Pegasis

Preliminary Design Review RockSat- C

Mitchell Aerospace and Engineering Mitchell Community College October 26, 2011

Outline of Presentation
Mission Overview

System Overview Subsystem Design

Prototyping Plan

Project Management

Pegasis
Mission Overview
Beau Brinkley

Mission Overview
Goal Statement:
Our goal is to design and implement various generators to passively collect energy for possible use by space based instrumentation. We expect to harvest energy from the flight

of the rocket, solar, magnetic and other sources.

Results may lower cost and power requirements for space

science by reducing the weight of electrical components.

Mission Overview
Theory and Concepts:
Various transducers will generate electrical power utilizing

Electromagnetic, Photoelectric, Seebeck, Peltier, and Piezoelectric effects.

Total power output from all transducers will be determined

and compared to the power needed to operate and

onboard off-the-shelf space science package.

Previous work includes:

Electrodynamic tethers tested with the Space Shuttle

MEMS based micro-engineered motion energy harvesting devices (Imperial College of London, 2007) MIDE out of Boston, Ma., founded in 1989, develops vibration energy harvesting devices

Mission Overview
Concepts of Operations

Mission Overview
Expected Results
For each transducer, voltage across a known resistor will

be measured and stored.

All transducers will require amplification of voltage at some

range.
The power used by the balloon board will be measured and

stored.
Measurable data from the balloon board will be saved.

Pegasis
System Overview
Mechanical
Brad Hager

Subsystem Definitions
EM Pendulum Magnet suspended on a pendulum over a copper coil will use horizontal vibrations and angular velocity Photovoltaic panel Magnet surrounded by a copper coil will use vertical vibrations

Aubade Jerk

Grow-Hot
Bristol

Peltier thermoelectric cooler will use temperature changes

Magnets in a circular track will use angular velocity

Crusher
Elvis

Piezoelectric block will use vertical gforces

Electromagnetic microphone will use sound vibrations

Diving Board

Piezoelectric cantilever will use horizontal vibrations

Subsystem Overview- Physical Model

Design in Canister

Right View

Left View

Front View

Critical Interfaces
Interface Name
BSTL/STR

Brief Description
Will mount on top of the 2nd plate *All mounting of transducers will be directly into Makrolon and designed to withstand appropriate Gee forces. Two separate assemblies: Bowl will mount to the bottom plate; pendulum to the bottom of the 2nd plate .

Potential Solution
Bristol will be mounted using 3/4 4-40 CSK bolts; located 1/2 from center

EMPD/STR

Pendulum mounted beneath 2nd plate using 1/24-40 CSK bolts, and 3/8 4-40 CSK bolts for the bowl Support tabs integrated into design and mounted using 3/8 4-40 bolts Support tabs integrated into design and mounted using 3/8 4-40 bolts Mounting brackets made of 6160 aluminum and mounted using 3/8 4-40 bolts.

DVBD/ STR

Tabs will be mounted directly to bottom plate and the transducer suspended vertically.

JERK/STR

Will span the entire z-axis of the payload; mounted directly to bottom and top plates

CRSH/STR

Piezoelectric plate actuators will be stacked vertically and constrained between two mounting brackets on the bottom and 2nd plate.

Critical Interfaces
Interface Name
ABDE/STR

Brief Description
Positioned facing the optical port: mounted on the bottom plate and option for bottom of 2nd plate

Potential Solution
Mounting options still to be defined before CDR

ELVS/STR

Mounted on the top of the 2nd plate

Mounting options still to be defined before CDR

Transducers/ Arduinos

Each transducer is connected to two analog inputs on the Master Arduino. Current runs through a series of op amps, low pass filters, and is then a known resistor; where voltage is measured. Power output will be calculated after rocket flight.

Use right angle Molex connectors from resistor inputs to insure clearance between Arduino and top plate.

System Level Block Diagram

Pegasis
System Overview
Electrical
Nathan Keller

Subsystem Definitions
Electrical is broken down into three

subsystems:
Power Energy Harvesting & Measurement Data Sensing

System Overview-Block Diagram

Subsystem Overview- Physical Model

OpenLog Arduino Microcontroller

High Altitude Sensing Board

System Overview- Physical Model

Critical Interfaces
Interface Name I2 C Brief Description
Inter-Integrated Circuit used to allow communication between a master and slave, or multiple slave, microcontrollers. Output voltage is linearly proportional to the difference between inputs by the factor of the gain.

Potential Solution
Interface uses serial data to communicate between Arduinos allowing the master to control the slave. Input signal range is amplified from millivolt to zero to five volts.

