spacegrant.colorado.eduspacegrant.colorado.edu/COSGC_Projects/space/fall_20… · Web viewAn Arduino will be programmed to sample and record the current and voltage off of this

Colorado Space Grant Consortium

GATEWAY TO SPACEFALL 2012

DESIGN DOCUMENT

Team Spirit of the Koala

Project Volt

Written by: Thomas Jeffries, Anthony Anglin, Starteya Pais, Colin Harkins, Dustin Fishelman,

Joao Mansur, Andrew Trujillo, Dylan Cooper

11/15/12

Revision C

Chris Koehler, 11/28/12,

What a picture…

Gateway to Space ASEN 1400/ASTR 2500___________________________________Fall 2012

Revision Log

Revision Description DateA/B Conceptual and Preliminary Design Review 10/18/12C Critical Design Review 11/15/12D Analysis and Final Report

Acronyms

Acronym MeaningTSOK Team Spirit of the Koala

Team SOK Team Spirit of the KoalaBalloonSat Balloon Satellite

Page 2 of 20Team Spirit of the Koala November 15, 2012Project VOLT Rev C


Table of Contents

1.00 Mission Overview…………………………………………………………………………..42.00 Requirements Flow Down…………………………………………………………………..63.00 Design……………………………………………………………………………………….74.00 Management………………………………………………………………………………..115.00 Budget………………………………………………………………………………………136.00 Test Plans and Results……………………………………………………………………...157.00 Expected Results……………………………………………………………………………198.00 Launch and Recovery………………………………………………………………………199.00 Results and Analysis……………………………….………………………………..……N/A10.00 Ready for Flight………………………………………..……………………………..…N/A11.00 Conclusion and Lessons Learned……………………..…………………………………N/A12.00 Message to Next semester……………………………………...……………………..…N/A



1.00 Mission Overview

1.01 Mission StatementDetermine the feasibility of using the flow of atmosphere across the surface of the

BalloonSat, flown to 30 kilometers, during accent, to provide power to a BalloonSat.

1.02 Primary Experiment

Team Spirit of the Koala will attempt to generate current using the rotation of the BalloonSat during the accent through the atmosphere. The BalloonSat will attach to the flight tube with ceramic stainless steel bearings. This will allow the BalloonSat to rotate independently of the flight tube during the accent. A magnet attached to the flight tube will spin within coils of copper wire. TSOK hopes to use this rotation to generate current.

This is a graphic taken from an online simulator, demonstrating the concept behind our experiment.


Kate, 11/25/12,

Great graphic, but you should explain what is being shown in the picture.


Good and to the point.


Very organized and you answered all the questions. If you could expand just a bit on each of your sections, it would be perfect. A few more sentences would do it.


http://phet.colorado.edu/en/simulation/generator

1.03 Experiment Background

The spinning of the magnet in the BalloonSat will create a change in flux, inducing a current in the copper wire, in accordance with Faraday’s Laws of electromagnetic induction. Faraday’s Laws state that the current produced in a coil of wire is proportional to the negative rate of change of magnetic flux. The greater the angular velocity of the magnet, the higher the change in flux will be. This means the faster the magnet spins, the higher current generated.

1.) "Faraday's Laws and Magnetic Induction." MIT Physics Notes. MIT, n.d. Web. <http://ocw.mit.edu/courses/physics/8-02sc-physics-ii-electricity-and-magnetism-fall-2010/faradays-law/MIT8_02SC_notes21.pdf>.

2.)"Faraday's Laws." Hyper-Physics. N.p., n.d. Web. 21 Oct. 2012. <http://hyperphysics.phy-astr.gsu.edu/hbase/electric/farlaw.html>.

1.04 Expected Discovery

We expect to discover that the current generated will be inconsistent. This will show that wind power is unfeasible for use as a primary power source on BalloonSat missions. We expect this result due to differences in turbulence at different altitudes. Another reason we expect this result is due to decreasing density of the atmosphere during accent. TSOK will use fins, composed of foam core attached to the exterior of the BalloonSat, to dampen fluctuations and provide a more consistent, improved spin rate.

