Kylie Flickinger – Mechanical Engineering


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Kylie Flickinger – Mechanical Engineering

  • Kylie Flickinger – Mechanical Engineering

  • Adam Kuhlman – Data Acquisition

  • William K. McDannell Jr. – Software

  • Chris Small – Strain Gauge Board

  • Robert Stottlemyer – Team Leader

  • Tim Svirbly – Test Equipment Development



BU Mag Dog Team

  • Sensors – Aichi – Shawn Doria

  • Sensors – Honeywell – John Gancarz

  • Power – Tracy Thai

  • Rabbit Controller – Andy Lee

  • Mechanicals – Jim Thumber

  • Software/Simulations/Analysis – TBD

    • Nanosat teams join after January 30


The purpose of this experiment is to investigate the mechanical stresses in an elastic structure during the flight of a sounding rocket. The structure proposed consists of a circular plate, the deck plate, which is supported by four longerons, which connect in turn to circular plates at either end of the longerons simulating a payload section of previous sounding rocket flights. A dummy mass is attached to the center of the deck plate. During the flight, dynamic loads in the axial and lateral directions will cause the deck plate to deflect. The resulting deformation will be measured at selected points using strain gauges connected to electronic boards to obtain time-varying voltage signals which in turn will be digitized and stored for later analysis. The obtained data will be compared to theoretical predictions. Careful pre-flight calibration of the entire data stream will be conducted.

    • The purpose of this experiment is to investigate the mechanical stresses in an elastic structure during the flight of a sounding rocket. The structure proposed consists of a circular plate, the deck plate, which is supported by four longerons, which connect in turn to circular plates at either end of the longerons simulating a payload section of previous sounding rocket flights. A dummy mass is attached to the center of the deck plate. During the flight, dynamic loads in the axial and lateral directions will cause the deck plate to deflect. The resulting deformation will be measured at selected points using strain gauges connected to electronic boards to obtain time-varying voltage signals which in turn will be digitized and stored for later analysis. The obtained data will be compared to theoretical predictions. Careful pre-flight calibration of the entire data stream will be conducted.


Novel Magnetometers Flight Experiment - Science

  • Design, assemble, and test two COTS, solid state 3-axis magnetometers with controller, data storage and power:

    • Honeywell HMR2003 - anisotropic magneto-resistance
    • Aichi Micro Intelligent AMI302 - giant magneto-impedance
  • Compare directly the X,Y,Z flight readings of both sensors

  • Measure EMI from the chips’ bias straps (Honeywell) and bias coils (Aichi).

  • Honeywell device proposed for U. Colorado small satellite design (2003). We have found no other evidence of its use in space flight.

  • Aichi chip under study by US Navy for navigation of autonomous marine vehicles. We have found no record of the Aichi chip being used in space.



Subsystem Requirements

  • Subsystem Requirements



Block Diagrams













After testing in SolidWorks, we determined that the deck plate would not deform enough for the strain boards that we built for the USERS program to amplify the signal enough to get meaningful data using metal strain gauges. After research, we decided to use semi-conductor strain gauges, which have a gauge factor of ~60 times that of a metal foil strain gauge. We will implement them in a configuration that would both double signal output and reduce concerns about temperature sensitivity. Using this configuration should allow us to use our boards from the USERS program with only minor changes.

  • After testing in SolidWorks, we determined that the deck plate would not deform enough for the strain boards that we built for the USERS program to amplify the signal enough to get meaningful data using metal strain gauges. After research, we decided to use semi-conductor strain gauges, which have a gauge factor of ~60 times that of a metal foil strain gauge. We will implement them in a configuration that would both double signal output and reduce concerns about temperature sensitivity. Using this configuration should allow us to use our boards from the USERS program with only minor changes.







