P09233 Master File Michael Skube - Mechanical Engineer (ME) James Hunt - Mechanical Engineer (ME) Joseph Peters - Electrical Engineer (EE) Kevin Li - Electrical Engineer (EE) John Isely - Mechanical Engineer (ME) William Atkinson - Mechanical Engineer (ME) Heidi Morgan - Electrical Engineer (EE) 1 Table of Contents Section A A.1 P09233 Introduction A.2 One Page project Summary Section B – Sensor Documentation B.1 Airspeed Sensor B.1.1 Device description B.1.2 Design Specification B.1.3 Pugh Analysis B.1.4 Components Specification B.1.5 Test Plan B.1.6 Test Results B.2 Altitude Sensor B.2.1 Device description B.2.2 Design Specification B.2.3 Pugh Analysis B.2.4 Components Specification B.2.5 Test Plan B.2.6 Test Results B.3 GPS Sensor B.3.1 Device description B.3.2 Design Specification B.3.3 Pugh Analysis B.3.4 Components Specification B.3.5 Test Plan B.3.6 Test Results 2 B.4 IMU Sensor B.4.1 Device description B.4.2 Design Specification B.4.3 Pugh Analysis B.4.4 Components Specification B.4.5 Test Plan B.4.6 Test Results B.4.7 Final Design B.5 Microprocessor B.6.1 Device description B.6.2 Design Specification B.6.3 Pugh Analysis B.6.4 Components Specification B.6.5 Test Plan B.6.6 Test Results B.6 Components Box Appendix Section 1 Airspeed Sensor 1.1 Device Manuals 1.2 Pugh Analysis 1.3 Test Results Section 2 Altitude Sensor 2.1 Device Manuals 2.2 Pugh Analysis 2.3 Test Results Section 3 GPS Sensor 3.1 Device Manuals 3 3.2 Pugh Analysis 3.3 Test Results Section 4 IMU Sensor 4.1 Device Manuals 4.2 Pugh Analysis 4.3 Test Results Section 5 Microprocessor 5.1 Device Manuals 5.2 Pugh Analysis 5.3 Test Results Section 6 Assembly 6.1 Box Part Drawings 6.2 Box Assembly Instructions 6.3 Pitot Tube Assembly Instructions 6.4 Wire Assembly Instructions Section 7 Bill of materials 7.1 Individual Box BOM 7.2 Complete Project Cost 4 Section A A.1 The mission of the Measurements group is to provide a means for measuring and calculating all the necessary parameters for the flight of Unmanned Aerial Vehicles. Primarily through the use of superior measuring devices, and accurate dynamic characterizations. We strive to provide accurate data from our measurement systems for in-flight control and monitoring. We strive to exceed engineering standards while encouraging an environment for intellectual growth. Specific roles and responsibilities or varying team members will be divided according to academic major and specialty. Mechanical Engineer Dynamic Characterization (Fluid/Structural); Sensor Design and Placement; Sensor Testing and Calibration Electrical Engineer DAQ; Power Management; GPS Implementation; Sensor Design and Placement; Sensor Testing and Calibration The work done will allow other teams in the R09230 - Open Architecture, Open Source Unmanned Aerial Vehicle for Imaging Systems Roadmap to control and monitor the airframe for continual safe flight. Initial testing will be done in the wind tunnel, or on basic test frames provided from other groups, the final measurements system will be integrated into the primary airframe and will directly interface with the on board control system. 5 A.2Senior Design Project Data Sheet Project # Project Name Project Track Project Family P09233 Airframe Measurements Vehicle Systems and Technologies R09230 Start Term Team Guide Project Sponsor Doc. Revision 20082 Dr. Jason Kolodziej RIT ME Department 1 Project Description Strategy & Approach Project Background: Assumptions & Constraints: The long term goal of this project is to create, field and implement a full system of measurement devices that will be used to control an unmanned aerial vehicle. This will be the first quarter that the project is being worked on, and the primary goal will be to implement off the shelf measurement devices to characterize the necessary parameters for in-flight control of an unmanned aerial vehicle. 1. 2. 3. 4. Access to necessary testing equipment. Group knowledge of all aspects required for the completion of the project Access to necessary calibration tools. The budget needs of the group as stated in DPM will be available (~$2860.00). Issues & Risks: Project Issues/Risks/Constraints Problem Statement: The project will combine several sensors to measure the fundamental parameters of in-flight movement to calculated the nessassry information to sustain flight. The project will deleiver this data in a user friendly interface. Objectives/Scope: 1. 2. 3. Measure real time position of test platform Measure flight parameters Ensure measurements are accurate and reliable Deliverables: - Project Knowledge New Project New Area of Study for Some - Available Resources Obtainin Resources Ordering Parts Lead Times Meeting Time - Understanding all of the Nessassary Measurements Needed for In-Flight Control Getting up to Speed on Sensor Implementation Using Hardware/Software Test platform that can measure the characteristics need for in-flight control Processed data for use in a control system Documentation of the calibration and use of the test platform Expected Project Benefits: Inexpensive and reliable measurements platform. Basis for future Senior Design development. Core Team Members: Michael Skube – Team Lead James Hunt – Team Lead Heidi Morgan John Isely Joseph Peters Kevin Li William Atkinson 6 B.1.1 Airspeed Sensor The Pitot - static tube is used to measure the velocity of the object the Pitot tube is attached to, through a fluid. For most applications that fluid is air and for this the project that is also the case. A Pitot tube works by measuring the Total or Stagnation Pressure, P o, which is measured at a hole pointing directly into the flow that creates a stagnation point; and the Static Pressure, P, measured through a port that is perpendicular to a given flow. The operational range of a