Op Amps

Transducers to Arduinos

Each transducer is connected to two analog inputs on the Master Arduino. Current runs through a series of op amps, low pass filters, and is then a known resistor; where voltage is measured. Power output will be calculated after rocket flight.

Use right angle Molex connectors from resistor inputs to insure clearance between Arduino and top plate.

System Level Software Flow Chart

Pegasis
System Overview
Project Level
Samuel Fox & Joseph Edwards

Requirement Verification Plan

Weight required for both electronic and mechanical

systems will be determined. Combined canister weight will

be less than the maximum requirement of 20 + 0.2 lbs .
Center of mass will meet requirements of the RockSat-C

Users Guide and not negatively effect partnered payload.

Mock up canister will meet specified requirements set by

the RockSat-C Users Guide for accurate payload

simulation.
Potential difference between plates will be zero. All plates

will be electrically connected to a common ground.

User Guide Compliance

Mitchells project will use the 1.SYS.1 payload activation

scheme, allowing us to receive power before G-switch

activation.
All wires will be tied and staked to prevent disconnects

during flight.

Sharing Logistics
Pegasis will be partnering with the New Jersey Space

Grant.
Planned communication will take place via teleconferences,

Google Chat & Google Docs along with Skype.

Pegasis will leave the top plate clear for the New Jersey

Space Grant Team. Our design has the capability to move CG in z & theta without constraining our partner.

Pegasis
Subsystem Design
Mechanical
Gary Staggers

Bristol Transducer Housing

Jerk Transducer
Perspex Tube

Neodymium Magnet

Aubade (Solar) Transducer

Electrodes

Solar Panel

Diving Board Transducer

Neodymium Magnets

Piezoelectric Plate Actuator

EM Pendulum Transducer

Magnetic Pendulum

Wire-wrapped Bowl

Elvis Transducer

Microphone

Base

Grow Hot (TEC) Transducer

Electrodes

Thermoelectric Cooler

Crusher (Piezo) Transducer

Electrodes

Piezoelectric Plates

Key Trade Studies

Piezoelectric Plate Cost Availability Coating Total Time to Customer Boston Piezo-Optics 8.5 10 9.5 8 Noliac 6 10 8 6

Made to order
Average

10
9.2

9
7.8

Key Trade Studies

Permanent Magnets Neodymium Iron Boron (NdFeB) Samarium Cobalt (SmCo)

Cost
Availability Flux Density Demagnetization (Oersted)

6
10 10 10

8
5.5 8.2 7.5

Max Power (BH)

Max Temperature (C) Curie Temperature (C) Average

10
7.5 7 8.6

6.5
10 10 8.0

http://www.coolmagnetman.com/magtypes.htm

Key Trade Studies

Plate Material Cost Availability Density Machinability Tensile Strength (Mpa) Electrical Insulation Aluminum 6061 10 10 4.4 7.5 10 0 Makrolon 5.7 9 10 10 6 10

Average

8.5

Subsystem Risk Matrix

Rare Unlikely Possible Likely

Negligible
Marginal Critical TFI.RSK MPI.RSK CNI.RSK RTC.RSK

TFC.RSK
ARF.RSK

Catastrophic

TFI.RSK: Transducer fixture issues TFC.RSK: Transducer functionality changes due to Gee-forces in flight MPI.RSK: Makrolon plate integrity CNI.RSK: Canister integrity ARF.RSK: Anomalies in rocket flight RTC.RSK: Rocket CATO

Pegasis
Subsystem Design
Electrical
Dylan Stobbe

Subsystem Block Diagram Power

Key Trade Studies Power

Battery Cost Availability Capacity 6v Tenergy 1600 mAh NiMH 8 10 8 Tenergy 7.2v 3800 mAh NiMH 9 10 10

Voltage
Weight Average

9
9 8.8

7
8 8.8

Subsystem Block Diagram Microcontroller

Key Trade Studies Microcontroller

uController ATMega2560 Rabbit BL4S100

Cost
Availability Clock Speed AD Convertors Programming Language Average

10
10 8 9 9

5
6 10 9 9

8.6

7.8

Subsystem Block Diagram Data Sensing

Key Trade Studies Data Sensing

Data Sensing Sparkfun High Altitude Sensing Board 10 10 10 8 7 9 DIY Printed Circuit Boards 7 7 10 10 10 8.8

Cost Availability Capabilities Expandability Structural Integrity Average

Risk Matrix
Rare Unlikely

Possible

Likely

Negligible

Marginal
Critical CSF.RSK

CRA.RSK
EOH.RSK UPE.RSK

VCL.RSK
GSM.RSK BCF.RSK

Catastrophic

MSD.RSK

GSM.RSK: G-force issues on surface mount electronics. BCF.RSK: Battery cell fails(internal delamination, overcurrent shorts battery, etc) VCL.RSK: Vibration causing loose connections. CRA.RSK: Cosmic rays affect electronic components in random matters. EOH.RSK: Excess heat causing electronics to malfunction. UPE.RSK: Unforeseen programming errors. MSD.RSK: MicroSD card fixturing ineffective. CSF.RSK: Canister seal failure.