Memory Needs : 12 Analog Signal Streams each digitized at ~250 samples/second to be sampled for 750 seconds at 2 bytes per sample = 4.5 Megabytes

  • Memory Needs : 12 Analog Signal Streams each digitized at ~250 samples/second to be sampled for 750 seconds at 2 bytes per sample = 4.5 Megabytes

  • Data stored on a SD card inserted into Miniboard (45mm x 55 mm) - www.futurlec.com/mini_sc.shtml

  • standard SD or SPI communication. 3 Volt power

  • Microcontroller Board – www.microchip.com/wwwproducts/devices.aspx?ddocname=en024691 Model : PIC24HJ256GP206 , 18 channels 12 bit A/D conversion at up to 500 ksps, 2-UART,2-SPI, 2-12C digital communication, 3 to 3.6 Volt power with on-chip 2.5 Volt power regulator, size 1.0”x2.2” . Programming language C



Special Requirements

  • MAPP Special Requirements

    • Shift in center of mass along length axis on rocket
  • BU Special Requirements

    • Minimize magnetic materials and fields


MAPP Commands and Sensors

  • Always On – Triggered by the G-Switch

  • Turned off by microcontroller before splash down

  • 12 Analog Signal Streams each digitized at ~250 samples/second to be sampled for 750 seconds at 2 bytes per sample = 4.5 Megabytes

  • Data stored on a SD card Miniboard (45mm x 55 mm) - www.futurlec.com/mini_sc.shtml

  • Microcontroller Board (protopic 28) – 1.0” x 2.2” – www.microchip.com/wwwproducts/devices.aspx?ddocname=en024691 Model : PIC24HJ256GP206 , 18 channels A/D conversion, on-chip 2.5 Volt power regulator

  • Strain Gauge: Vishay or Semiconductor (to be decided)

  • Data Acquisition Controlled by Microcontroller initiated by power on



MAPP Test Plans

  • Mechanical Stress Distribution

    • SolidWorks
    • Thin Plate Theory
    • Static Force Rig (similar to the one we used for USERS)
  • G-Switch and Latched Relay

    • Spring loaded launch in a controlled setting
    • Ensure compliance with no-volts requirement when integrated with power supply
  • Strain Gauges

    • Temperature sensitivity
    • Circuitry and Signal Strength – simple beam test
    • Compare to metal foil strain gauges
    • Calibration
  • Data Acquisition/Storage

    • Store and retrieve data
  • All electronics: Burn in period



By the end of fall semester (12/19/08)

  • By the end of fall semester (12/19/08)

    • Critical design review completed
    • Begin ordering parts
    • Wrap up design phase
  • Over Christmas Break (12/19/08 – 01/12/09)

    • Continue ordering parts
    • Begin planning build phase
  • Beginning of Spring Semester (01/12/09)

    • Meet to plan build phase
    • Take an inventory of parts
  • Between (01/12/09 – 03/15/09) Build Phase

      • Manufacture circuit board for data collection
      • Alter strain gauge boards
      • Manufacture testing rigs—Static force rig like we used for USERS, Spring mechanism to test G-Switch
      • Manufacture G-switch
      • Manufacture plates, longerons, alter dummy weight from USERS, braces, and housing for battery and g-switch.
  • Between (3/15/09 – 4/25/09) Testing Phase

      • Test performance of Semiconductor Strain Gauges—Compare to metal foil strain gauges. Also test temperature drift.
        • Static force rig similar to the one we used for testing for the USERS project
      • Test performance of G-Switch and power supply
        • see that it meets launch safing no volts requirements.
        • Use spring mechanism to test the performance of the “ball and tube” part of the G-Switch
      • Test performance of Data Acquisition unit
      • Burn in period for electronics
  • Preliminary Integration Phase (4/25/09 – 5/3/09)

      • Assemble structure
      • Attach strain gauges to test points in structure
      • Integrate electronic components—manufacture wire harnesses
      • Have structure ready to install in can
  • Finals week (5/4/09 – 5/8/09)

  • See you in June! Launch at Wallops



MAPP Parts List

  • Mechanical parts

  • # Item Status # Item Status

  • 4 Brace A designed 1 Test Weight Completed

  • 4 Brace B designed 4 Trays Completed

  • 8 Brace C designed 4 Longeron designed

  • 1 Bottom Disk designed 1 Deck Plate designed

  • 1 Top Disk designed

    • Not at the nut and bolt level… just major hardware that will be purchased or built in house
    • Lead times (This can make or break a project)
    • Distributors
    • Manufacturers
    • Cost (Don’t forget to consider shipping and tax)


