TEAM CHINESE BANDIT
OZONE PAYLOAD CRITICAL
DESIGN REPORT (CDR)
Zach Baum
Harry Gao
Ryan Moon
Sean Walsh
1
TABLE OF CONTENTS
Mission Goal
 Objectives
 Requirements
 Electrical Design
 Software Design
 Thermal Design
 Mechanical Design
 Payload Construction Plan
 Mission Operations
 Master Schedule
 Master Budget

2
MISSION GOAL
Create
a profile of ozone
concentration with respect to
altitude from ground level to
100,000ft.
3
Ozone sensor reading for 2012 UND/UNF HASP payload
SCIENCE OBJECTIVES
 Map
peak of ozone concentration in
upper atmosphere.
 Create ozone concentration profile
with respect to altitude.
 Map out any fluctuations within
ozone profile.
4
TECHNICAL OBJECTIVES
 The
payload must measure ozone
concentration
 The onboard program will be able to:
 Take temperature readings within
close proximity to ozone sensor
 Maintain proper operating
temperature for all necessary
components
5
SCIENCE REQUIREMENTS
 The
payload must take
measurements of ozone
concentration every 3 seconds
 Team Chinese Bandits must receive
time and altitude GPS information
for analysis from LaACES
management
 The payload must measure the peak
ozone concentration to within
.2ppmv
6
TECHNICAL REQUIREMENTS

The payload must:

Not have a mass greater than 500g

Not exceed 3oz/in2 on any surface




Have two holes 17in apart through which the payload will interface with
the balloon
Costs must remain within the allotted $500 budget for Chinese Bandits
In order for the payload to create an ozone profile of the atmosphere, the
following requirements must be met:
Payload must take measurements of ozone concentration throughout the
flight

Payload must be recovered for post-flight analysis

Altitude must be known to within 65 feet

For the accuracy to be known within 65 feet, the following requirements
must be met:
 Real-time clock must be synced with GPS time during pre-flight
 Real-time clock must be accurate to within 3 seconds of the LaACES
LASSEN iQ GPS
7
SENSORS
OZONE SENSORS

ITO acts as a variable resistor whose resistance
changes in the presence of ozone


Applying a constant current allows us to relate the
change in output voltage to the resistance and ozone
concentration as measured by each sensor
Has a small operating temperature range,
therefore a thermal controlling system will be
needed
8
SENSORS
OZONE SENSORS
Calibration data will be obtained from Dr. Patel
 The equation [𝑥 = (𝑦 − 𝑏)/𝑚] can be used to
relate the resistance of each sensor to the ozone
concentration


Y = sensor resistance, X = concentration of ozone, m =
slope of the calibration curve, b= y-intercept of curve
9
SENSORS
THERMISTOR

KC003T-ND thermistor
Property
Value
Operating Temperature
Range
R0 (Resistance at 25°C)
-50°C - 150°C
Temperature Coefficient (@
25°C)
Accuracy (@ 25°C)
-4.40%/°C
Resistance at 20°C
12.5 kΩ
Resistance at 30°C
8.055 kΩ
10 kΩ
+/- 1°C
10
HEATER
KHLV-101/5 Kapton Heater
 1in. X 1in.
 Provides up to 5W of heat with 28V max voltage

Property
Value
Resistance
150 Ω
Current draw
80 mA
Power draw
0.936 W
11
SENSOR INTERFACING
OZONE SENSOR
12
OZONE SENSOR INTERFACING
Zero temp-coefficient
circuit for the
constant current
source
Resistor
value LM234 current

(Ω)
0
10
100
600
1000
1400
1500
1600
2000
2400
2800
3200
3600
output (mA)
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.24
1.48
13
THERMISTOR INTERFACE