1.05 Experiment Origins

The reason for conducting this mission is to determine the feasibility of using wind to power experiments in future BalloonSats. Weight could be saved on BalloonSat missions, by reducing the number of batteries necessary to power the BalloonSat, if power can be generated using wind.

1.06 Special Features

TSOK’s BallonSat will include a GO PRO video camera. This footage will assist in displaying our experiment at the design expo, demonstrating what the flight experience was like. This can also be used to inspire outside interest in BalloonSats, engineering, and space exploration.


Kate, 11/25/12,

Overall, good mission overview. I think more information about the tradeoff of battery to wind power (maybe a mass example) would be more effective in proving the importance of your experiment.

Kate, 11/25/12,

Put your references all together at the end of the report.

Kate, 11/25/12,

Showing some equations here would be useful.

http://phet.colorado.edu/en/simulation/generator


2.00 Requirements Flow Down

This Requirements flow down chart will guide us in project development. It is used to keep our project on track and for us to verify each requirement as traceable, necessary, verifiable, attainable, and clear. Our level zero requirements are derived from the RFP requirements and our mission statement. These primary systems are labeled A-E with their corresponding sub-systems.

Number Requirement OriginLevel 0 Requirements

Experiment

0.1 Project Volt shall collect data on current and voltage created by an electric generator as the BalloonSat spins.

Mission Statement

0.2 The BalloonSat will rotate independently of the flight string. Mission Statement

Structure

0.3 The BalloonSat will withstand the environment at up to 30,000m and the forces of balloon pop.

Mission Statement

Data

0.4 The BalloonSat will take data about the environment to give meaningful comparison for data obtained from the electric generator.

Mission Statement

Level 1 RequirementsExperiment

1.1 A functional electric generator will be constructed and integrated into the attachment point of the flight string to the BalloonSat.

0.1

1.2 An Arduino will be programmed to sample and record the current and voltage off of this generator using an Attopilot combined current and voltage breakout.

0.1

1.3 The flight string attachment point will be mounted to the body of the BalloonSat via a set of ceramic bearings.

0.2

Structure



Burst would be a better word.


Much improved…


1.4 All instruments flying in the BalloonSat will be contained within a hard, heated and insulated structure made from both foam core and insulating foam.

0.3

1.5 All items inside the BalloonSat will be tightly secured to the sides using Velcro to avoid damage in the post balloon pop environment.

0.3

Data

1.6 The BallonSat have a GoPro Hero 2 and a Canon A780 onboard to record the flight.

0.4

1.7 The BalloonSat will be launched with an accelerometer, a pressure sensor, internal and external temperature sensors and a humidity sensor

0.4

1.8 An Arduino will be programmed to record all environmental data coming from the different sensors

0.4

3.00 Design Overview

3.01 Design Plan

Project Volt’s structure will accommodate for all necessary systems. Team SOK will build a prototype BalloonSat that will be used for all ground testing. At this moment all materials have been purchased or received. If we need more structural materials they are available at the Gateway Store. Team SOK will adhere to the schedule and complete all tasks to ensure a successful flight. During the testing process if we find that a redesign is necessary we will address it quickly and effectively. Since the primary objectives of generating rotational velocity relies upon our fin design, we will perform multiple tests and try different designs to ensure this system works on the ground before flight. We understand that this has been a primary objective of previous flights and they have failed. By thoroughly testing this system we will ensure completion of this objective. Following recovery of our BalloonSat, we will collect and analyze all data recorded from the flight.

3.02 Structure

The mission is going to be completed by building a 16x16x16 cm cube made out of foam core. It will be held together with hot glue and aluminum tape. Fins will be glued to the outside of the structure, one four for each side of the cube. The design of the fins has not been determined yet, because that is part of our testing experiment, to see which design will create the most spin. The inside of the cube will be lined with one or two layers of thermal insulation to



ensure the BalloonSat is kept warm during flight. Through the top and bottom will be a hole, each filled with a ceramic stainless steel bearing. The flight tube will go through the middle of the BalloonSat and be held in place by a string tied in a figure eight knot.

