EarTh HOrizon Sensor
Manufacturing Status Review
Team
Noah Buchanan
Matthew Busby
Matthew Cirbo
Taylor Dean
Jesse Keefer
Patrick Klein
Thomas Konnert
Cole Oppliger
Neal Stolz
Customers
Joe Breno
Randy Owen
Advisor
Dr. John Farnsworth
7/12/2016
University of Colorado Aerospace Engineering Sciences
1
Outline
• Overview
• Schedule
• Manufacturing
– Software
– Electrical
– Algorithm
– Mechanical
• Budget
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
2
CONOPS
REFERENCE
PITCH DEFLECTION
ROLL DEFLECTION
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
3
CONOPS
Sensor Housing
Camera Field of View
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
4
FBD
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
5
Levels of Success
LEVEL TWO
LEVEL THREE
LEVEL FOUR
SENSOR CAPABLE OF
COLLECTING DATA FROM
SIMULATED EARTH AT
ALTITUDE OF 250-750 KM
INTEGRATED IN BASIC
HOUSING
HOUSING MEETS
WEIGHT AND VOLUME
REQUIREMENTS
POWER
REQUIREMENTS MET.
INPUT OF 22-34 V AND
MAX DRAW OF 5 W
SENSOR CAPTURES
DATA AND RETURNS
DISPLACEMENT
VECTOR OUTSIDE OF
ECLIPSE
TEST DEVELOPED TO
PROVE ECLIPSE
FUNCTIONALITY
CAPABLE OF
RECORDING 200
MINUTES OF HEALTH
TELEMETRY
COMMUNICATION
OVER CAN PROTOCOL
AT <388 KBPS
SOFTWARE CAPABLE
OF DETERMINING
DISPALCEMENT
VECTOR TO WITHIN
0.5 DEGREES
DISPLACEMENT
VECTOR DETERMINED
IN ECLIPSE REGION OF
35 MIN
LEVEL ONE
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
6
Schedule
MSR
SPRING
BREAK
Financial
Algorithm
Test
Mechanical
Electrical
Software
Uncertainty
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
7
Schedule
MSR
Financial
Algorithm
Test
Mechanical
Electrical
Software
Uncertainty
7/12/2016
SPRING
BREAK
Mechanical Manufacturing
Slightly ahead of schedule –
50% complete
Planned finish date: 27 FEB
University of Colorado Aerospace Engineering Sciences
8
Schedule
MSR
SPRING
BREAK
Powerboard Manufacturing
Behind original schedule – 60% complete
Planned finish date: 27 FEB
Financial
Algorithm
Test
Mechanical
Electrical
Software
Uncertainty
7/12/2016
Health Sensor Code
Planned finish date: 15 FEB
Physical Camera Interface
Board designed/ordered
Planned finish date: 20 FEB
University of Colorado Aerospace Engineering Sciences
9
Schedule
MSR
Financial
Algorithm
Test
Mechanical
Electrical
Software
Uncertainty
SPRING
BREAK
1 MAR
Camera Interface Software
Slightly behind schedule – 50 % Complete
CAN Communications Code
Begin 3 Feb
Algorithm Production
100% complete
Will require minor adjustments
7/12/2016
University of Colorado Aerospace Engineering Sciences
10
Schedule
MSR
SPRING
BREAK
1 MAR
Software/Algorithm Integration
Passing variables and memory locations
Memory allocation
Timing adjustments and troubleshooting
Financial
Algorithm
Test
Mechanical
Electrical
Software
Uncertainty
Analog Video to USB connection
Existing COTS parts
Team experience with USB data transfer
Visual camera via USB
12 March
7/12/2016
University of Colorado Aerospace Engineering Sciences
11
Schedule
MSR
1 MAR
SPRING
BREAK
15 APR
Financial
Algorithm
Test
Mechanical
Electrical
Software
Uncertainty
Full System Testing
7/12/2016
University of Colorado Aerospace Engineering Sciences
12
Software
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
13
Software Data Flow
1. The IR sensor captures a frame and begins
outputting to the DIO pins on the BeagleBone
Black.
2. PRU0 acts as a software interface, and saves the
data to a buffer in RAM.
3. Once an entire frame has been stored in RAM,
the CPU is prompted to begin calculating the
displacement vector.
4. After the displacement vector has been
calculated, it is saved to an SD card with a time
stamp and flag.
