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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

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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