Pitot tube and especially for this project, the Bernoulli Equation (Eq 1.) can be used to calculate the velocity of the craft from the measured Total and Static pressures from the Pitot tube. The Bernoulli Equation is valid because of four 7 assumptions: 1) The flow is along a Streamline; 2) The flow is inviscid; 3) The flow is steady; 4) The flow is incompressible. The fourth assumption had to be checked because of the speeds that the UAV was going to be flying at (0 – 50 mph). For the flow to be considered incompressible, the speed of the flow must be less than or equal to three tenths of the speed of sound (≤0.3a). To find the speed of sound the equation a = (γRT)1/2 was used and the speed of sound was found at two extremes, the summer and winter in Rochester, NY. In the summer, a was found to be 349m/s, meaning the compressibility limit was 104.7m/s or 234.2mph. During the winter, a was found to be 327.2m/s, giving a compressibility limit of 98.2m/s or 219.6mph. The UAV is flying at a speed well below these two limits, therefore the flow can be treated as incompressible and the Bernoulli Equation is valid. 𝟏 𝝆 𝑽𝟐 𝟐 Eq 1. – Bernoulli equation to calculate velocity, V 𝑷𝒐 = 𝑷𝒔𝒕𝒂𝒕𝒊𝒄 + In most Pitot tubes today, there is temperature compensation. This means that the Pitot tube is measuring the Total Temperature of the flow through the total pressure port, which Tstatic can be found from. With most applications and this project the working fluid is air and that can be considered an ideal gas, therefore the ideal gas equation (Eq. 2) can be used to find the density. This density can then be used in the Bernoulli equation the find velocity. 𝑷𝒔𝒕𝒂𝒕𝒊𝒄 𝑹𝑻 Eq 2. – Ideal Gas Equation to find density, ρ 𝝆= The Pitot tube is important because it provides the pilot or the control system with the important measurement of velocity. The velocity measurement is important because the pilot or the control system needs velocity to help them navigate, find aero coefficients that are dependent on velocity, for example coefficient of Drag and Lift, for the control system, flight times (e.g. ETA or time to a waypoint), and fuel consumption. This makes the Pitot tube an important part of this project because it will be one of the important sensors that will help make this UAV autonomous. B.1.2 Design Specification The main requirement that is expected out of the Pitot tube is velocity, whether it is velocity or a voltage that can be converted to a velocity. The next set of design requirements involves physical attributes, power requirements, and inputs. The design requirements for a suitable Pitot tube are as follows: 1. Weight 1 oz. or less 2. Smaller than 1” x 1” x 1” for a chip and no longer than 6” for Pitottube 3. Capable of measuring both static and dynamic pressure 4. Measure Speeds from 0 to 100 mph 8 5. Resolution of ± 1 mph 6. Input voltage of 3.3V 7. Sample rate of no less than 1 sample/second These design specs (1, 2, 4) came from the customer (Airframe B, P09232) in which the sensors had to be light and small, so as to leave more room and weight for the payload that the UAV is to carry. Some of them also can from the MCU (Microcontroller Unit), which uses 3.3V (6). Other design specs (3, 5, 7) were set by the team thinking from the point of view of the control systems team; in this case the MAV Controls team was consulted, P09122. B.1.3 Pugh Analysis After the different types of sensors were laid out as to what was needed to fly a UAV, each member picked and then researched that sensor. In regards to the Pitot-tube, there were three Pitot-tubes that fit the bill of being capable of meeting the customer needs. These three Pitot-tubes are, in no particular order: 1) Eagle Tree Systems Airspeed Microsensor; 2) Eagle Tree Systems Airspeed Microsensor w/ eLogger; and 3) Space Age Control Pitot-Tube 300933. The first step in the Pugh Analysis is the Concept Screening Matrix. The selection criteria in the Concept Screening Matrix was based on what the team as a whole felt was most important to accomplish the customer’s needs, along with one or two extra selection criteria’s that were important to that individual sensor. For the Pitot-tube, the individual sensor selection criteria’s are Airspeed, Live Data, and Calibration. Using the standard Eagle Tree Systems Airspeed Microsensor as the reference, each sensor was given a “+”, “0”, or “-“, depending on how it measured up to the reference sensor. After this was completed, the Space Age control Pitot-tube was dropped and the two Eagle Tree Systems Airspeed Microsensors moved on to the Concept Selection Matrix. The main reason that the Space Age Control Pitot-tube did not move on was the fact that this was just a shell of a Pitot-tube. To make this a functioning Pitot-tube, pressure transducers, temperature transducers, tubing and wiring would be needed and bought separately. This greatly increased the cost, as a single pressure transducer was more expensive than the Eagle Tree Systems Airspeed Microsensor. In the Concept Selection Matrix, the same selection criteria were used along with the individual selection criteria for each individual sensor. The difference is that in the Concept Selection Matrix, a percentage out of 100% is given to each selection criteria. These percentages were discussed and decided upon as a team. Then each sensor was rated, 1 through 5 on each selection criteria and then weighted according to the percentage assigned to that selection criteria. Once each selection criteria was weighted, they were added up and the sensor with the highest score was chosen. The sensor that was on top was the Eagle Tree Systems Airspeed Microsensor w/ eLogger. The reason that the other Eagle Tree System was not picked was mainly that the two Eagle Tree Systems are the same Airspeed Microsensor which only measures max velocity. With the addition of the eLogger, the capability of the Airspeed Microsensor is greatly increased because the eLogger with the software packaged with the eLogger, allows the storage and analysis of data, along with real time telemetry. 