Electronic Parts :

  • Electronic Parts :

  • # Item Status

  • 2 Strain gage board Modification needed

  • 1 Power regulator board Modification needed

  • 1 G-switch and associated electronics needs more design work

  • 1 data acquisition/storage + controller needs more design work



MAPP Budget



RockSat Payload Canister User Guide Compliance (MAPP & BU)

      • Mass estimate includes everything shown in slide 16 . Missing are the electronic boards ( 4 of 4”x4” ) for MA and electronic boards and battery for BU
      • m = 10.86 lbs (< 12.75, the heavy test mass can be reduced)
      • Center of mass 0.35” off axis and 1.06” below geometric center. Because electronic boards and tray for the BU experiment have not been included, the center of mass will move slightly closer to the geometric center.
      • Entire structure fits into a cylinder of 9” (<9.2) diameter and
      • 9.275” (<9.4) height leaving 0.125” for washers.
      • Connection with 5 bolts to top and bottom bulk head , respectively, is provided.


RockSat Payload Canister User Guide Compliance– cont.

  • Payload Activation

  • a battery , a G-switch, and shorting wires to Wallops shorting plug form a complete loop with electric current flowing only if both the G-switch and shorting plug are in closed position simultaneously. Once current is flowing a circuit consisting of a second battery (ies) and all electronic boards is activated using a solid-state latched relay and switch transistor. This second loop maintains itself even when the G-switch subsequently falls back into its open position (during ballistic flight phase).



Shared Can Logistics Plan

  • Boston University (Mike Ruane)

  • Penn State Mont Alto (Zig Herzog)

  • Sharing mechanical structure but independent power supply, controller, data acquisition, and data storage. Possibility of future sharing of these items is not excluded .



Dr. Siegfried Herzog

  • Dr. Siegfried Herzog

  • Penn State University at Mont Alto

  • Assistant Professor of Mechanical Engineering

  • 1 Campus Drive

  • Mont Alto, PA 17237

  • Tel (717)-749-6209    Fax (717)-749-6069

  • E-Mail: hgn@psu.edu

  • Dr. Michael Ruane

  • Professor, ECE Dept.,

  • Boston University

  • 8 St. Mary's Street, Boston, MA 02215

  • Phone: 617-353-3256 617-353-6440 fax

  • E-Mail: mfr@bu.edu



MAPP Conclusions

  • Lab space available

  • Students are nervous but excited

  • We have some previous experience with the USERS program and can re-use some parts

  • We aim to finish by the end of April (end of the spring semester)

  • Looking forward to beach time! 



BU Subsystems

  • Sensor 1 Aichi

  • Sensor 2 Honeywell

  • Power (Battery + Regulation)

  • Controller

    • Sequencing of sensors
    • Data A/D conversion
    • Storage to SD card


Sensing technology

  • Sensing technology

    • Based on Magneto-Impedance effect of amorphous magnetic wire
  • Range of measurable magnetic flux density: -2 to +2 gauss

  • 3 sensors for length, width, and height (X, Y, Z)

  • Inputs and Outputs:



Supply Voltage: -0.3 to +6.5 VDC

  • Supply Voltage: -0.3 to +6.5 VDC

  • Maximum Supply Current: 200 mA

    • Approximately 1% duty cycle on this peak current
  • Operating Temperature: -20 to +85°C

  • Magnetic Characteristics

    • Operating Test Conditions
      • Ambient Temperature: 25°C
      • Power Supply: 3 VDC
      • 10 μF ceramic capacitor between Power Supply and Ground


Sensing technology

  • Sensing technology

    • Anisotropic magneto-resistance
  • Range of measurable magnetic flux density: -2 to +2 gauss

  • 3 sensors for length, width, and height (X, Y, Z)

    • One output for each direction (Xout, Yout, Zout)


Supply Voltage: 6 to 15 VDC

  • Supply Voltage: 6 to 15 VDC

  • Maximum Supply Current: 20 mA

  • Operating Temperature: -20 to +85°C

  • Magnetic Characteristics

    • Operating Test Conditions
      • Ambient Temperature: 25°C
      • Power Supply: 12 VDC
      • Set/Reset switching is active