Different constant current, op amp
Output voltage
3V
.2V
Thermistor resistance
12.5KΩ
6.5KΩ
14
CONTROL ELECTRONICS
BASIC STAMP PIN LAYOUT
Pin no.
1
2
3
4
5
Pin no.
13
14
15
16
17
Pin Function
I/O (EEPROM)
RTC (EEPROM)
Reset RTC
DATA (RTC)
I/O (RTC)
6
Pin Function
Serial Out
Serial In
ATN
Vss
Data Output
(ADC0838)
RTC (ADC0838)
18
7
8
9
10
11
12
CS (ADC0838)
NA
LED Output
LED Output
LED Output
LED Output
19
20
21
22
23
24
Data Output
(ADC0834)
RTC (ADC0834)
CS (ADC0834)
VDD
RES
Vss
VIN
15
CONTROL ELECTRONICS
ADC0838 PIN LAYOUT
Pin no.
Function
Pin no.
Function
1
CH0
11
2
CH1
12
Analog
Ground
VREF
3
CH2
13
Shift Enable
4
CH3
14
DO
5
CH4
15
SARS
6
CH5
16
CLK
7
CH6
17
DI
8
CH7
18
CS
9
COM
19
V+
10
Digital Ground 20
VCC
16
CONTROL ELECTRONICS
CIRCUIT INTERFACING
Sensor
Board (16
card edge
connector
)
16
14
12
10
8
6
4
3
2
*Other
pins not
16 wire
Ribbon
Cable
S1
S2
S3
S4
S8
S7
S6
Common
S5
Condition
ing Board
(8x2 pin
Header)
1
2
3
4
5
6
7
8
9
*Other pins
not used
S1
S2
S3
S4
S8
S7
S6
C
S5
17
CONTROL ELECTRONICS
CIRCUIT INTERFACING
Conditionin
g Board
(13x1 pin
header)
1
2
3
4
5
6
7
8
9
10
*Other pins
not used
26 wire
Ribbon
Cable
Vcc (5V in)
Vref (3V ref.)
ADC0
(Thermistor
I/O)
Not used
Not used
Not used
P0 (I/O ITO)
P1 (RTC
ADC0838)
P2 (CS
ADC0838)
P3 (3V Vref.)
BalloonSat
(13x2 pin
header)
1
3
5
7
9
11
13
15
17
19
All Even pins
Ground
*Other pins
not used
Vcc (5V in)
Vref (3V ref.)
ADC0
(Thermistor
I/O)
Not used
Not used
Not used
P0 (I/O ITO)
P1 (RTC
ADC0838)
P2 (CS
ADC0838)
P3 (3V Vref.)
18
POWER SUPPLY AND DISTRIBUTION

Two power sources: one 9V, one 12V
19
HEATER AND RELAY CONFIGURATION
Will Use a 2N3904 transistor as a relay
 BASICStamp will send 3V to base pin to
saturate it, allowing the 12V load to flow through
the transistor and power heater
 10KΩ resistor placed before the base pin will
limit the base current that can flow into the
transistor

20
POWER BUDGET
Consumer
Ozone
Sensors
Thermistor
Heater
80 mA
12 V
Balloon Sat
53 mA
9V
Total
213.01 mA
Power
Supply 1
Needed
capacity
Power Budget
Voltage
Consumption
Rate
1 mA * 8
Variable
sensors = 80 (dependent
mA
on sensor,
3V max)
.01 mA
3V
Power
Supply 2
665.05 mAh 400 mAh
Required 9 V
Voltage
12 V
Energy
400
mAh
.05
mAh
400
mAh
265
mAh
1065.05
mAh
AA Lithium
Ion
Voltage (per
battery)
1.5 V
Capacity(per 3000 mAh
battery)
21
THERMAL DESIGN
LaACES Thermal Flight
Earth-Space
Parameters
Stefan-Boltzmann
Isun (solar constant)
T-space
Flight altitude
Isun
UNIT
S
1377.0
W/m2
Latitude
31
degrees
T-float
210
K
Albedo
0.5
4 K
Day of year
141
day
30500 m
Hour of day
14
hr
5.67E- W/m2
08 K4
1377 W/m2
Earth orbit eccentricity
0.01672
Declination angle
19.91164
deg
T-earth
273 K
638000
0 m
Inclination angle
29.14873
deg
R-earth
IR Fluxmin
160
W/m2
Internal Heat
2.96
W
Payload Parameters
View factor payloadearth
View factor payloadspace
0.451
Sphere radius
0.103 m
Effective Isolar
1360.54
Effective
Isphere
339.12
ENERGY BALANCE
calculations
bladder thickness
0.000 m
Qsun
15.824 W
kevlar shell thickness
0.000 m
Qalbedo
13.861 W
bladder conductivity
0.026 W/mK Qpower
2.960 W
kevlar shell conductivity
0.040 W/mK Q-IR
2.046 W
0.700
W/m2
W/m2
22
THERMAL DESIGN
Insulation
Parameters
Total input:
34.690 W
insulation absorptivity
0.350
hrad,earth
1.862 W/m2 K
insulation thickness
0.019 m
hrad,space
0.769 W/m2 K
insulation emissivity
0.850
constant1
0.248 W/K
insulation conductivity
W/m
0.027 K
constant2
0.103 W/K
constant3
0.053 W/K
Area Calculations
Total sphere projected
area
3.33E02 m2
Qrad-to-earth
2.295 W
Total sphere surface
area
1.33E01 m2
Qrad-to-space
28.542 W
Qconv-at-float
3.853 W
Total output:
34.690 W
Ti outer
9.2
degC
Ti inner
22.5
degC
Tk inner
22.5
degC
Tb inner
Tavg interior
air
22.5
degC
24.7
degC
23
MECHANICAL DESIGN
24
WEIGHT BUDGET
Componen
t
Quantity
Mass
BalloonSat
1
68.9g
+/- 0.05g
Measured
Lithium
AA
Batteries
(9V total
unit)
6
88.3g
+/- 0.1g
Measured
Lithium
AA
Batteries
(12V total
unit)
8
FOAMULA
R Casing
1
ITO sensor
1
Total
117.9g
57.5g
Uncertaint Calculate
y
d/Measur
ed
+/- 0.1g
+/- 2 g
13g
+/- 0.1g
345.6g
+/- 2 g
Measured
Component
Approximate
Mass
Operational
Amplifier
57g
Sensor
Interface
15g
Electrical
Wiring
15g
Heater and
Thermistor
10g
Glue, Paint,
Structural
Components
10g
Total
112g
Calculated
Measured
25
PRE-FLIGHT SOFTWARE
26
PRE-FLIGHT SOFTWARE: INITIALIZATION
STAGE
27
PRE-FLIGHT SOFTWARE: TESTING STAGE
28
FLIGHT SOFTWARE
29
FLIGHT SOFTWARE SUBROUTINES
30
FLIGHT SOFTWARE SUBROUTINES CONT.
31
POST FLIGHT SOFTWARE
Byte
Offset
Data
Description
0
1
2
3
4
5
6
7
8
9
10
11
Hour
Minute
Second
ITO1
ITO2
ITO3
ITO4
ITO5
ITO6
ITO7
ITO8
Thermistor
Timestamps the Data
Reads ozone
concentration
Reads temperature of
ITO Array
32
PAYLOAD CONSTRUCTION PLAN
HARDWARE FABRICATION AND TESTING
Full system testing will be conducted after each
subsystem is tested and proven
 Payload design will be updates after testing
 A delay in any subsystem will cause combined
testing to be delayed