Pegasis
Safety
Sam Fox

Goal Statement
Our team will pay acute attention to detail and complete an

honest assessment of risks, failures and hazards associated

with this project. The whole team will be educated on all safety precautions and must pass a safety test before

assembly and testing begins.

Safety Risk Management

Hazard
Chemicals in paint, solvent, adhesive

Effect of Hazard
Possible respiratory and skin irritation

Mitigation
Take precautions and wear gloves, safety glasses and have good ventilation Follow safety rules; wear cotton clothing and do not smoke or have other static producing items in the area

Ignition of pyrotechnic compounds

Fire, damage to equipment, personal injury

Use of power tools

Cuts or other injuries, damage to equipment, flying debris

Follow manufacturers safety instructions; wear safety goggles and do not operate without supervision

Misfire on launch pad

Rocket may not be safe to approach

Write procedures to plan for this contingency and follow NAR and TRA safety rules

Pegasis
Prototyping Plan
Mechanical
Samuel Fox

Chart
Risk/Concern Magnetic Shielding Faraday Shielding and Fixtures Proper shielding of sensors Possible loose components damaging sensors Prototype shielding for magnetism by CDR Verify fixtures through testing Action

Canister Design in plastic

Risk/Concern Proper fit of payload components Confirmation of center of mass

Action Mock-up canister printed

Transducers Design table top versions of each transducer

Risk/Concern Does transducer operate as expected

Action Fully test and evaluate each transducer design

Pegasis
Prototyping Plan
Electrical

Chart
Arduino Master and Slave Risk/Concern Improper communication between Master and Slave Arduino Action Functional tests of the Ardunio Microcontrollers Connection and grounding tests

Magnetic Shield Faraday Shield

Risk/Concern Magnetic fields may interfere with electronics and other payloads

Action

Must design a Faraday shield for both Arduino microcontrollers

Action Complete schematic plans

Wiring Paths and Connections

Risk/Concern Shorting and loosening before/during flight

Battery

Risk/Concern Batteries cannot provide current needed Voltage regulators generate heat Lifetime of voltage regulators

Action Functional tests of electronic systems

mA hrs required Voltage regulation

Saving Data Openlog interface to Arduino Fixturing of MicroSD card

Risk/Concern Saving data from Arduino to microSD card may be difficult Connection between the OpenLog and SD card lose contact during flight

Action Intensive programming attention given to saving data. Test possible fixturing methods of microSD card in Openlogger

Pegasis
Prototyping Plan
Test

Chart
Rocket Flight Testing vibration and gee forces on components and payload Risk/Concern Rocket must be reusable and stable for consistent test flights Action Complete construction of component testing rocket using proven techniques and materials.

Shake Tables Low/High Frequency Tables

Risk/Concern Shake tables must be able to simulate vibration for full time of flight + 50% more.

Action Begin construction of shake tables with prototype testing

Electronic Testing Tests on Arduinos and layouts of wire paths

Risk/Concern Wire must not short and be stress tested

Action Perform grounding tests while prototyping Evaluate different wire paths while testing

Full Scale Payload Testing

Risk/Concern Canister mockup must be constructed to WFF specifications Center of gravity must be addressed Full scale test rocket must have similar flight characteristics of WFF flight

Action Complete design of full scale integration test of payload Continue design of fullscale test rocket.

Mock-up Canister construction Full scale test rocket

Component Rocket Schematic

Length: 46.50 inches Diameter: 4 inch payload to a 3 inch body tube Mass: 3.3 lbs Max Altitude: 2000 ft

Pegasis
Project Management Plan
Beau Brinkley

All project management documents are large working files therefore, are viewed as screenshots in this presentation. Actual documents may be viewed outside of this construct.