9 The Eagle Tree Systems Airspeed Microsensor w/ eLogger is the best system because it is ready to go out of the box, directly outputs velocity, is able to store and analyze data, real time telemetry capability, very small and very light. It is also a complete kit which helps with troubling shooting and interfacing issues. The Pugh analysis can be seen in section 1.2 of the appendix. B.1.4 Components Specification In the appendix there are more detailed specs as to what the eLogger and Airspeed Indicator can handle, how they work, and what they output. To use the Airspeed Indicator and the eLogger, all that needs to be done is to simply connect them together as shown in the manuals. From the Pitot-Tube, there is a Static port and a Pressure port. Using the tubing that came with the kit, the Static Port is connected to the minus sign on the Airspeed chip and the Pressure port is connected to the plus sign on the Airspeed chip. Then the chip can just be directly connected to the eLogger following the pattern displayed on the eLogger. Once this is done the eLogger can be connected to the planes battery for standalone power or connected to a computer with the eLogger software by USB. When the eLogger is connected directly to a computer, live telemetry can be viewed while the eLogger still records data. The Airspeed chip itself directly output velocity to the eLogger and the eLogger records data anywhere from 1-10 samples a second depending on what the user desires. Mounting is simply done with a clamp to hold the Pitot-tube and the Airspeed chip and eLogger can be placed on small plates that can be placed where they are needed. To use this device, simply power the eLogger through the plane’s battery or a computer. This device is not sensitive to anything, vibration, EMF, or temperature. Plus this device never has to be calibrated before each test. With the temperature measurement that the Airspeed chip takes, the airspeed is calibrated for the current local atmospheric conditions. In terms of maintenance and cost, there is no maintenance that needs to be done for this device and if it breaks, the best course of action would be to by a new system since it is already fairly inexpensive. B.1.5 Test Plan There are four tests planned to test and verify that the Eagle Tree Systems Pitot-tube works as claimed and is accurate. Test #1 Wind Tunnel Test of ETS Pitot-Tube in small and large wind tunnel at RIT. This will be done against a hot wire probe, pressure transducers, and/or and anemometer. This test will help to verify that ETS Pitot-tube is accurate; can hold a steady velocity reading without outside noise, like wind; and find the lower limit of the Pitot-tube, ETS claims 2 mph. This test will be done against observations not time. 10 Test #2 “Car test” of ETS Pitot-tube against anemometer. This test will help to see the Pitottube’s delay through live telemetry, also how the Pitot-tube is across changing speeds and higher speeds, along with the addition of possible winds, angle of attacks and side slip angles to check that the Pitot-tube will work with these angles. This will be done on a car with the Pitot-tube pointing forward directly into the flow, along with the anemometer. Both will be fixed to the outside of the vehicle. One person will drive and call out when to record, while one person records the live data off of the computer with the ETS system attached while another person records the data off of the anemometer. This test will also be against observations not time. Test #3 This test is a time delay test. With a certain length of tubing there is going to be a certain time delay as the column of air in the tubing changes and that change is picked up by the Airspeed chip. It is important to determine this time delay to know how much tubing can be used to achieve a reasonable time delay. This is also important for the future knowledge of the Controls Team so they can account for or if necessary, change the length of the tubing to achieve a desired and acceptable time delay. Test #4 This will be the final test and will take place in Airframe A. This is an integration test of all the sensors that will be placed in the “Sensor Box.” Test #5 Velocity comparison between the GPS and ETS Pitot tube. This will help to determine how closely related the two velocities are and if they can be considered redundant systems, with one being possibly eliminated for the sake of weight and simplicity. B.1.6 Test Results Test #1 - Small Wind Tunnel at RIT This wind tunnel can only go up to 5 mph. This was perfect to test the lower limits of the Pitot-tube. The benchmark for this test was the anemometer. Table 1.3.4 in the appendix shows the results of this test. When the speed was below about 5mph, the Pitot-tube was having trouble making a consistent reading. This is most likely due to the fact that to Pitot-tube is reaching a stall point and cannot accurately read the velocity. This is not a problem due to the fact that if the plane is flying this slowly, it has already stalled and will nose dive and pick up speed above this level. However this test does confirm that the lower limit is 2 mph ± 1mph as claimed by ETS. 11 Figure 1.3.6 in the appendix shows the test results for the big wind tunnel. This wind tunnel could go up to 120 mph, so it helped to see where; if at all the ETS Pitot tube had an upper limit. This was not the case, as the Pitot-tube was able to go all the way up to 120 mph with no problems