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Individual Subsystem Testing Report
Patrick Weber, Michael Stephens, Heather Choi, Kevin Brown, Ben Lampe, Anne-Marie Suriano, Eric Robinson, Dorin Blodgett
February 24, 2011
2/24/2011
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Mission Overview
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Presenter: Dorin Blodgett2/24/2011
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Mission Overview
Scientific Mission o Primary: Collect space dust.
o Particle size = nano and micro level
o Space Dust Composition (10-6)
o Exhausted Rocket Fuel
o Meteor / Metal Fragments
o Other Miscellaneous Gases
o Donate collected aerogel tablets to UW Geology Department for further analysis
o Secondary:o Capture Detailed data throughout flight duration
o Thermal Data
o Seismic/Vibration Data
o Earth images/video
Presenter: Dorin Blodgett2/24/2011
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Mission Overview
Engineering Missiono Engineer an extendable boom to mount a dust collector.
o Use aerogel as dust collectors.
o Engineer modular electronic systems for:o Capturing and storing images from optical devices.
o Actuating Telescopic Boom
o Recording thermal and seismic data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry.
Presenter: Dorin Blodgett2/24/2011
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Mission Overview
Concept of Operations
Presenter: Dorin Blodgett
t ≈ 0 minLaunch
Systems Power On (t = -2 min)-Collection of Sensor Data Begins
t ≈ 0.7 minEnd of Orion Burn
t ≈ 1.7 minShedding of Skin
Boom Extends via First Timed Eventt ≈ 2.8 min
Apogee
t ≈ 4.0 minBoom Retracts via Arduino Controller
Boom Power Shut Down
t ≈ 8.2 minChute Deploys
t ≈ 15 minSplash Down
Payload Power Down
2/24/2011
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Design Description
Subsystem Overview
Presenter: Dorin Blodgett
MCU Arm Control
Temp. Sensor
Optical Camera
PWR
Wallops Telemetr
y
Wallops
EPS
EPS/STR Interface
OC/STRInterface
TB/STRInterface
TB/EPSInterface
OC/EPSInterface
STR
TB OC
Aerogel
BoomMoto
r
Boom
IS IS/EPSInterface
IS/STR Interface
Temperature Sensor
Accelerometers
Optical Camer
a
Optical Camera
Accel.Sensor
Control Box
Motor
2/24/2011
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Design Description/ Design Changes
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Presenter: Dorin Blodgett2/24/2011
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Design Description
New Design Parameterso Full Canister Available
o 30 ± 1 lb weight requirement
o Payload material changed to Steel
o Payload – 16.7 lb
o Ballast – 13.3 lb
o Higher centrifugal forces
o More powerful motor needed - holding torque of 57.6 lbin
o Load increased on tape reel
o Loading Stress – 16.5 ksi
o Axial Deflection – 5.93E-4 in
o Boom Seal
o Tapered Seal
o O-ring (Durometer Shore A:70)
Presenter: Dorin Blodgett2/24/2011
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Design Description
New Design Parameterso Skin Ejection
o Clam-like skin shed after motor burn-out
o Payload section will not be pressurized
o Temperatures at Reentryo Max of 350oF – well after apogee
o Bearing material changed to Teflon
o Higher operating temperature is 500F, melting of 635F
o Radial thermal expansion, Δ T of 273F
o Teflon = 3.3E-2 in
o Steel = 3.3E-3 in
o High temperature o-ring (A:70)
o Aerogel cover over electric components
Presenter: Dorin Blodgett2/24/2011
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Design Description
New Design Parameterso Boom Vacuum
o Boom will be pre-vacuumed prior to launch
o Atmospheric pressures will ensure internal vacuum during reentry
o Vacuum will aid in holding boom closed
o Aerogel Contaminationo Aerogel tablets will be inserted in clean room
o Boom will be vacuumed
o Aerogel Properties
o Pore Network is open
Presenter: Dorin Blodgett2/24/2011
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Design Description
Program Management o No Changes
Presenter: Dorin Blodgett
Project ManagerShawn Carroll
Team LeaderPatrick Weber
Physics Faculty AdvisorDr. Paul Johnson
Engineering Faculty AdvisorDr. Carl Frick
Integrated Sensors (IS)Michael Stephens
Heather Choi
Electrical Power System (EPS)Michael Stephens
Ben Lampe
Telescopic Boom (TB)Patrick WeberEric RobinsonDorin Blodgett
Optical Camera (OC)Kevin BrownNick Roder
2/24/2011
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Design Description
Program Management o Team Picture
Presenter: Dorin Blodgett2/24/2011
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Design Description
Program Management o Schedule Update
o Manufacturing delay (approval for construction)
o Electrical manufacturing is on schedule and has begun assembly
o Resolve Issueso Final drawings will soon be submitted to machine shop
o Manufacturing should be done in two weeks
o Concernso Will a vacuum/ clean room be available at Wallops?