33
INTEGRATION PLAN
After each subsystem is tested, individual
systems will be connected together to ensure
interfaces work properly
 Electrical/software interfacing has been tested
and proven
 Tests on interfacing electrical, mechanical, and
thermal will ensure proper operation
temperature can be maintained
 Testing will be done on all systems in a
simulated flight to complete payload integration

34
FLIGHT SOFTWARE IMPLEMENTATION AND
VERIFICATION
Flight software was tested with electrical
prototypes to ensure it was functioning correctly
 Pre-Flight will be loaded the day before flight to
clear EEPROM and sync GPS time to RTC
 A computer located on site will be used to run
programs and retrieve data

35
FLIGHT CERTIFICATION TESTING
Tests will be conducted to ensure payload can
survive flight
 Temperatures of -70°C to 30°C
 Pressure of .163mBar to 1000mBar
 Impact upon landing
 A shock test and a thermal/vacuum test will be
conducted

36
SYSTEM TESTING PROCEDURE

Payload needs to survive 8.94 m/s

𝑉=
2∗𝐻∗𝑔
8.9408 = 2 ∗ 𝐻 ∗ 9.8
 H = 4.08m or 13.38 ft.
 Procedure checklist







Power up payload
Run preflight software
Run flight software
Drop from13.4 feet onto the floor
Run post-flight software
Verify that all onboard electronics are operating
properly
37
VACUUM TEST PROCEDURES








Power up payload
Run preflight software
Run flight software
Place payload in Vacuum Testing Chamber
Make sure that vacuum chamber is sealed and
pressure gauge is turned on
Simulate flight environment in vacuum testing
chamber.
 This include having a temperature range -70 to
30C
 This include pressure of .163 mBar- 1000 mBar
Run post-flight software
Analyze and verify data
38
SYSTEM TESTING RESULTS
ITO removed
from box
Preliminary tests
Resistance vs Time
600.0
done to test if
500.0
sensors will work
400.0
 Spark gap created in
300.0
box to create ozone
200.0
 ITO warmed to
operating
ITO placed
100.0 ITO warmed to
25°C
in box
temperature and
0.0
placed in box until
Seconds After Beginning Test
480 seconds
 After speaking with Dr. Patel, long reaction times
may be due to not enough ozone to fully react, or
not enough airflow across the sensor
Resistance
1
30
59
88
117
146
175
204
233
262
291
320
349
378
407
436
465
494
523
552
581
Change in Resistance of original value of 1.4kΩ