Outline
2/2/2015
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
14
Software: Status & Future Work
Task
Testing
Enable PRU & load code Write & test code with LED
Feb 1st
Load drivers to enable
DDR access for PRU
Save data to RAM, access
from CPU
Feb 8th
Interrupt CPU from PRU
Control LED based on CPU
interrupt from PRU pin
Feb 15th
Configure and receive
data from IR camera
Correctly display images
from IR camera on CPU
Feb 25th
Trigger horizon algorithm using PRU data
Outline
2/2/2015
Projected
Completion Date
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Mar 20th
Budget
15
Software: Timing Diagram
0
1
2
3
Outline
7/12/2016
PRU Initialization
Wait for first falling edge
Save data to RAM
Skip chroma byte
Data is pulled from data lines
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
16
Software: Risk Mitigations
Risk
Mitigations
Add instruction delay instead of
waiting for falling edge
8-bit double-clocked YCbYCr 4:2:2
(45.73 ns) is too fast
Mask data on CPU
Try 14-bit or 16-bit YCbCr CMOS
mode 4:2:2 (95.062 ns)
Outline
2/2/2015
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
17
Electrical
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
18
Electrical System: Status
Requirements:
DR.2.2.1 – Monitor operating voltages
and currents
DR.3.5 – Use less than 5 W
DR.3.6 – Accept 22 – 34 V
- Must output 5 V for Tau 2 and BBB
Vin
22 – 34 V
Voltage Regulator
Vin
Vout
GND
Tau 2
Camera
5V
BBB
Von
Vin
R
3.3 V GPIO
C
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
19
Electrical System: Status
• All parts have been purchased
• Built on breadboard
– Tested to take in 22 – 34 V and outputs a constant 5.06 V
Power Board Issues
Solution
Regulator chip needs Von (< 6 V) to let
power through
Add a capacitor that is
charged via 3.3 V pin on BBB.
This means the chip is always
on
Switching Regulators do NOT regulate
until there is a load on them
Use BBB controlled relays to
prevent unregulated voltages
from hitting camera
Purchased adjustable regulator chip
instead of fixed output
Use resistors in feedback loop
to control output voltage
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Implemented
Yet?
Yes
No
Yes
Budget
20
Electrical System: Future Work
Major Remaining Tasks
• Integrate voltage/current sensors into circuit
• Solder components onto a proto-board
• Test for voltage transients upon initial power
on
– If no transients, relays may not be necessary
• Planned completion 27 Feb
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
21
Algorithm
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
22
Algorithm
Purpose: To receive and process images from the camera and output pitch
and roll displacement angles.
Major Requirements:
– DR.2.1.1 Displacement outputs must be accurate to withing 0.5°.
– DR.2.1.2 Displacement in pitch and roll must be determined.
– DR.2.1.3 Displacement angles must be calculated at a rate of ≥ 12 Hz.
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
23
Algorithm: Status
•
•
All major functions needed
for attitude determination
have been written and
tested on the BeagleBone
Black.
Algorithm requirements
are being met.
Max Error
[deg]
Max
Corrected
Error
[deg]
Mean
Error
[deg]
Mean
Corrected
Error
[deg]
Roll
0.8606
0.1256
0.1825
0.0257
Pitch
1.9207
0.0688
1.1090
0.0265
Requirements
Current Status
DR.2.1.1 – Accurate to within 0.5 degrees
Successful: Max error = 0.1256 degrees
DR.2.1.2 – Determine displacement in
pitch and roll
Successful
DR.2.1.3 – Calculate displacement with a
rate of >= 12 Hz
Successful: Average rate = 400 Hz
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
24
Algorithm: Future Work
Major Remaining Tasks:
• Manually read image from memory locations
• Add assertions to check for anomalous
conditions
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
25
Mechanical System
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
26
Mechanical
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
27
Mechanical: Design Solution
Housing
• Machined out of Aluminum 6061
• Dimensions: 4.21 x 3.74” x 2.48”
• Camera mount redesigned to allow
access to back of camera
Test Stand:
• Custom 2 DOF Gimbal
• Machined out of Aluminum 6061
• No major design changes
Outline
7/12/2016
Schedule
Power Regulator
Board
BeagleBone Black
Camera
4.21”
Camera
Mount
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
28
Mechanical: Status
Housing
• Purchased: Metal
• Manufactured: Top, Bottom, Left,
and Right pieces. Mounting holes
to be drilled.