Presenter: Dorin Blodgett2/24/2011
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Design AnalysisSubsystem Updates
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Presenter: Eric Robinson2/24/2011
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Design Analysis
Subsystem Listo Telescopic Boom (TB)
o Optical Camera (OC)
o Integrated Sensors (IS)
o Electrical Power System (EPS)
Presenter: Eric Robinson2/24/2011
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Design Analysis - TB
Boom Force Parameterso Forces on Boom - Testing on Earth
Presenter: Eric Robinson
Force Equations Value UC Unit
FN,extension =mboom*32.2 = 5.80 ± 0.03 lbf
FN,retraction =mboom*32.2 = 76.01 ± 0.03 lbf
Ffriction,static,extension =μstatic*FN,extension = 0.23 ± 0.01 Ibf
Ffriction,static,retraction =μstatic*FN,reaction = 3.04 ± 0.01 Ibf
Fvacuum,sea-level =14.7psi*SABoomEnd 141.4 ± 0.03 lbf
Ftapereel,launch =Fcentrifugal,launch + 25G*mboom*32.2ft/s2 - Fvacuum,sea-level= 165 ± 0.20 Ibf
Ftapereel,extension =Ffriction,static,retraction-Fcentrifugal,apogee = 0.82 ± 0.04 lbf
Ftapereel,retraction =Fcentrifugal,apogee+Ffriction,static,retraction = 5.26 ± 0.04 lbf
Ftapereel,reentry =Fcentrifugal,reentry - Fvacuum,sea-level = -55.6 ± 2 lbf
2/24/2011
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Design Analysis - TB
Boom Force Parameterso Forces on Boom – Throughout Launch
Presenter: Eric Robinson
Force Equations Value UC Unit
FN,extension =mboom*32.2 = 0 ± 0.03 lbf
FN,retraction =mboom*32.2 = 0 ± 0.03 lbf
Ffriction,static,extension =μstatic*FN,extension = 0 ± 0.01 Ibf
Ffriction,static,retraction =μstatic*FN,reaction = 0 ± 0.01 Ibf
Fvacuum,sea-level =14.7psi*SABoomEnd 0 ± 0.03 lbf
Ftapereel,launch =Fcentrifugal,launch + 25G*mboom*32.2ft/s2 - Fvacuum= 23.3-165 ± 0.20 Ibf
Ftapereel,extension =Ffriction,static,retraction-Fcentrifugal,apogee = -2.22 ± 0.04 lbf
Ftapereel,retraction =Fcentrifugal,apogee+Ffriction,static,retraction = 2.22 ± 0.04 lbf
Ftapereel,reentry =Fcentrifugal,reentry - Fvacuum = -55.6 - 85.9 ± 2 lbf
2/24/2011
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Design Analysis -TB
Boom Force ParametersForce Ranges
through Launch
Force Ranges
through Reentry
Presenter: Eric Robinson
0.0020.00
40.0060.00
80.00
100.00
120.00
140.00
160.00
180.000.00
5.00
10.00
15.00
20.00
25.00
Force (lbf)
Altit
ude
(mile
s)
-80.00-60.00
-40.00-20.00
0.0020.00
40.0060.00
80.00
100.000.00
5.00
10.00
15.00
20.00
25.00
Force (lbf)
Altit
ude
(mile
s)
2/24/2011
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Design Analysis -TB
Motor Parameterso Torque Load on Motor Throughout Launch
Presenter: Eric Robinson
Torques Equations Value UC Unit
Tmotor,launch =Ftapereel,launch*rtapespool = 8.14 - 57.6 ± 0.05 lbin
Tmotor,extension =Ftapereel,extension*rtapespool = -0.78 ± 0.05 lbin
Tmotor,retraction =Ftapereel,retraction*rtapespool = 0.78 ± 0.05 lbin
Tmotor,reentry =Ftapereel,reentry*rtapespool = -19.4 - 30.1 ± 0.1 lbin
2/24/2011
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Design Analysis -TB
New Payload Design
Presenter: Eric Robinson2/24/2011
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Design Analysis - TB
New Payload Design
Presenter: Eric Robinson2/24/2011
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Design Analysis -TB
Payload Boom Lengths
Presenter: Eric Robinson
o Retracted – o 11.4 in boom
o Extended – o 27.1 in boom
o 14.6 in reach
2/24/2011
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Design Analysis -TB
Telescopic Boom - Stress
Key Resultso Stress
o Peak von Mises
o ~1350 psi at Motor Support
o Verified with Empirical Models
Loading of 50G in all directions and 100G vertical impulses
Presenter: Eric Robinson2/24/2011
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Design Analysis - TB
Telescopic Boom – Deflection
Key Resultso Deflection
o Peak Deflection
o 0.24 thousandths ofan inch
o Occurs at center ofboom.