and match the hot wire probe step for step as the speeds were increased and then decreased. There are some slight variations between the two data sets, which is most likely due to the fact that the hot wire probe mount was slightly at an angle and not directly perpendicular to the flow. Test #2 - Car test The car test, shown in the Figure 1.3.5 in the appendix, shows how well the Pitot tube measures up against the anemometer. This test showed that the Pitot tube can react very well to changes in velocity and do it accurately. The reason for some of the error is the fact that the anemometer at times would "stick" when taking a reading and also the fact that the two sensors were on opposite sides of the vehicle. This could lead to one sensor being "shielded" from crosswinds or changes in direction of the vehicle leading to slight differences in values. Test #3 - Time Delay Test Figure 1.3.1 in the appendix shows the theoretical time delay for a worst case scenario where tubing has to be run down the entire length of the wing, in this case 5ft. It can be seen that the time delay with a step input into the system (linear ODE used in StateSpace) is on the order of tens of nanoseconds. Therefore the time delay can be assumed to be zero according to the theory. Figure 1.3.7 in the appendix shows the actual test data for the Pitot Tube Time Delay Test. In this case the time delay was found to be, on average of 0.01 sec. The discrepancy between the two is mostly due to the fact that the release of the end of the Pitot Tube was not entirely instantaneous as is the step input modeled in the theory. 12 B.2.1 Altimeter This device will be used to measure static pressure at a constant rate in order to output the airplanes altitude in real time. The altimeter will have a crucial role in autonomous flight and prevention of crashes due to flying too low for optimal flight conditions. The altimeter will also have a function related to the relative height of the imaging equipment to be used in a later project to take aerial photographs. B.2.2 Design specifications During weeks 1 and 2 of MSD1, our team’s main goal was to directly identify what sensors would be needed for completely autonomous flight. A rough list of the main components was assembled and each team member was given a sensor to research. 13 The altimeter device will output data directly to the microprocessor and will be analyzed in real time in order to keep the plane at the desired altitude for different functions including but not limited to a safe flying altitude and required height for appropriate image capture as outlined by the imaging science senior design team. The initial function of the altimeter for project P09233 will be to gather a streaming set of data points that accurately plot the airplanes flight path through the sky. There were a few different types of altimeters on the market ranging from model RC plane altimeters to full size aircraft altimeters. Due to the size constraints of airframe B as well as the cost in acquiring a full size mechanical altimeter, which was much higher and out of our budget range, the full size altimeter option was not really possible; this left only the RC plane altimeters. B.2.3 Pugh Analysis: After much searching online, the best options for recording altitude for a plane the size of Airframe B were found. Each altimeter is listed along with its specifications in section 2.3 in the appendix. Each altimeter had its pro’s and con’s, but in general, they were all roughly the same size and weight, but with increasing cost, the capabilities of the altimeter also increased. The main thing that the altimeter must do is to record altitude data live, and it must be able to output this data to our microprocessor, so that in the future, the data can be used in flight to analyze how the airplane is moving. The size, weight, power draw, sampling rate, and accuracy (within reason) were all secondary to the ability to output the data recorded in real time. The Pugh analysis, located in the appendix section 2.3, shows the process used for choosing the altimeter. The ram3 was initially thought to be the best fit for the project, and was therefore made the reference sensor. In the first part of the Pugh analysis, we see that the “How High” and “Eagle Tree stand alone altimeter” were poor at interfacing with the computer and did not record live data, only max height. These were easily eliminated. In the second phase of the Pugh analysis, weights were given to certain assets that the altimeters have. Cost, size, weight, interface, resolution, and power consumption received their weights as part of a group analysis of what would matter for the project as a whole, not necessarily for each component. The sampling rate, calibration, and live data weights were decided based on what would be needed for the altimeter and were different for each sensor. The ram3 and the zlog both had roughly the same price tag, and the eagle tree eLogger was being purchased for a different sensor already, so the total cost for the just the altimeter sensor dropped considerably when you factor that in. The ram3 and Zlog both had accuracy <1ft, while the eagle tree sensor had only accuracy <1meter. The main concern overall is the interface with computers for testing, and with the microcontroller for in flight data recording. All three of the sensors will interface with the computer, but only the Zlog altimeter has the ability to output the data live, the other two altimeters flight data is stored to the device and must be pulled later by computer. 