3.03 Imaging

TSOK will image the environment during flight using both a Canon camera and a GO PRO. The Canon and the GO PRO will be attached to the walls of the BalloonSat, pointing outward. Holes will be cut in the exterior of the BalloonSat, over the lenses of the Canon and GO PRO, allowing the Canon and GO PRO to record images of the environment.

3.04 Generating Current

Inside the BalloonSat, a magnet will be glued, oriented perpendicularly, to the flight tube. On each side of the flight tube, wire will be coiled, about an axis parallel to the magnet. These coils will be placed as close to the magnet as possible, while still allowing the magnet to spin freely without contact. The ends of the coil will be attached to a combined current/voltage sensor.

3.05 Arduinos and Other Sensors

The combined current/voltage sensor will be attached to an Arduino unit with a shield and micro SD card in order to record the data from the experiment. The Arduino will be powered by 9V batteries. A heater will be attached with a switch inside the cube. The heater will also be powered by 9V batteries. Next to the heater will be another Arduino unit with a shield and micro SD card. This Arduino will have a relative humidity sensor, an internal temperature sensor, a pressure sensor, and an external temperature sensor connected to it. The external temperature sensor will be placed on the exterior of the BalloonSat.

3.06 Parts/Hardware Needed

Canon Camera (Space Grant) GO PRO (Purchased by team member) Neodymium Magnets (apexmagnets.com) Voltage/Current Sensor (sparkfun.com) Copper Wire (Home Depot) Arduinos (Space Grant) Arduino Shields (Space Grant) SD cards (Space Grant) Environmental Sensors (Space Grant)



Think you could add a whole lot more detail to this section. Would love to see more detail on how you designed this generator. How the bearings work. Etc.


Not the right knot but close enough.


3.07 Parts Ordered and Received

Ordered Parts: Neodymium Magnets Sealed Ceramic Stainless Steel Ball Bearings Current/Voltage Sensor

Order Status: Magnets: Received Bearings: Received Current Sensor: Received Copper Wire: Purchased GO PRO: Purchased

3.08 3D and 2D Pictures


Magnets

Copper Wire Coils

Heater


Picture is good but I would challenge you to come up with a better mechanical model of your balloonsat by the final report. Or take really good pictures of you the actual unit.


How are these held to the tube as shown in the picture?



Kate, 11/25/12,

Dimensions?


3.09 Functional Block Diagram

4.00 Management and Scheduling

4.01 Management


Kate, 11/25/12,

Final Parts List with details as to where parts were ordered, cost, and part number?


Cameras are not labeled. Where are your accels?


4.02 Scheduling

*Team Meetings every Sunday and Monday and as necessary*September 28th………………………………………………………... Turn in proposal (4:00 pm)October 2nd….………………………………………………...CoDR Presentations Due (7:00 am)October 4th………………………………………………………………….Order all the hardwareOctober 5th………………Authority to Proceed by appointment with Chris (9:00 am - 3:00 pm)October 7th………………………………………………………..Finalize design + Team meetingOctober 13th…………………………………………….......................Have acquired all hardwareOctober 14th…………………………………………………………………….Begin constructionOctober 18th………………Design Document Rev A/B (7:00 am) + pCDR Slides Due (7:00 am)October 21st…………………………………….Testing: Structural Test: Drop Test and Roll TestNovember 4th………………………………………………………………..Finalize programmingNovember 13th..........................................................Testing: Structural Test: Whip Test and Cooler Test + Sensor Test: Imaging TestsNovember 14th…………………………………Testing: Overall Test: Experimental Systems TestNovember 15th……………………………………..Design Document Rev C (7:00 am) + In-