Top
Test Stand
• Purchased: Thin-Section ball
bearing and pitch ball bearings
• Manufactured: Roll Bracket
– Critical Element: Interference
fit with thin-section ball
bearing
Outline
7/12/2016
Schedule
Bottom
Manufacturing
University of Colorado Aerospace Engineering Sciences
Left
Right
Budget
29
Roll Bracket (Picture)
• Machined on CNC mill to 0.0004” tolerance
• Initial machining attempt unsuccessful
• Allows sensor housing to roll
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
30
Mechanical: Future Work
Housing:
• Purchase: Metal for camera mount & screws
–
–
•
Lead time: 1 week
Setback: None, already 1 week ahead of schedule
Manufacturing: CNC Final 3 pieces
–
–
2.23”
Front, Back, & Camera Mount
Mount camera to within 1/32” in vertical direction
Power Regulator
Board
BeagleBone
Black
Test Stand:
• Purchase: L brackets and bolts
–
–
•
Manufacturing:
–
–
–
–
•
Lead time: 1 week
Setback: none, planned into schedule
CNC face mount for sensor housing to 0.0004” tol
Manual milling machines for remaining pieces
Measure assembled housing height to 1/32”and
manufacture disk for calculated radius
“Earth Disk” manufactured
4.21”
Camera
Camera
Mount
Planned finish 27 Feb
Outline
7/12/2016
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
31
Budget Status
Future Expenses ≈ $885
Sensor and
Housing,
$2,125.84
Margin,
$1,985.00
Testing
Materials,
$626.54
Printing,
$50.61
Outline
7/12/2016
Electronics,
$212.01
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
32
Budget Progress
$4,124.93
$3,230.92
$3,015.00
$215.92
Projected Total
Outline
7/12/2016
Expected
Actual Expenses Budget Variance
Expenses for
for Parts
Parts Purchased
Purchased
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
33
7/12/2016
University of Colorado Aerospace Engineering Sciences
34
Backup Slides
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7/12/2016
University of Colorado Aerospace
Engineering Sciences
35
Upcoming Testing
•
Power Regulation Board (DR.3.6)
Sensor
– Ensure 22-34V can be input and
converted into two 5V outputs
•
Algorithm (DR.2.1)
22-34V
5V
Power Regulation Board CONOPs
Inclinometer
–
•
Power
Regulation
Board
Microcomputer
– Verify algorithm functionality, speed,
and accuracy meets requirements
•
5V
Verify the functionality and calibrate
for use in manufacturing, camera/BBB,
and full tests
Inclinometer
Boresight
Manufacturing (DR.3.3)
– Verify the dimensions of manufactured
components as well as the initial focal
point of the test stand on the disk
α
Focal Point
Height
Horizon Disk Radius
Inclinometer and Manufacturing CONOPs
7/12/2016
University of Colorado Aerospace
Engineering Sciences
36
Voltage Regulator Testing
7/12/2016
University of Colorado Aerospace Engineering Sciences
37
Ringing in Camera Lines
Problem:
Due to impedance differences between the camera
and the BBB, ringing in lines may occur
Testing for Problem:
Connect BBB and camera and probe with o-scope
Mitigating the Problem:
-Keeping the lines short
-Digital Line Drivers
-Series resistors in lines to match impedances
7/12/2016
University of Colorado Aerospace Engineering Sciences
38
Power Board with Relays
7/12/2016
University of Colorado Aerospace Engineering Sciences
39
Algorithm Settings
•
•
7/12/2016
Algorithm settings are stored in shell environment variables
Environment variables are loaded into globals to reduce the frequency of memory allocation
to increase execution speed
University of Colorado Aerospace
Engineering Sciences
40
Software: Assembly Code
Outline
2/2/2015
Schedule
Manufacturing
University of Colorado Aerospace Engineering Sciences
Budget
41
All Test Plans
•
Power Regulation Board
– Ensure 22-34V can be input and converted into two 5V outputs
•
Algorithm
– Verify algorithm functionality, speed, and accuracy
•
Software
– Verify BeagleBone correctly computes algorithm and uses specified components,
communication with camera, health data, and CAN functionality
•
Inclinometer
–
•
Verify the functionality and calibrate for use in manufacturing, camera/BBB, and full tests
Manufacturing
– Verify the dimensions and weight of manufactured components as well as the initial focal
point of the test stand on the disk
•
Camera/BBB
– Verify the reception and saving of camera data via the BBB, the functionality of the algorithm
on the BBB
•
Full Test
– Validate the functionality of all aspects of the project as an integrated unit and determine
what level of success is met
7/12/2016
University of Colorado Aerospace
Engineering Sciences
42
Power Regulation Board Test
• Purpose: Ensure the Power Regulation Board takes an input of 2234V and outputs 5V for both the camera and microcomputer. The
Board should output 5V regardless of input voltage.