14 After the Pugh analysis, it is clear that the Zlog is the best altimeter for this project, it is small, light, and accurate, and records data live, and has the ability to interface with our micro controller. This altimeter was purchased before Christmas. At the advice of Dr. Kolodziej, the eagle tree systems altimeter was also purchased. It had such a low cost compared to the Zlog and since we had already ordered the eLogger system for the airspeed sensor by the same vendor, it was decided that we should purchase and test the sensor as well. B.2.4 Components Specifications: The Zlog altimeter is ready to go out of the box. In normal use the sensor will be powered directly from the aircraft’s power supply, but in our case, we will draw power from the microcontroller. The Zlog was purchased mainly for its ability to gather data live and output it while in live data mode via an usb or serial cable. We will use this feature to output the data directly to the microcontroller instead of a computer. The microcontroller will store all outputted data on the SD card. Until the microcontroller is up and running, the Zlog altimeter also comes with a usb cable and recording software so that we may test the sensor before the measurement box is put in the air. The Zlog requires there be at least 0.25 in2 area open to atmospheric conditions in order for the pressure sensor on the altimeter to accurately measure static pressure. This is a concern, but due to how most model aircraft are constructed, as well as the way that our box will be constructed, there will be more than enough open surface area exposed to atmospheric conditions. We can easily use double sided tape or other adhesive to mount to the measurements box without worry of device failure. The manufacture normally suggest wrapping the device in bubble wrap or other similar cushioning device, but our measurements box will have ample cushioning and shock absorption to make any extra unnecessary. The Zlog altimeter is zeroed every time it is turned on. So each test the device can be zeroed for atmospheric conditions and the altitude recorded will be the altitude from the ground, not sea level. The manual and specification sheets for the Zlog can be found in the appendix. The Eagletree systems altimeter currently requires the use of the eLogger to capture and store live data. Our goal for this sensor will be to use the microcontroller as a replacement for the eLogger and be able to store data from the altimeter live just as the eLogger would. Again, since the microcontroller isn’t functioning as of now, we also have purchased the eLogger system in order to do initial tests on both the altimeter and the airspeed sensor. The eLogger system allows us to use the included data acquisition program with a computer to store data directly to a hard drive for initial tests. The eagle tree altimeter also can be mounted very easily directly in the measurements box in a similar way to the Zlog, but we also have the added possibility of mounting the altimeter directly to the static port on the back of the Pitot tube thus sharing the static port with the use of a t fitting. The advantage to this would be that both the altimeter and airspeed sensor would both be receiving the same static pressure data from the Pitot tube. This isn’t a requirement for the mounting of this sensor, just an added option. The eagle tree systems altimeter is zeroed every time it is turned on. So each test the device can be zeroed for atmospheric conditions and the altitude recorded will 15 be the altitude from the ground, not sea level. The data sheets and manuals for the eagle tree systems altimeter as well as the eLogger can be found in the appendix. B.2.5 Test Plan: The test plan for both sensors will be the same, and whenever possible, the two sensors will be tested simultaneously to prevent any potential errors. Test 1: Stair test This test will be used to determine the accuracy of the two altimeters on a small scale. The altimeters will be attached to a length of string marked every foot and lowered down a stairwell. At the bottom of the stairwell, both sensors will be zeroed and the test will begin. The string will be slowly raised the full height of the stairs, and readings will be taken from both sensors and graphed against each other to show the altitude increase. In this particular test, we will use two flights of stairs with a known height of 30’. Test 2. Altimeter vs. GPS accuracy test After the GPS sensor is up and running correctly, we will run a test using the altimeter and the GPS to do a drive around campus measuring altitude along the way. We will plot the altimeter data and the GPS data on the same graph to show the accuracy of both sensors. Test 3: Vacuum Chamber This will include testing of both sensors in a vacuum chamber. Both sensors will be placed in the chamber at the same time. The vacuum chamber will then be sealed and the pressure will be reduced over a short period of time. The pressure in the chamber will be reduced to that of atmospheric pressure around 1500 ft. The pressure from the vacuum chamber will be recorded with a pressure sensor (gauge pressure) outputted on a multimeter. Due to the nature of the pressure sensor, the data will be taken over a period of events and not based on time. The pressure data will then be converted to altitude. After the data test, the vacuum chamber data will be plotted against both altimeters as plot of altitude versus the taken data at each event. After all these tests are complete; the altimeter should be ready for use with UAV and imaging applications further down the road. B.2.6 Test Results Test 1a: Stair Test with both altimeters The first stair test was done with both altimeters. The altimeters were lowered down the staircase and zeroed on the ground floor. The altimeters were slowly raised up the staircase the full 30’. The graph of the data taken can be seen in the appendix section 2.3.1. It is seen from this