Download - Team Tesla
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TEAM TESLA Anthony ThompsonPhilip de la VergneAaron WascomBrandon Sciortino
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Overview
• Address items added since PDR• Electrical Design• Software Design• Mechanical Design• Hardware Fabrication and Testing• Integration Plan• Flight Software Implementation and Verification• Flight Certification Testing• Testing Procedure• Testing Results• Mission Operations• Calibrations• Data Analysis• Schedule, Risk Management, etc.
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Sensors
• Temperature• F3141 RTD sensor
• Linear resistance with temperature• Accuracy of +/-0.65°C• Range of -70°C to 40°C
• Requirements• Linear Output• Accurate to 1°C• Range of -70°C to 40°C
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Sensors
• Pressure• Measurement Specialties 1230 sensor
• Accuracy of +/- .05%• Range 0 to 7000 mbar• Range -40°C to 135°C
• Requirements• Accurate to 2 mbar• Range of 10 mbar to 1013 mbar
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Sensors
• Humidity• HIH-4000
• Accurate to 3.5% RH• -40°C to 85°C• 0% to 100% Relative Humidity
• Requirements• Accurate to 3.5% Relative Humidity• Range of 0% to 100% Relative Humidity
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Temperature Sensor Interfacing
• Gain: 7.6 Offset: 5.52V • R1=7.5kΩ R2=5.44kΩ R3=10kΩ R4=2.1kΩ
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Pressure Sensor Interfacing
• WBEE Manual
Figure 4. Pressure Measuring Circuit
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Humidity Sensor Interfacing
• Gain: 1.572 Offset: .4545V • R1=7.5kΩ R2=41.98kΩ R3=10kΩ R4=29.9kΩ
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Control Electronics
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Power Supply
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Power BudgetComponent Current Voltage Power Time Capacity
BalloonSat 52 mA 12V 1790mW 4 Hours 224mAh
Pressure sensor 2mA 12V 24mW 4 Hours 8mAh
Humidity sensor 2mA 3V 6mW 4 Hours 8mAh
Temperature Sensor
1mA 3V 3mW 4 Hours 4mAh
DAC 4mA 5V 20mW 4 Hours 16mAh
ADC2 5mA 5.5V 27.5mW 4 Hours 20mAh
Integrated Circuits (5)
.8mA 15V 84mW 4 Hours 16mAh
EEPROM 1mA 5.5V 5.5mW 4 Hours 4mAh
JK Flip-flop 32mA 5.5V 176mW 4 Hours 128mAh
5V Reference 1.6 mA 9V 14.4 mW 4 Hours 6.4 mAh
Voltage Comparator
6mA 15V 90mW 4 Hours 24mAh
HVDC(Max load)
300mA 5V 1500mW 4 Minutes 20mAh
HVDC(No load)
20mA 5V 100mW 3 Hours56 Minutes
79.6 mAh
Totals(Full Load)
405.8 mA 15V 3726 mW 4 Hours 478 mAh
Totals(No Load)
127.4 mA 15V 2340.4 mW 4 Hours 554 mAh
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Batteries
• AAA Lithium batteries compared to Alkaline
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Batteries• AAA Lithium batteries compared to Alkaline
• Batteries needed that provide adequate charge
• 12 AAA Lithium Batteries chosen to supply voltage
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Data Format and StorageSignal Source/Type Example Value Conditioned
Value Converted typeFinal
Example Value
Temp/ Analog Analog(0-1V) 0.1V Analog(0-3V).3V 1 Byte 77
Pressure/Analog (bi-pol)
Analog difference(0-1V)
.5V
Analog(0-3V)1.5V 1 Byte 128
Humidity/Analog Analog(0-1V) 0.8V
Analog(0-3V)2.4V 1 Byte 205
Time/Hour/Digital Digital4 NA 1 Byte 4
Time/Min/Digital Digital45 NA 1 Byte 45
Time/Second/Digital Digital15 NA 1 Byte 15
Voltage1/Analog Analog(0-1V).6554V
Analog(0-3V)1.9662V 2 Bytes 42,952
Voltage2/Analog Analog(0-1V).7892
Analog(0-3V)2.3676V 2 Bytes 51,721
Curent1/Analog Analog(0-1V).6V
Analog(0-3V)1.8V 1 Byte 154
Current2/Analog Analog(0-1V).12
Analog(0-3V).36V
Digital Byte(0-255) 31
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Pre-Flight Software
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Flight Software
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Flight Software
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Flight Software
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Flight Software
