter3]c)d=fmin(fnd2[iter3]d)

avg1=(a+c)2avg2=(b+d)2

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

98

Labview Setupbull Labview VI to allow input for control lawdamping argument pitch

angle

bull Need graphs of outputs to verify predicted behavior (process each image and feedback angle rate to Labview for graphing)

- Separate process that doesnrsquot interfere with

timing

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

99

Image Processing and Motor Controlbull A good motor controller does not necessarily have the required

processing power

- eg Arduino DUE has 84 MHz clock speed

bull A good image processor board does not necessarily have the required peripherals for motor control

- eg Gumstix needs expansion boards to include

peripherals

bull Suggests pairing a good processor with a good motor controller (design solution that has been chosen by at least 1 previous team)

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

100

Motor Controller Code

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

101

Image Processor Code

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

102

Communication Driversbull ldquodelayMicrosecondsrdquo sets baud rate

bull ldquopinModerdquo sets transmit and receive pins

bull ldquodigitalWriterdquo transmits data

bull ldquodigitalReadrdquo receives data

bull ldquoSWprintrdquo used to debugmake sure serial connection functions as expected

bull Maximum reliable baud rate = 9600 bps

httpwwwarduinoccenTutorialSoftwareSerial

Bac

kups

103

Arduino Functionsbull ldquopinModerdquo sets pin to type of output or input

bull ldquoanalogWriterdquo assigns voltage to a specified pin

bull ldquoanalogReadrdquo gets voltage from specified pin

bull ldquodigitalWriterdquo writes either HIGH or LOW to specified pin

bull ldquodelayrdquo pauses program for specified time in miliseconds

bull ldquoSerialprintlnrdquo prints data to serial port as ASCII text

bull ldquomotorBackwardmotorForwardrdquo user defined functions

bull ldquoSerialbeginrdquo sets library to specified baud rate

Bac

kups

104

Camera Drivers ISPImage Signal Processor (ISP) Drivers

bull VPFE ndash processes raw image signal appears in Linux command as ldquoCCDCrdquo (supporting module)

bull VPBE ndash converts RGB to YUV (preview module) resizes if desired (resizer)

bull Example (supported) order of driver calls SEN-CSI2-CCDC-PREV-RESZ-MEM

-High Performance Pipeline

bull Set image capture rate in actuation call

(eg -r 60)

httpomappediaorgwikiCamera-ISP_DriverCamera_States

Bac

kups

104

Camera Drivers ISPImage Signal Processor (ISP) Drivers

bull VPFE ndash processes raw image signal appears in Linux command as ldquoCCDCrdquo (supporting module)

bull VPBE ndash converts RGB to YUV (preview module) resizes if desired (resizer)

bull Example (supported) order of driver calls SEN-CSI2-CCDC-PREV-RESZ-MEM

-High Performance Pipeline

bull Set image capture rate in actuation call

(eg -r 60)

httpomappediaorgwikiCamera-ISP_DriverCamera_States