• Materials:
–
–
–
–
Power Supply from Trudy’s lab
Any lab with proper outlet
Voltmeter
Completed Power Regulation Board or prototype
Measurement
How it’s Verified
Supply Output Voltmeter measured to be between 22-34V
PRB Outputs
7/12/2016
Voltmeter measured to be 5V
University of Colorado Aerospace
Engineering Sciences
Requirement
DR.3.6
DR.3.6
43
Algorithm Test
• Purpose: To verify the algorithm produces a reasonably
accurate output less than .5ᵒ at a rate between 12 and 30
Hz. To ensure its functionality prior to larger scale testing.
• Resources Needed:
– BeagleBone Black microcomputer loaded with algorithm
– Other computer for microcomputer output
– Group members to critique code
7/12/2016
Measurement
How it’s Measured
Requirement
Pitch/Roll
Angle
Output Speed
Image processing by the algorithm
DR.2.1.2
Recorded after vector data is output
DR.2.1.3
Error
Calculated vector data is compared to actual vector
DR.2.1.1
University of Colorado Aerospace
Engineering Sciences
44
Manufacturing Test
•
Purpose: Verify the manufactured components of the project (test stand, Earth disk, and sensor
enclosure) closely align to the calculated values. Calculate the error introduced by manufacturing.
•
Materials:
–
–
–
–
–
–
–
Sensor Enclosure
Earth Disk
Test Stand
Level
Inclinometer
External Computer
Tape Measure
Measurement
Enclosure
Focal Point Height
Disk Radius
Experimental α
α (16”)
α (9.07”)
7/12/2016
Expected Value
How it’s Verified
2.48” x 4.21” x 3.74” Measured value compared to expected value
4.52” ± .0625”
Measured value compared to expected value
16” ± .11”;9.07” ± .11” Measured value compared to expected value
Use for comparison to inclinometer angle for
𝑟𝑎𝑑𝑖𝑢𝑠
−1
90° − tan
test stand error
ℎ𝑒𝑖𝑔ℎ𝑡
15.79ᵒ± .14ᵒ
Compared to calculated angle, yields error
26.52ᵒ± .14ᵒ
Compared to calculated angle, yields error
University of Colorado Aerospace
Engineering Sciences
45
Inclinometer Test
•
Purpose: Verify the functionality and calibrate for use in manufacturing,
camera/BBB, and full tests
•
Materials:
•
•
•
•
Inclinometer (ADIS16209)
BeagleBone Black
External Computer
Assembled Test Stand
• Process:
– Connect inclinometer to BeagleBone Black
– Use written software to establish communication between inclinometer and
BeagleBone Black
– Run software to collect inclinometer data
– Verify output is received by BBB with external computer
– Calibrate inclinometer for zero degrees of displacement at test stand
horizontal perturbation
University of Colorado Aerospace
Engineering Sciences
7/12/2016
46
Test Stand Scaling
α
Boresight
Focal Point
Height
Horizon Disk Radius
Altitude
Scaled Horizon
Radius
Focal Point
Height
Alpha
* Measured by
inclinometer
250 km
16” ± 0.30”
4.52” ± 0.09”
15.79°
750 km
9.07” ± 0.11”
4.52” ± 0.09”
26.52°
University of Colorado Aerospace Engineering Sciences
7/12/2016
University of Colorado Aerospace Engineering Sciences
47
Height Measurement
Focal Point
Distance
Relative to
Rear
Distance From
Front of Sensor
Housing
Measure distance
between front of
sensor box and
Horizon disk
Total distance of
disk to focal point
< 1/16th”
University of Colorado Aerospace Engineering Sciences
7/12/2016
University of Colorado Aerospace Engineering Sciences
48
Error in Stand Height
β
Focal Point
Height
α
Bore
Sight
• |α – β| = Angular Error
• Stand Height = 4.52”
• Focal point height must be known to 1/16”
to keep total error below 0.5°
7/12/2016
Change in
Height
University of Colorado Aerospace Engineering Sciences
Nominal Focal
Point Height
Test
Horizon
Half-Disk
Radius
49
Error in Disk Radius
α
Focal
Point
Height
φ
• Disk Radius = 16.00” for 250 km
= 9.07” for 750 km
• φ is smaller than pixel resolution for both
250 and 750 km disks
• Manufacturing tolerance governed by pixel
resolution
• 0.30” for 250 km
• 0.11” (a little less than 1/8” )for 750 km
Error in
Radius
University of Colorado Aerospace Engineering Sciences
7/12/2016
Camera
Focal Point
Test Horizon
Half-Disk
Radius
50
Analog to Digital Test
A cheap analog to digital converter has been tested and has shown that it is
possible to use the BeagleBone Black to pull images from the converter.