graph that the zlog altimeter is much more accurate at smaller increments than the eagle tree altimeter. The specification sheets for both altimeters 16 document that the eagle tree is accurate to within one meter while the zlog is accurate to within one foot, so the outcome is not unexpected. Test 1b: Stair test with the Zlog altimeter After the reviewing the initial stair test, it was concluded that the zlog was indeed more accurate than the eagle tree system’s altimeter. We decided to try the test again with only the zlog, and to pause every one foot while pulling the zlog up the staircase. The graph in appendix section 2.3.2 shows the results of the test. As shown in the graph, the zlog is extremely accurate. The +/- 1ft tolerances seem to be fairly reliable as well, and after this test, we’ve decided to use the zlog in the final design instead of eagle tree systems altimeter. Test 2: Altimeter vs. GPS After the GPS sensor was up and running, we decided to test it against the altitude measurements given from the GPS. The sea level of Rochester is around 450ft above sea level. Normally the Zlog will give readings in the 400-500ft range for RIT’s location, but for some reason on the day of the first test, the zlog altimeter was reading around 100-200 ft range, probably due to a high pressure system over Rochester that day. The graph in appendix section 2.3.3 shows the readings of the two sensors. The test doesn’t really yield very good results. After previous tests, we know the altimeter is very accurate, but it seems that its absolute pressure readings can be off by a fairly substantial amount. Test 3: Simulated high altitude in a vacuum chamber. For this test, we tested both sensors in a vacuum chamber vs. a gage pressure sensor that measured between 0 and 10 psi. A vacuum chamber simulates altitude as the pressure drops. With this vacuum chamber we didn’t have very good control over how little we could change the pressure, and we also didn’t have a data acquisition system for the pressure sensor, so we used a multimeter and took event based data for all the sensors at the same time. The data’s graph can be seen in the appendix section 2.3.4. The two altimeters took excellent data vs. each other, but as the pressure dropped, the pressure sensor’s data consistently was lower than the two altimeters. This could be for a correction factor for altitude that the altimeters have built in that the gage pressure sensor does not. Other then the altimeter’s reading being higher than the pressure sensor, the test was a success. 17 B.3.1 GPS Sensor Global Positioning System (GPS) is actually a constellation of 27 Earth-orbiting satellites where 24 of them are in operation and the other three are extras in case one fails. The GPS receiver's job is to locate four or more of these satellites, and calculate the distance to each. Using this information, the receiver derives its own location. This process is based on a simple mathematical principle called tri-lateration. The GPS receiver must find the distance to three satellites of known positions to locate it. If the receiver finds that it is X miles from one satellite, it knows that it must be somewhere on an imaginary sphere, with the satellite as the center and a radius of X. if the receiver can generate these spheres for two satellites, it knows it can only be located where the surfaces of the two spheres intersect. The two spheres overlap in a ring of possible receiver positions. By generating a sphere for a third satellite, the receiver narrows its possible positions down to two points. The receiver ejects the point located in space, leaving only one possible position. The GPS receiver has to know two things to make this calculation, the location of at least three satellites above you and the distance between you and each of those satellites. The GPS receiver analyzes high-frequency, low-power radio signals from the GPS satellites to calculate both of these things required. The receiver can figure out how far the signal has traveled by timing how long it took the signal to arrive. The receiver begins running a digital pattern which has been transmitted from the satellite along digital pattern. When the satellite's signal reaches the receiver, its 18 transmission of the pattern will be delayed a bit behind the receiver's playing of the pattern. The delay length is equal to the signal's travel time. The receiver multiplies this time by the speed of light to calculate how far the signal traveled. To make this measurement, the receiver and satellite both need clocks that can be synchronized down to the nanosecond. To make a satellite positioning system using only synchronized clocks, all the satellites would need to have atomic clocks and the receiver itself uses an ordinary quartz clock, which it constantly resets. The Quartz clock has been chosen for the receiver instead of the atomic clock because the atomic clock is expensive in the range of $70,000 which wouldn’t be in the reach of each individual. The receiver looks at incoming signals from four or more satellites and estimates its own inaccuracy so there is only one value for the current time that the receiver can use. The correct time value will cause all of the signals that the receiver is receiving to align at a single point in space. That time value is the time value held by the atomic clocks in all of the satellites. So the receiver sets its clock to that time value, and it then has the same time value that all the atomic clocks in all of the satellites have. When the distance to four located satellites is measured, four spheres can be drawn that all intersect at one point. Three spheres will intersect even if the numbers are way off, but four spheres will not intersect at one point if the