39
PRE-LAUNCH REQUIREMENTS AND OPERATIONS:
CALIBRATIONS
Two Instruments that require calibration
 Thermistor

Calibrate for low temperature of 20°C
 Calibrate for high temperature range of 35°C


ITO Sensor
Do not have necessary equipment to calibrate
 Will be provided by Dr. Patel of the University of
North Florida

40
PRE-LAUNCH REQUIREMENTS AND OPERATIONS:
CALIBRATION PROCEDURES

Thermistor
Fill glass with cold water in a heat metal container
 Place thermometer and thermistor
 Record the sensor reading using the voltmeter and
flight software for temperature from 20°C to 35°C


ITO

Will be provided by Dr. Patel
41
ITO Circuit
Thermistor
PRE-LAUNCH CHECKLIST
Event
Time
Time
Needed
Materials Needed
Verify all systems
are flight ready
2 days
before
flight
12 hours
before
flight
20 minutes
The full Chinese Bandits payload,
multimeter
15 min.
Set time of
BalloonSAT clock
12 hours
before
flight
15 min.
Replace battery
packs with fresh,
tested packs
12 hours
before
flight
5 min.
The full Chinese Bandits payload,
one computer with BASIC Stamp
Editor software, one 9-pin serial
cable
The full Chinese Bandits payload,
one computer with BASIC Stamp
Editor software, one 9-pin serial
cable, the LaACES GPS unit with
computer hookups
Fresh, tested 9 and 12 volt battery
packs
Load Flight
Software onto the
BalloonSat
12 hours
before
flight
5 min.
Connect battery
packs, close and
seal payload lid
1 hour
before
flight
5 min.
Run Pre-Flight
Software
The full Chinese Bandits payload,
one computer with BASIC Stamp
Editor software, one 9-pin serial
cable
Tape
42
FLIGHT REQUIREMENTS, OPERATIONS AND
RECOVERY
Batteries will provide the BalloonSat and sensors
with enough power for the duration of the flight
 EEProm will have enough memory to take
measurements for the duration of the flight
 Must find and recover EEProm during recovery;
Extra BallonSats will be brought in order to
retrieve the data from the EEProm

43
DATA ACQUISITION AND ANALYSIS PLAN:
GROUND SOFTWARE

The following procedure will
be used to complete
Ground Software and
export flight data.
44
DATA ACQUISITION AND ANALYSIS PLAN:
DATA ANALYSIS PLAN
ADC values will be converted into ozone
measurements in PPM(Parts Per Million)
 Thermistor values will be converted to degrees in
Celsius
 Sync GPS value with time to get altitude data

45
DATA ACQUISITION AND ANALYSIS PLAN:
DATA ANALYSIS PLAN (CONTINUED)

The following graphs will be made from flight
data to help with the analysis process
Ozone vs. altitude
 Ozone vs. time
 Temperature vs. time
 Ozone vs. temperature