Mission Overview
Organizational Chart

Mechanical Team Members

Brad Hager, 22 Architecture UNC Charlotte

Michael Brown, 20 Mechanical Engineering UNC Charlotte

John Benfield, 20 Biology, Psychology, Psych/Neuro TBD

Gary Staggers, 31 Mechanical Engineering UNC Charlotte

Electrical Team Members

Dylan Stobbe, 21 Computer Engineering UNC Charlotte

Ryan Howard, 22 Associate of Science Degree Air Force

Nathan Keller, 17 Associate of Science Degree

Test Team Members

Samuel Fox, 20 Chemical Engineering NC State

Derek Spencer, 34 Biology, Pre-Med UNC Charlotte

Joseph Edwards, 40 Mechanical Engineering Technology UNC Charlotte

Project Manager & Safety Officer

Beau Brinkley, 22 Systems Engineering UNC Charlotte

Erin Wilson, 25 Veterinary School NC State

Team Members & Contact Information:

Name E-Mail Phone Contact

Erin Wilson Brad Hager

Michael Brown John Benfield Beau Brinkley Nathan Keller

erwilson28244@mitchellccmail.com bwhager@mitchellccmail.com
mdbrown1819@mitchellccmail.com jbenfield@mitchellccmail.com bhbrinkley@mitchellccmail.com nlkeller@mitchellccmail.com

704-657-3866 704-500-9508
704-497-4225 704-775-5530 704-902-0627 704-872-2323

Samuel Fox
Derek Spencer Dylan Stobbe Ryan Howard Joseph Edwards Gary Staggers

sjfox@mitchellccmail.com
dpspencer@mitchellccmail.com drstobbe@gmail.com ryo242@gmail.com jdedwards925@mitchellccmail.com garystaggers@gmail.com

704-928-5172
704-883-4731 828-278-9466 704-663-2299 704-500-4003 704-778-0588

Management
Budget Overview
Equipment Budget
Department
Mechanical Equipment
Makrolon Bolts Wire Magnets Rubber Bushings Piezoelectric speaker element

Estimated Cost
$ $ $ $ $ $ $ $ $ $ $ $ $ 110.00 16.75 19.00 33.50 19.75 52.50 30.00 42.00 23.50 21.50 24.25 48.00 83.00 42.00 22.25 210.00 40.00 26.25 14.00 20.50 175.00 32.50 23.00 32.25 42.00 85.25 22.00 35.25 50.50

Cost Description
Mounting Plates for Sensors and Generators Mounting Generators Generators Shock Absorbtion for Plates and Hardware Generator Data Storage Electronic Activation Voltage Output Amplification Electronics Electrical System Cicrcuit Board Program Controller Data Collection Shake Table Shake Table and Test Rocket Construction Shake Table and Test Rocket Construction Test Rocket Test Rocket Test Rocket Test Rocket Test Rocket Test Rocket Test Rocket Test Rocket Test Rocket Test Rocket Test Rocket Test Rocket

Mechanical Total: $251.50

Electrical Total: $441.25 Test Total: $1411.50 Travel Total: $3500.00 Total Available Funds: $5604.25

Electrical

Micro SD Card G - Switches Op Amps Blank Printable Circuit Board Various Resistors Etchant Arwdino Atmega

Data Loggers ( Micro SD Shield of Open Log ) $

Test

Plywood

$ $ $ $ $ $ $ $ $ $ $ $ $ $ $

Assorted hardware Cardboard tube Epoxy resisn Fiberglass Motors & Propellent Tubular Nylon Nose Cone Ignitors Kevlar Sheeting Rocket Electronics Parachute Table for shake test Vibration electronics and sensor

Total
$ 1,396.50

Mechanical
$ 251.50

Electrical
$ 314.25

Test
$ 830.75

Management
Schedule

Schedule Milestones Project Charter Introduced 8/29/2011 Project Scope Defined 9/19/2011 Conceptual Design Review 10/3/2011 Preliminary Design Review Progress Report 10/17/2011 Preliminary Design Review 10/26/2011 Critical Design Review Progress Report 11/14/2011 Critical Design Review 11/30/2011

Management
Work Breakdown Structure

Project Phase 1 Timeline 8/15/2011 1/9/2012 Project Phase 1 Deliverables Conceptual Design Review Preliminary Design Review Critical Design Review

Conclusion
Going Forward
Mechanical Mechanical component procurement. Construct Prototype designs and begin 3d printing of part models. Electrical Testing of the Arduinos, writing and debugging code for component test flights. Test voltage readings from the Arduinos with known voltages to confirm accuracy and resolution. Interface with Mechanical regarding initial wiring paths. Test Begin construction of shake table and other testing equipment. Construct component Test Rocket flights for equipment performance results. Project Management Updates to project schedule and budget estimates as compared with actuals. Plan control contingencies and risk mitigation. Safety program implementation with hardware construction. Begin interfacing with New Jersey regarding payload requirements.

Conclusion
Questions
How much flight hardware needs to be built by CDR? Data concerning sounding rocket vibration frequencies and

amplitude?
Expectations from CDR to down select in January?