1GB of storage – mini-SD memory card

  • 1GB of storage – mini-SD memory card

  • Runs at 58.9MHz

  • 20 parallel digital I/O lines

  • 8 channel analog input with 12 bit resolution

  • Max asynchronous transfer rate =Clk (58.9MHz)/8

  • 4 PWM registers, 10 bit counter, priority interrupts

  • Input/Output:

  • 3 Inputs from Aichi - X axis / Y axis / Z axis output from Aichi

  • 3 Inputs from Honeywell - X axis / Y axis / Z axis output from Honeywell



Aichi

  • Aichi

  • Use timer to time selection of outputs for x, y, z axes

  • Iterate outputs from RabbitCore to read different axes on Aichi

  • Different channels for x, y, and z axes

  • Take input and pass through A/D converter from each Aichi channel

  • Store converted values onto SD flash memory for future use

  • Honeywell

  • Use timer to constantly poll Honeywell for all x, y, and z axes nearly-simultaneously

  • Store data from each axis on a separate place on the SD flash

  • Each axis is read from a separate output pin on Honeywell chip

  • Use A/D converter to store as value and store converted value on flash

  • Both chips

  • User timer to select which chip is off for EMI comparisons



BU – Sensor Schematics



BU - Science Experiment Timing



BU - Data Flows

  • 2 sensors, 4 data sources, housekeeping

  • 12 b/sample on Rabbit RCM4300

  • Slow change in Earth’s field over flight

  • Changes from spin of rocket (<10 Hz)

  • Sample 10 pts/cycle or 100 Sa/s

  • Estimated flight 22.5 min or 1350 s

  • 135k Sa x 4 x 12b/Sa = 6.48 Mb = 0.8MB

  • Well within low-end SD card capacities



BU Testing Plans

  • Electrical systems operation

    • Timing test for sequencing
    • DAQ test with sensors
    • SD card storage and retrieval
  • Sensor operation

    • Earth field testing
    • Helmholz coil testing of boards
  • Power operation

    • Charging/discharging
    • Voltage regulation and distribution


BU - Parts & Vendors

  • Aichi AMI302 (3 on hand from Aichi; two week order time)

  • Honeywell (2 on hand; distributors; 2 week order time)

  • PCB fab - turnaround (5 business days)

  • PCB Assembly for Aichi (10 business days)

  • Rabbit Core 4300 (Dev kit on hand)

  • Miscellaneous DigiKey/Newark parts



BU - RockSat Payload Canister User Guide Compliance

  • Sensor PCB ~15 cm x 15 cm x 2 cm; < 150 g

  • Rabbit PCB ~ 5 cm x 8 cm x 1 cm; <100 g

  • Battery ~ 6 cm x 10 cm x 2 cm; <150 g

  • (Easily reside in ½ canister or even ¼ height)

  • Will follow G-switch and Rocket wire protocol

  • Independent of MAPP system except CG



Shared Can Logistics Plan

  • Penn State Mont Alto - Boston University

  • Each system is independent

  • Structural interfacing (PSMA)



BU Mechanical Layout



BU Timeline



BU Budget



BU Conclusions

  • BU Conclusions

    • BU Mag Dogs Team is closing out its semester and catching up to the RockSat schedule
    • We have an enthusiastic group of students, a lab space for work, and a Nanosat team becoming available in January
    • Our experiment is building on a sensor board from USERS and a microcontroller DAQ system


Appendices – Backup Slides



Management

  • Dr. Michael Ruane

  • Professor, ECE Dept.,

  • Boston University

  • 8 St. Mary's Street, Boston, MA 02215

  • Phone: 617-353-3256 617-353-6440 fax

  • E-Mail: mfr@bu.edu

  • Dr. Siegfried Herzog

  • Penn State University at Mont Alto

  • Assistant Professor of Mechanical Engineering

  • 1 Campus Drive

  • Mont Alto, PA 17237

  • Tel (717)-749-6209    Fax (717)-749-6069

  • E-Mail: hgn@psu.edu







Rabbit Daughter Board



BU - Expedited & Day in the Life Testing














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