Expected uncertainties for thermistor will be 1
percent while the uncertainties for the ozone
sensor will be 0.2ppm
46
PROJECT MANAGEMENT
WBS
47
PROJECT MANAGEMENT
WBS
48
PROJECT MANAGEMENT
WBS
49
STAFF ORGANIZATION AND
RESPONSIBILITIES
Category
Team Member
Project Manager
Zach Baum
Software Developer and
Lead
Mechanical Lead
Harry Gao
Electrical Lead
Harry Gao
Calibrations
Harry Gao
Integration
Zach Baum
Version Control and
Editing
System Testing
Ryan Moon
Sean Walsh
Sean Walsh
50
MASTER BUDGET
EXPENDITURE PLAN
Parts For
Testing (1)
Quantity
1
1
1
Parts For
Testing (2)
1
1
1
1
1
1
Part no.
ADC088S102
CIMT/NOPBND
LM234Z6/NOPB-ND
AT24C512CSSHM-B-ND
2N7002K-T1E3CT-ND
KHLV-101/5
Description
8 channel ADC
Unit Price
$3.09
Total Price
$3.09
Constant
Current Source
64KB
EEPROM
Transistor for
relay
Heater
$1.27
$1.27
$1.76
$1.76
$0.38
$0.38
$31.00
$18.99
TIP112TUND
24LC512-I/PND
ADC0834CC
N/NOPB-ND
LM234Z6/NOPB-ND
ADC0838CC
N/NOPB-ND
ITO Sensor
for Testing
Transistor for
relay
64KB
EEPROM
4 Channel
ADC
Constant
Current Source
8 channel ADC
$31.00
Shipping
Total
$0.66
$1.96
$1.96
$3.11
$3.11
$1.27
$1.27
$2.97
$8.91
Borrowed
$0.00
Shipping
Total
$14.94
Ozone Sensor
$0.66
51
MASTER BUDGET
EXPENDITURE PLAN
Parts for
Fabrication
24
AA Energizer
L91 batteries
Batteries for
power supply
6
AD822ANZ-ND
Op-Amp for ITO’s $6.28
2
AD820
$4.54
$9.08
18
3299W-104LFND
LM234Z6/NOPB-ND
TIP112TU-ND
Op-Amp for
Thermistor
Variable resistor
$2.60
$46.80
Constant Current
Source
Transistor for
relay
Back-up heater
Back-up
EEPROM
Printed Circuit
Board
$1.27
$15.24
$0.66
$1.32
$31.00
$1.96
$31.00
$1.96
$177.70
$177.70
Borrowed
$0.00
$0.46
$5.52
$8.14
$8.14
Shipping Total
$18.99
Total
Total Expected
Expenditure
$416.85
$502.18
12
2
1
1
1
1
12
1
KHLV-101/5
24LC512-I/PND
PCB
Flight-ready
ITO sensor
445-5327-ND
Pack of Real
Velcro
10microF
capacitor
$49.95 for 24pack
$49.95
$37.68
52
MASTER BUDGET
MATERIAL ACQUISITION PLAN
Material
BalloonSat
Qua
ntiti
es
1
How
Acquired
When
Needed
When to Order
Supplied by
LaACES
Supplied by
LaAces
Ordered from
Digikey
Calibration
and testing
Calibration
and testing
Calibration
and testing
Already Have
1 week before
fabrication
already have
Capacitors, resistors,
wires, etc
ADC088S102CIMT/NOPBND
8 channel ADC
LM234Z-6/NOPB-ND
Constant Current Source
x
12
Ordered from
Digikey
AT24C512C-SSHM-B-ND
64KB EEPROM
2
Ordered from
Digikey
2N7002K-T1-E3CT-ND
Transistor for relay
1
Ordered from
Digikey
One for
Calibration
and testing,
the rest for
fabrication
One for
Calibration
and testing,
the other for
backup
Calibration
and testing
KHLV-101/5
Heater
TIP112TU-ND
1
Ordered from
Omega
Ordered from
Calibration
and testing
Calibration
1
1
Already Have
Already Have
Need 1 more
already have
already have
53
MASTER BUDGET
MATERIAL ACQUISITION PLAN
24LC512-I/P-ND
64KB EEPROM
1
Ordered
from
Digikey
Calibration
and testing
already have
ADC0834CCN/NOPB-ND
4 Channel ADC
1
Supplied by
LaAces
Calibration
and testing
already have
LM234Z-6/NOPB-ND
Constant Current Source
1
Ordered from
Digikey
Calibration
and testing
already have
ADC0838CCN/NOPB-ND
8 channel ADC
1
Ordered from
Digikey
Calibration
and testing
already have
ITO Sensors
1
Borrowed
Calibration
from Dr. Patel and testing
already have
24
AA Energizer L91
batteries
Batteries for power supply
AD822ANZ-ND
Table 22: Material
Acquisition Plan
Op-Amp for ITO’s
6
Order Online
through
Amazon
Fabrication
Need to order 1
week before
fabrication
Ordered from
Digikey
Fabrication
Need to order 1
week before
fabrication
54
RISK MANAGEMENT AND CONTINGENCY
PLAN
System
Risk
Contingency Trigger
Plan
Electrical
Not returning
correct data
Calibration
and testing in
simulated
conditions
Changes in
output related
to unexpected
conditions
Electrical
Interface and
component
problems
Faulty wiring
and
components
Harry
Mechanical
Inclement
weather
Weather
Sean/Ryan
Electrical/M
echanical
Inability to
maintain
operating
temperature
Testing
components
hardware and
software
before, during,
and after
assembly
Structurally
sound and
sealed
mechanical
design and
testing
Using a
heater and
thermistor,
testing in
simulated
Extreme cold
Team
Who is
responsible
Team
55
RISK MANAGEMENT AND CONTINGENCY
Electrical
Frying
EEPROM
All systems
Loss of
payload
All systems
Loss of team
member
Project
Not meeting
Management deadlines
All systems
Over budget
Have backup parts,
and use
extreme
caution preflight
Prepare
failure report
Carelessness Zach
Loss of
payload
during flight
Rest of team
Increased
would pick up workload
responsibilitie
s
Set early
Poor project
management
deadlines to
allow for
mistakes to be
fixed
Find cheaper Not enough
money
and more
cost-effective
components
Team/LaACE
S staff
Team
Zach
Team
56