Loading of 50G in all directions and 100G vertical impulses
Presenter: Eric Robinson2/24/2011
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Subsystem Testing
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Presenter: Patrick Weber2/24/2011
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Subsystems Testing
Tests to be Performedo TB
o Mechanical Test
o Tape – reel buckling test Completed
o Vibration test Not Completed
o Drop impact test Not Completed
o Water seal test Not Completed
o Thermal expansion test Not Completed
o Cyclic extension/retraction test Not Completed
Presenter: Patrick Weber2/24/2011
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Subsystems Testing
Tests to be Performedo EPS/ IS/OC
o Electrical Test
o Temperature sensor functionality test In Progress
o Accelerometer functionality test Not Completed
o Optical camera functionality test Not Completed
o Thermal loading on electronics test Not Completed
o Software Test
o Asynchronous data capture test Not Completed
o Motor control test Not Completed
o Integration test Not Completed
o Data recovery test Not Completed
Presenter: Patrick Weber2/24/2011
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Subsystems Testing - TB
Tape-reel Buckling Test
Key Results (14” Tape – reel)
o Extension load - eartho 0.23 lbf
o Buckles loading ofo 16.28 lbf
Bucking Load with respect to
Tape – reel Length
Presenter: Patrick Weber
0 100 200 300 400 500 600 700 800 900 10000
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10
15
20
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Loading (lbf)
Leng
ht (i
n)
2/24/2011
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Subsystem Integration
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Presenter: Patrick Weber2/24/2011
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Subsystem Integration
Plano Based on where you are now, how will you ensure the
subsystems will be integrated and tested for the Subsystem Integration and Testing Report?o Manufacture Payload
o Assembly Payload
o Test Payload
o What are the major hurdles going to be?o Approval for Construction/ME Faculty
o Part Backorder/Wait Time
Presenter: Patrick Weber2/24/2011
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Subsystem Integration
Lessons Learnedo What have you learned about subsystem testing and
engineering so far?o The payload is over-engineered
o What would you do differently?o Push ME Faculty harder for approval for construction
o What has worked well so far?o We have analytical justification for all models
Presenter: Patrick Weber2/24/2011
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Fabrication and Assembly
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Presenter: Patrick Weber2/24/2011
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Fabrication and Assembly
Mechanical Fabricationo Payload Frame – 1018 Carbon Steel
o CNC machined
o Bolted down to base
o Telescopic Boom –1018 Carbon Steelo Boom Housing
o Tubing epoxied into frame
o Intermediate Arm
o Threaded tubing and bearing mounts
o Teflon bearing
o Aerogel Arm
o CNC machined
o Aerogel Purchased
o Tape Reel housing
o CNC machined
o Bolted to frame
Presenter: Patrick Weber2/24/2011
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Fabrication and Assembly
Mechanical Assemblyo Manufacturing Instructions
Presenter: Patrick Weber2/24/2011
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Detailed Mass Budget
o Total Mass Budget (30±1 lbs)o Structure (16.7 lbs)
o Boom (13.7 lbs)
o Circuit Trays (2.99 lbs)
o Camera (0.25 lb)
o Other Sensors (1 lb)
o Modular Electrical System (1 lb)
o Ballasting (13.3 lbs)
Presenter: Patrick Weber
Mass Budget
Boom Circuit TraysCamera Other SensorsModular Electrical System Ballasting
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Monetary Budget
o Monetary Budget (~$1300)o Structure ($675)
o Boom ($300)
o Aerogel ($375)
o Camera ($100)
o Other Sensors ($110)
o Modular Electrical System ($225)
o Contingency (+$15%)
Presenter: Patrick Weber
Monetary Budget
Boom CameraOther Sensors Modular Electrical SystemAerogel Correcting Factor
2/24/2011
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Conclusions
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Presenter: Patrick Weber2/24/2011
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Conclusionso New Design Parameters Effects on Design
o Reentry temperatures of 350oF – Teflon Bearings
o Boom vacuum created before launch and at reentry
o Prevent aerogel contamination
o Full canister available
o Payload made of 1018 Carbon Steel –
o Less ballasting but greater centrifugal forces
o Motor must withstand a holding torque of 57.6 lbin
o New tape reel and frame design will survive loadings
o Fabrication and Assembly
o Vacuum/Clean room availability Presenter: Patrick Weber2/24/2011
Questions?
2/24/2011