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Flight Software
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Post-Flight Software
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External Mechanical Structure
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Internal Mechanical Structure
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Weight BudgetItem Mass Uncertainty Measured
or EstimatedPressure sensor (1230 Series)
3 g +/- .5g Datasheet
Temperature sensor (F301 RTD)
10 g +/- 1g Datasheet
Humidity sensor (HIH-4000)
1g +/- 1g Measured
BalloonSat 67.6 g +/- 5g Measured
Payload box 120g +/- 20g Estimated
HVDC 15g +/- 5g Datasheet
Spark Gap 30g +/- 10g Estimated
Wiring 20g +/- 5g Estimated
Signal Conditioning 60 g +/- 1g Estimated
(12) AAA Lithium Batteries
91.2g +/- 2g Datasheet
Circuit Boards 30g +/- 4 g Estimated
Total 447.8 g +/- 24.5g Estimated
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Payload Construction Plan
• Control Electronics Fabrication and Testing• Test each piece individually• Connect pieces one at a time, test• Assemble system, check timing diagram• Connect to HVDC
• Spark Gap Fabrication and Testing• Spark gap created for testing• After CDR, create a flight gap
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Integration Plan
• Humidity and temperature designed on a single board• Wires connect board to BalloonSat
• Control Electronics on single board• Wires connect board to BalloonSat through DAC and
conditioning circuits• Velcro Straps to connect to the payload
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Flight Software Implementation and Verification
• Flight software has multiple functions• Keep accurate time• Read data from ADC• Output to DAC• Sense trips in high voltage circuit• Reset high voltage circuit• Store data to EEPROM
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Testing Procedure/Results
• Temperature Sensor• Put sensor in a box of dry ice• Used equation from data sheet to calculate resistance• Measured resistance with multimeter
• Results
Temperature Measured Calculated Resistance Measured Resistance
-61 763.589 760
-48 811.002 807
21 1081.819 1094
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Testing Procedure/Results
• Pressure Sensor• Connect sensor to hand pump• Compare sensor output to hand pump gauge
• Results
Measured pressure (mbar)
Test One Voltage Output (V)
Test Two Voltage Output (V)
-844.5 0.50 0.51-676.0 1.00 1.02-507.0 1.50 1.51-338.0 2.00 2.04
0 3 3
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Testing Procedure/Results
• Humidity Sensor• Follow Procedure in WBEE manual• Check voltages at key points• Exhale on sensor, observe change in voltage
• Results
BLACK Lead point
RED Lead point Expected value Measured value OK?
GND Test Loop P201-1, the pin of P201 nearest R102 marked “+V”
5.0 V 5 V Yes
GND Test Loop U201-5 Between 1.5 and 3.5 volts
2.56 V Yes
GND Test Loop U201-5 Voltage increases slightly when you exhale onto the sensor
2.60V-3.55VYes
GND Test Loop U201-1 Voltage can be increased/decreased by adjustments of either R201 and/or R204
2.00V-2.43VYes
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Testing Procedure/Results
• Spark Gap Testing• Use high voltage source to create corona• Test in the vacuum chamber to confirm operation
• Results
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 100
2
4
6
8
10
12
14
16
18
20 Current vs Voltage: 0 feet
Trial 1
Trial 2
Trail 3
Voltage (kV)
Cur
rent
(mV
)
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Testing Procedure/Results
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 100
5
10
15
20
25
30
35 Current vs Voltage @ 15,000 feet
Trial 1
Trial 2
Trail 3
Voltage (kV)
Cur
rent
(mV
)
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Testing Procedure/Results
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 100
20
40
60
80
100
120
140
Current vs Voltage @ 35,000 feet
Trial 1
Voltage (kV)
Cur
rent
(mV
)
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Testing Procedure/Results
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 2.1 2.20