The converter used had
the wrong chipset for
use with linux, but an
image was still
received.
Good images should be
possible using the
correct chipsets.
7/12/2016
University of Colorado Aerospace Engineering Sciences
51
Algorithm Settings
•
•
7/12/2016
Algorithm settings are stored in shell environment variables
Environment variables are loaded into globals to reduce the frequency of memory allocation
to increase execution speed
University of Colorado Aerospace Engineering Sciences
52
Error Reduction Polynomials
• Record output over roll and pitch angles between 0°
and 20° at various altitudes
• User polynomial interpolation to fit an equation to
the measured angle vs actual angle data
• Interpolate between the polynomial coefficients in
order to come up with equations that give the error
correction polynomial coefficients vs altitude
7/12/2016
University of Colorado Aerospace Engineering Sciences
53
Error Reduction Polynomials
Provide pitch and roll error correction coefficients for a given altitude.
7/12/2016
University of Colorado Aerospace Engineering Sciences
54
Error Reduction Polynomials
Given the measured pitch or roll and the error correction polynomial
coefficients, determine the actual pitch or roll angle.
7/12/2016
University of Colorado Aerospace Engineering Sciences
55
Algorithm Overview
7/12/2016
University of Colorado Aerospace Engineering Sciences
56
Determining Roll Angle
y
Roll is the angle between
the sensor y-axis and the
vector from the center of
the sensor frame to the
center of the least squares
circle, (xc, yc)
x
ϕ
æ xc ö
f = -tan ç ÷
è yc ø
-1
(xc, yc)
7/12/2016
Center of Least Squares Circle
University of Colorado Aerospace Engineering Sciences
57
Determining Pitch Angle
y
Calculate Height:
Height = pixelPitch (Vc - Rc )
Calculate Pitch Angle:
x
æ Height ö
q = -tan ç
÷
è FocalLength ø
-1
Vc - Rc
Pitch Angle
Height
FOV
Vc
Rc
Focal Length
Earth center
7/12/2016
University of Colorado Aerospace Engineering Sciences
58
Pitch and Roll Errors
Pitch and roll errors are
negligible after error
reduction equation.
DR.2.2.1
Displacements
have errors less
than 0.5o
Error correction
polynomial reduces
errors to
≤ 0.06o
7/12/2016
University of Colorado Aerospace Engineering Sciences
59
Software: Line Timing, CMOS Protocol
8-bit Double-Clocked YCbCr CMOS mode (‘YCbYCr’ 4:2:2 Cosited)
2/1/2015
7/12/2016
University of Colorado Aerospace Engineering Sciences
60
Software: Frame Timing, CMOS Protocol
2/1/2015
7/12/2016
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61
Software:
Timing Scheme for CPU and PRU0
2/1/2015
7/12/2016
University of Colorado Aerospace Engineering Sciences
62
Software:
FBD for CAN communication
1. A CAN message is received from the simulated
satellite bus through the DIO pins, which interrupts
the CPU.
2. The CPU determined if the message is intended for
ETHOS, and saves the message to a buffer in RAM.
3. If the message is commanding a displacement
vector output, the CPU will finish computing the
displacement vector for the current frame. If the
message is commanding a health telemetry output,
the CPU will sample the voltage and current.
4. The CPU will send the commanded data over the
CAN bus.
2/1/2015
7/12/2016
University of Colorado Aerospace Engineering Sciences
63
Mechanical: Face Mount
½“ Aluminum
¼“ Ø
2.48
”
3.74”
5.00”
2/2/2015
University of Colorado Aerospace Engineering Sciences
64