Thomas JeffresLeader, Budget

Manager, Structural Design, Backup

ProgrammerAnthony Anglin

Coordinator, Researcher

Starteya PaisStructures, Researcher

Colin HarkinsStructures, Secretary

Dustin FishelmanCoordinator,

Structures, Secretary

Joao MansurResearcher, Structures

Andrew TrujilloResearcher, Backup

Structures

Dylan CooperLead Programmer


Class Demo (Mission Simulation Test)November 25th………………………………………………Finalize satellite and prep for launchNovember 27th………………………………………………………….LRR Slides Due (7:00 am)November 30th……………………………………………………………………...Final Weigh-inDecember 1st ……………………………………...Launch day @ 6:50 AM (Weather Permitting)December 2nd…………………………………………………………………….Celebration PartyDecember 3rd……………………………………………………………….System Failure TestingDecember 4th……………………………………Launch Recap/Report + Data Analysis GuidanceDecember 8th………………………………………….ITLL Design Expo + Design Document

Rev D Due (7:00 am) + Extra Credit Video DueDecember 11th………………………………………………………..Final Presentations and Reports (7:00 am) + BalloonSat hardware turn-inDecember 12th (Final Class) ……………………...Final Team Evaluations + Homework #09 Due

*Schedule after December 1st if launch postponed will be pushed back according to the postponed launch date*

5.00 Budget

5.01 Weight

Hardware Weight (g) Quantity SubtotalBearings 9.07185 2 18.1437

Magnets 132.297 1 132.297

Current Sensor 1 1 1

Arduino 30 2 60

Arduino Shield 30 2 60

Copper Wire 34.8 1 34.8

Accelerometer 1 1 1

Pressure Sensor 1 1 1

Temperature Sensor 1 2 2

GoPro 200 1 200

Camera 130 1 130

Humidity Sensor 1 1 1

Batteries 40 6 240



Heater 300 1 15

Structure 415 1 415

Total N/A N/A 1211

We are currently 86 grams overweight. TSOK is working to reduce weight or “buy” some weight from other BalloonSat teams.

5.02 Budgeted Expenses

Hardware Cost Quantity S/H SubtotalBearings 14.95 2 6.11 36.01

Magnets 19.99 2 6.65 46.63

Current Sensor 19.95 1 0 19.95

Copper Wire 22.23 1 0 22.23

Total N/A N/A N/A 125.82

5.03 Additional Expenses

Hardware Usage Cost Quantity SubtotalDry Ice Cooler Test 1 26 1 26

Dry ice Cooler Test 2 1

Total N/A N/A N/A

5.04 Provided Items

Item Quantity UsageArduino 2 Data Collection

Arduino Shield 2 Data Collection

Accelerometer 1 Measuring Acceleration

Pressure Sensor 1 Measuring Pressure

Temperature Sensor 2 Measuring Temperature

Camera 1 Environment Imaging

Batteries 5 Power

Heater 1 Maintain TemperaturePage 14 of 20

Team Spirit of the Koala November 15, 2012Project VOLT Rev C


Switches 3 Control Electronics

LEDs 4 Indicators

Foam Core N/A Structure

Insulation N/A Maintain Temperature

Hot Glue N/A Structure

Flight Tube 1 Attach to flight String

Washer 2 Structure

Aluminum Tape N/A Structure

Wires N/A Electronic Connections

Solder N/A Electronic Connections

6.00 Testing

To test the integrity of the satellite, we will have a variety of different simulations and tests under different conditions. These include drop tests, cooler tests, whip tests, imaging tests, mission simulation tests, experimental system tests, and tests looking at the effectiveness of different fin types and sizes.