2
4
6
8
10
12 Current vs Voltage @ 100,000 feet
Trial 1
Voltage (kV)
Cur
rent
(mV
)
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Calibrations
• Conditioning circuits• Correct output for ADC• Correct gain
• RTC• Correct time for timestamp data
• GPS• Used for altitude
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Pre-Launch ChecklistTime Item-27 minutes Install new batteries-25 minutes Check voltages-14 minutes Load pre-flight checklist-11 minutes Install BalloonSat-10 minutes Install circuits-9 minutes Verify sensors are positioned correctly-8 minutes Verify spark gap distance-6 minutes Connect all systems-4 minutes Close Lid-2 minutes Tape lid shut0 minutes LaunchTotal: 27 minutes
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Flight Requirements, Operations, Recovery
• Flight Profile• 0-100% Relative Humidity• 10-1010mbar• -70 to 40°C
• No particular orientation or telemetry• Tracked by GPS, recovered after flight
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Data Acquisition
• Term32 will be used to extract data from EEPROM
• Stored on PC as text file• Converted to decimal
• Using conversion factor depending on bits
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Data Analysis Plan
• Use text files• Create graphs to identify correlations
• Pressure vs. Corona• Temperature vs. Corona• Humidity vs. Corona
• Use Microsoft Excel
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Updated Project Management
Functional Group Team Member
Project Management Anthony Thompson
Science Requirements Philip de la Vergne
Electronics Aaron Wascom
Flight Software Aaron Wascom
Mechanical Integration Philip de la Vergne
System Testing Brandon Sciortino
Data Processing and Analysis Anthony Thompson
Documentation Anthony Thompson
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Master Schedule
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WBS
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WBS
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WBS
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Staffing Plan
Task Member ResponsibleCompleting Schematics Brandon SciortinoPlace orders for shipping Anthony ThompsonCalibrations Philip de la VergneSoftware Design/Development Aaron WascomElectrical Design/Development Aaron WascomSoftware Testing Aaron WascomExternal/Internal Construction Anthony ThompsonTesting Brandon SciortinoData Analysis Anthony ThompsonFabrication Brandon Sciortino
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Master BudgetItem Manufacture vender Number of
UnitsCost
HVDC HVM Tech Digi-key 1 270DAC Texas Instrument Digi-key 1 1.54ADC Texas Instrument Digi-key 1 1.04
EEPROM Interfacebus Digi-key 1 0.98JK Flipflop Texas Instruments Digi-key 1 1.62
Voltage Comparator Texas Instrument Digi-key 1 1.52Relay Digi-key 1 2.82
Spark Gap Phillip de le Laverne Lowes 1 50
Humidity Sensor Honeywell LaAces Staff 1 8.9Lithium ultimate
batteries (AA)Siemens Amazon 5 0
Pressure Sensor Measurement Specialist
LaAces Staff 1 12
BalloonSet Bsat12 LAAces Staff 1 0Shipping 20Resistors Digi`-key LaAces Staff 12 0
Breadboard/ PC board Globalsources Digi-key 2/1 12/175
AD822 Analog Devices LaAces Staff 2 0AD820 Analog Devices LaAces Staff 6 0
Temperature Sensor Omega Omega 1 50
Velcro strap Feinersupply Amazon 1 6Voltage Reference (5V) ANALOG
DEVICES, INCDigikey 1 7.19
10% Reserve 50Total: $ 425.01/ 594.01
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Expenditure PlanBudget Budget
Item Unit Cost
Number of Units
Cost Item Unit Cost
Number of Units
Cost
HVDC 270 1 270 HVDC 270 1 270DAC 1.54 1 1.54 DAC 1.54 1 1.54ADC 1.04 1 1.04 ADC 1.04 1 1.04
EEPROM 0.98 1 0.98 EEPROM 0.98 1 0.98JK Flip-flop 1.62 1 1.62 JK Flip-flop 1.62 1 1.62
Voltage Comparator
2.83 1 2.83 Voltage Comparator
2.83 1 2.83
Relay 50 1 50 Relay 50 1 50Spark Gap 8.5 1 8.5 Spark Gap 8.5 1 8.5
Humidity Sensor 0 1 0 Humidity Sensor 0 1 0Lithium Ultra-
Batteries (AAA)2.5 5 12.5 Lithium ultimate-
batteries (AAA)2.5 5 12.5
Pressure Sensor 0 1 0 Pressure Sensor 0 1 0Resistors 0 12 0 Resistors 0 12 0