measured values were incorrect. Since the receiver makes all its distance measurements using its own built-in clock, the distances will all be proportionally incorrect. The receiver can easily calculate the necessary adjustment that will cause the four spheres to intersect at one point. Based on this, it resets its clock to be in sync with the satellite's atomic clock. The receiver does this constantly whenever it's on, which means it is nearly as accurate as the expensive atomic clocks in the satellites. Once the receiver makes this calculation, it can tell you the latitude, longitude and altitude of its current position. To make the navigation more useful and easier to follow, most receivers plug this raw data into map files stored in memory. You can use maps stored in the receiver's memory, and connect the receiver to a computer that can hold more detailed maps in its memory. B.3.2 Design Specification: A standard GPS receiver will not only place you on a map at any particular location, but will also trace your path across a map as you move. If you leave your receiver on, it can stay in constant communication with GPS satellites to see how your location is changing. With this information and its built-in clock, the receiver can give you several pieces of valuable information such as, how far you've traveled (odometer), how long you've been traveling, your current speed (speedometer), your average speed, a "bread crumb" trail showing you exactly where you have traveled on the map, and the estimated time of arrival at your destination if you maintain your current speed. 19 B.3.3 Pugh Analysis: A big search was done to find a GPS Receiver that meets our requirements. After narrowing down our choices, we ended up with ten GPS receivers. A comparison was done for the ten GPS receivers according to the following features: accuracy, voltage supply, and power consumption, battery backup pin, built in antenna, baud rate, dimensions, weight, price, and number of channel tracking. The best four GPS receivers were picked out of the ten after the comparison was done. See attached spreadsheet in appendix section 3.2. Concept screening matrix was the next step, where the four GPS receivers were rated with a + or – or 0 on each selection criteria in each GPS receiver. The 0 means it doesn’t have any effect on our ranking decision that is because it is either all the GPS receivers have the same feature or there is no big difference between them. The + means it is ranked the best in this criteria over the rest of the other GPS receivers. The – means this GPS receiver has a weakness in this criteria or it is not preferred according to the other GPS receivers which have a better rank in this criteria. The ranking is based on the following selection criteria: Cost, size, weight, resolution, range, power consumption, interface, and baud rate. When each GPS receiver has been ranked for each criteria, we sum the ranking rates +’s, -‘s, and 0’s for each GPS receiver. Then the sum from the –‘s get subtracted from the sum of the +’s, and that will be the net score. According to the net score we rank each GPS receiver, highest net score means the top ranked and lowest net score means ranked the last favored. The highest ranked GPS receivers are picked to continue to the next concept-screening matrix. See attached spreadsheet in appendix section 3.2. The second concept-screening matrix is a refinement for the first Pugh’s matrix where only the highest ranked ones from the first Pugh’s matrix will be in this and the weighting will be added for each criterion. Weights are selected according to how important each feature is to our design. The scale will be refined in this stage from 1 to 5, where 5 is the best and 1 is the worst. An average criterion is selected for a reference, and then a comparison is made for each criterion for each GPS receiver to reference criteria. Summing weighted scores ranks concepts. Highest ranked will be the best concept that will be purchased. All three GPS receivers, which were selected to continue to the second concept-screening matrix, have the same size, weight, range, power consumption, and interface; the only difference was in the channel tracking, cost, and baud rate. Choice B and c have the same default baud rate, and same number of channels, however B is cheaper than C. Therefore choice B is better than C. Choice A has a higher baud rate and more channels than B. A has 32 channels compared with B which has 20 channels. Even though choice A cost $99.95 and B cost $61, choice A is worth the $29 extra since it has almost double the channels which means more reliable. Therefore choice A was ranked the highest. See attached spreadsheet in the appendix section 3.2. 20 B.3.4 Components Specification: The best concept, which was purchased, is the 32 Chan San Jose Nav., part number GPS-08266 from Spark Fun Electronics. It has a 3.3m accuracy, 3.3-5V-voltage supply, 33-59mA-power consumption; it has a battery backup pin, built in antenna, baud rate of 38400 bps, with dimensions of 1.2 x 1.2 x 0.3'', and weights 15 grams, it has 32 channel tracking and cost $99.95. This receiver has a 5Hz update rate. Please note at 5Hz the serial stream is large enough the default baud rate is 38400bps but the unit is completely configurable! The unit configuration is stored in volatile memory and is reset when power cycled. Use a battery backup to maintain user settings. The MiniGPS software that was provided by San Jose Navigation allows for an easy to use GUI to reconfigure the FV-M8 as well as data log incoming NMEA sentences! It is able to track over 9 satellites indoors. Pin Definition Pin No. Title I/O Note 1 Vin P Voltage input 3.3~5V DC +/- 10% 2 GND G Ground 3 TX1 O Serial port 1 (leave open if not