6.01 Drop Test

A prototype version of the structure of our BalloonSat will be constructed with the same dimensions and weight. This prototype will include the insulation and to simulate mass will include rocks that are taped into place (to prevent damage because of the rocks moving around). These rocks will need to weigh a total of approximately 980 grams to properly simulate the mass of the components that will be housed inside the BalloonSat. Once this is completed a variety of different drop tests will be conducted from different heights available to us. All heights should be in excess of 10m and with additional force pushing the prototype toward the ground. This will simulate a worse-case scenario landing. If the BalloonSat structure survives this, we can be sure that it will survive the landing and the balloon pop on launch day.Results:

The prototype box was dropped from a height of approximately 13m with mass simulators weighing a total of approximately 2kg. This weight of more than our allowed mass is to ensure that the box will hold up to a large amount of kinetic energy being transferred from it as it impacts the ground. The mass simulators were secured inside the box with duct tape. In the end, the box survived very well (enough to repeat the test two more times with the same results) aside from a few dents along the edges. There were no breaks in the box and all of the rocks were still secured when the box was opened again.



6.02 Cooler Test

With the same prototype as mentioned above a cooler test using dry ice will be conducted. During this test the dry ice will bring the BalloonSat down to temperatures similar to those at the coldest point during its fight. Inside the prototype there will be a single Arduino Uno with internal and external temperature sensors wired up to it and the heater, constructed out of ceramic resistors and 3 9 volt batteries. In addition to these systems all of the camera systems will be functioning and recording. These systems will provide data on how close to flight temperatures we achieved with the dry ice, as well as how well the insulation kept the temperature up in the BalloonSat. This data will also give information on how all of the components inside the BalloonSat function at low temperatures. Through this we can determine what systems will need to be closest to the heating system. To succeed in this aspect of the mission we need to keep the internal temperature above -10 degrees Celsius.

Results:



5 357 709 1061141317652117246928213173352538774229458149330

10

20

30

40

50

60

Cooler Test Data

Pressure (psi) AccelX (g) AccelY (g) AccelZ (g) Humidity (%) Internal Temp (Deg C)

Time

5 335 665 995 1325 1655 1985 2315 2645 2975 3305 3635 3965 4295 46250

5

10

15

20

25

30

35

Cooler Test Data

Voltage (V) Current (I) Internal Temp (C) External Temp (C)

Time

The cooler test was a success because the internal temperature stayed above 10 degrees Celsius for the duration of the test.

6.03 Whip Test

To ensure the integrity of the flight string attachment point, we will need to conduct extensive whip tests simulating the forces that will be experienced after balloon pop. These tests will need to be so extensive because our entire experiment depends on this point. With a



Results?

Kate, 11/25/12,

Does this Cooler Test really validate our system when your external temperature only goes to a minimum of 7 deg. C.

Kate, 11/25/12,

Assuming your time is in seconds…specifiy!


prototype box we will construct a working mock-up of the flight tube and the bearings that let it rotate independently of the BalloonSat. Mass simulators will be put in place of all hardware. From this point we will connect the flight tube to a section of string in the same manner that it will be connected on launch day. The BalloonSat will be violently whipped around in an effort to simulate the extreme forces present when the balloon pops. Whether or not the fight tube and the rest of the structure attaching the bearings hold up will tell us whether or not we need to rethink the attachment points.

6.04 Imaging Tests

Imaging tests will be conducted inside of one of our prototype boxes. This will ensure the placement and that the software that controls the Canon A780 camera. In addition to this, the imaging test will show us how long the batteries will last on both the Canon Camera and the GoPro.

Results:

Both cameras were mounted into the BalloonSat and turned on to test their field of view as well as their battery life. The field of view on each of the two cameras included the fins on the sides of the box to watch for any failure during the flight. Both of the cameras were mounted inside and turned on to the mode they will be running in during the flight and both tested to have a battery life around the range of 2.5 hours. We know that temperature often has a very large effect on battery usage in electronics. To negate some of this effect we will be locating the heater next to the batteries for both Arduinos and the Canon A780 camera. The Go Pro Hero 2 has a built in heater to preserve its battery life in very cold temperatures.