Breadboard 6 1 6 PC Board 175 1 175AD822 0 3 0 AD822 0 3 0AD820 0 5 0 AD820 0 5 0
Shipping 20 1 0 Shipping 20 0 0Temperature
Sensor20 1 20 Temperature
Sensor20 1 20
10% Reserve 50 1 50 10% Reserve 50 1 50Total:
$425.01 Total:
$594.01
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Material Acquisition PlanItem When Needed When
OrderedHow Acquired Number of Units
HVDC Control Electronics testing Not ordered HVM Tech 1
DAC Control Electronics testing Not ordered Order online from Digi-key 1
ADC Control Electronics testing Not ordered Order online from digi-key 1
EEPROM Control Electronics testing Not ordered Order online from Digi-key 1
JK Flip-flop Control Electronics testing Not ordered Order online from Digi-key
1
Voltage Comparator Spark gap testing Ordered Order online from Digi-key
1
Relay Control Electronics testing Not ordered Order online from Digi-key 1
Spark Gap Spark gap testing Ordered Picked up from Lowes 1
Humidity Sensor Sensor testing Ordered LaAces Staff 1Lithium Ultimate
Batteries (AA)Flight Not ordered Order online from Amazon 5
Pressure Sensor Testing Ordered LaAces Staff 1Resistors Prototyping conditioning
circuitsOrdered LaAces Staff 12
Breadboard Prototyping conditioning circuits
Not ordered Digi-key 1
AD822 Prototyping conditioning circuits
Ordered LaAces Staff 2
AD820 Prototyping conditioning circuits
Ordered LaAces Staff 6
BalloonSat Software testing Already have LaAces Staff 1Temperature Sensor Sensor testing Already have Omega 1
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Risk Management and ContingencyRisk Event Likelihood Impact Detection Difficulty When
Faulty Power Supply 3 5 2 Flight
Faulty Preflight Procedure 2 4 4 Pre-Flight
Incorrect Coding 3 5 1 Calibration
Sparking 3 3 2 FlightLosing a Team
Member 2 3 1 Pre-Flight
Faulty Parachute 1 3 1 Flight
Component Failure 3 4 2 During Flight/ Testing
Impurities on Electrode Surface 3 4 2 Pre-Flight/During
FlightLoss of Payload 1 5 5 Post-Flight
External Deadlines not Met 2 5 3 Pre-Flight
Over Budget 4 4 2 Pre-Flight
Memory Deficiency 4 4 3 Flight
Unexpected Environmental
Conditions2 3 1 Flight
Unavailable Parts 3 3 2 Pre-FlightChange in Electrode
Distance 2 5 5 Flight
Bad Connection During Fabrication 2 4 4 Fabrication
Ice On Payload 3 4 4 Flight
Short Circuit InPayload
2 5 3 Flight
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ContingencyRisk Event Response Contingency Plan Trigger Responsibility
Faulty Power Supply Reduce Switch out with new Batteries
Sensors Malfunction or Break
Philip de la Vergne
Faulty Preflight Procedure
Reduce Pre-Flight To-Do list Pre-Flight Set up Anthony Thompson
Incorrect Coding Reduce Recode Will not load to BASIC Stamp
Aaron Wascom
Sparking Reduce Electrode geometry, sparking type, and Faraday cage
Faulty Programming Aaron Wascom
Losing a Team Member Reduce Work is shared among remaining members
Sudden Workload Increase
All Members
Faulty Parachute Transfer Build payload to protect data storage
Parachute failure Dr. Guzik
Component Failure Transfer Order another from a different company or have a spare
Device does not operate properly
Aaron Wascom
Impurities on Electrode Surface
Reduce Check surfaces prior to launch
Condensation or dust Brandon Sciortino
Loss of Payload Share Prepare Failure Report Lack of Payload All MembersExternal Deadlines not Met
Retain Pray we don’t get fired Lack of Project Management
All Members
Over-Budget Transfer Find cheaper Component or Apply for More Funds
Cost Analysis All Members
Memory Deficiency Restart program before launch
Obtain more memory Loss of Data Points/ Taking data before flight.
Anthony Thompson
Unexpected Environmental Conditions
Reduce Increase Sensor Ranges Sensor Failure and Data Spikes
All Members
Part Unavailability Reduce Different Supplier Research SupplierChange in Electrode Distance
Reduce Strengthen stability of electrodes
Carelessness during Fabrication
Brandon Sciortino
Bad Connection During Fabrication
Transfer Double and triple check all solder joints
Faulty circuit Anthony Thompson