6.05 Experimental Systems Test

The Experimental Systems test will be the test of the experimental structure. The flight tube will be mounted on the bearings with the magnets attached to the flight string. The system of coils will be constructed and there will be an Arduino located inside the BalloonSat prototype. The BalloonSat will be spun around the flight tube and it will also be tested in a wind tunnel at different wind speeds. The current and voltage produced by the generator will be written onto a 2GB SD card and stored. For the test in the wind tunnel/the box spinning test this data will correspond to different wind speeds. This test will ensure that all of our coding for the experiment works properly and that the system actually functions to generate current. All of this will be done in the wind tunnel/ during the spinning test with a variety of different fin types and sizes. The data received from this test will tell us what type of fin to use during our flight.

6.06 Mission Simulation Test

To simulate the entire mission we will have all of the components that will be present on launch located inside the BalloonSat. This includes all cameras, the Arduinos, and the entire experimental system. The system will be put in dry ice and the experimental system will be



Results?

Kate, 11/25/12,

Results?


I expected these results in this rev.

Kate, 11/25/12,

Show example picture to prove that the cameras worked.


Should have images here…

Kate, 11/25/12,

Results?


running (the flight string will be spun so that current and voltage can be measured). In addition to this test, there will be a complete mission simulation test outside the cooler. This test will be done in class on Thursday, November 15, 2012. This test will ensure that all components running in the mission work properly while running at the same time.

6.07 Safety

SOK will use many techniques to ensure both the safety of ourselves, as well as the safety of any onlookers during our tests. During flight the BalloonSat will be securely fastened to the string of the balloon, preventing the BalloonSat from falling separately from the balloon apparatus. During all drop tests team members will station themselves about the drop area to prevent any persons or items from entering the landing area. Whip tests will only be conducted in open spaces with all nearby persons warned of the possibility of whip test failures and pieces or all of the BalloonSat launching through the air. During cooler tests we will ensure that the cooler is not sealed, allowing a pressure release so that CO2 will not buildup and violently rupture the container. Additionally, SOK will place an American flag sticker onto the outside of the BalloonSat. University of Colorado Boulder’s contact information will also be written on the side of the BalloonSat. These two measures will help if the BalloonSat is recovered by a non-SOK team member. Basic common sense will also be used to maintain safety of all involved.

7.00 Expected Results

We hope to recover data from our flight confirming our hypothesis that wind power is not a feasible primary source of power for BalloonSats. We expect that the amount of power generated will be greatest in the first part of the flight. It will increase to its highest near the top of the troposphere, where average wind speeds are highest. From this point it will start to go down because the air is much less dense in the high atmosphere. The lower density of the air should make for less force spinning the balloon. This would mean that to apply this power toward the entire flight, it would need to be stored throughout in some type of system. All of this data will come in the form of discrete data points of current and voltage. By putting all of this data through a function to multiply the two, the instantaneous power going through the circuit. This data will be graphed and compared to the altitude of the BalloonSat (calculated from the atmospheric pressure samples obtained during flight.

8.00 Launch and Recovery

On December 1st, 2012 our BalloonSat will launch. TSOK member Dustin Fishelman will be the team member holding the BalloonSat as it launches. The entire TSOK will be traveling to recover the BalloonSat which will be located through the GPS sensor that is launched with the BallonSat. This GPS data will be relayed to us by Professor Koehler. To recover all of the flight data, we will remove the 2 GB SD cards from each of the Arduinos and


Kate, 11/25/12,

Show visuals of your ecpected results. Some sort of analysis should be shown.


OK but I am also looking for examples of what your flight data would look like. For all sensors and your experiment.

Kate, 11/25/12,

Results?


the Canon Camera and the 32 GB SD card from the Go Pro Hero 2. At this point, the data will be put on a computer and backed up to another drive before being analyzed and graphed in Microsoft Excel. We have done this same procedure when preforming cooler testing to verify that it actually works.


Documents

spacegrant.colorado.eduspacegrant.colorado.edu/COSGC_Projects/space/fall_20… · Web viewAn Arduino will be programmed to sample and record the current and voltage off of this