used) 4 RX1 I Serial port 1 (leave open if not used) 5 TX2 O Reserve 6 RX2 I Serial port 2 (leave open if not used) 7 1PPS O Time Pulse (leave open if not used) 8 BAT I Backup input voltage 2 ~ 5V DC +/- 10% P: Power B.3.5 I: Input O: Output G: Ground Test Plan: Simulate experimental conditions on the ground by driving around the RIT loop at approximately 15 mph while the GPS Receiver is connected to the laptop and 21 Evaluation board. Data will be captured every few seconds using the GPS Locator Utility software. Each sample will show the latitude, longitude, altitude, number of satellites used, total number of satellites in view, and speed. Accuracy, orientation effects and material interference will be tested. The measurements from each test will be compared to results from google map and google earth measurements. In addition, Satellite Time Fix will be also tested for the cold, warm and hot start-up modes. Twelve samples will be tested using the hot and warm start-up mode and 22 samples for the cold start-up mode. Then, the GPS will be connected to the MCU to collect data by driving around. The collected driving data will be plotted on Google map. B.3.6 Test Results: a) Accuracy test Data was captured every five seconds. There were approximately 134 samples of data captured. From observing the data results, the maximum, minimum, and average of available satellites used are 13, 9, and 10 respectively. This means that 83% of the available satellites were used. GPS altitude measurements were compared with google earth altitude results. There is a 1% error from the GPS altitude according to google earth measurements. Figure 3.3.1 and 3.3.2 shows the speed and altitude for the entire RIT loop, respectively. Each data sample was plotted on google earth as shown in Figure 3.3.3, which represents the entire drive test around the RIT loop. The gray marker represents the starting point, red marker indicates that there was a stop sign; yellow marker indicates that we had to slow down for a speed bump or for people crossing the street, and Green marker shows an average driving speed. Figure 3.3.4 and Figure 3.3.5 show a closer view for a few sample points. Figure 3.3.6 shows a sample view of a screen shot to the GPS Locator Utility software. 22 b) Orientation effects and Material interface test Data was captured every seven seconds. There were 105 samples of data captured. From observing the data results, the maximum, minimum, and average of available satellites used are 13, 9, and 11 respectively. This means that 88.8% of the available satellites were used. GPS altitude measurements were compared with google earth altitude results. There is a 1% error from the GPS altitude according to google earth measurements. Figure 3.3.7 and 3.3.8 shows the speed and altitude for the entire RIT loop, respectively. Each data sample was plotted on google map as shown in Figure 3.3.9, which represents the entire drive test around the RIT loop. The gray marker represents the starting point, red marker indicates that there was a stop sign and Green marker shows an average driving speed. Figure 3.3.10 show a closer view for a few sample points at the starting and ending locations. Figure 3.3.11 shows a sample view of a screen shot to the GPS Locator Utility software at one location and Figure 3.3.12 shows the same location in google earth. Using Figure 3.3.11 and Figure 3.3.12, we can compute the percentage error for the altitude measured by the GPS. c) Satellite Time Fix test This test examines how long does it take for the GPS receiver to start up using cold or warm or hot mode. The GPS receiver starts after it views at least four satellites. 12 starts up trials were done for hot and warm-mode types and 22 for the cold-mode. Cold-mode will be used and set to the default. See Figure 3.3.13, Figure 3.3.14, and Figure 3.3.15 for test results. The maximum cold start up time was 3 minutes and 22 seconds and the minimum was 53 seconds. On average the cold start up time was 1.9 minutes. The maximum warm start up time was 2 minutes and 49 seconds and the minimum was 27 seconds. The average warm start up time was 1.7 minutes. The maximum hot start up time was 3 minutes and 4 seconds and the minimum was 17 seconds. The average warm start up time was 1.4 minutes. It is clear from these results that it takes the longest time to start up if it is in cold start up mode, less time if it is in warm start up mode, and the fastest 23 start up time when it is in the hot start up mode. Fast start-up time means more power consumption. Figure 3.3.16 shows a box plot trend for the three start-up modes and Table 3.3.1 shows the 25th percentile, minimum, mean, 50th percentile, maximum, and 75th percentile start-up time in seconds for each mode. d) Drive test while the GPS is connected to the MCU inside the box The GPS was tested after it has been connected to the MCU by driving around. Two driving test were done and the data were collected every 2 seconds. More than 400 sample points were captured for each driving test. The speed for each driving test was plotted verses time as shown in Figure 3.3.17 and Figure 3.3.18. Each data file was plotted on google map using GPS Visualizer. First drive test plots are shown in Figure 3.3.19, Figure 3.3.20, and 3.3.21 and Figure 3.3.22. The second drive test is shown in Figure 3.3.23, Figure 3.3.24, Figure 3.3.25, and Figure 3.3.26. 24 B.4.1 IMU Sensor An Inertial Measurement Unit (IMU) is a device that uses accelerometers and gyroscopes to measure axial and rotational accelerations as well as orientation based upon initial conditions. A six degree of freedom IMU has 3 accelerometers and 3 gyroscopes to measure x, y, and z accelerations and roll, pitch, and yaw. This sensor is important for UAV’s because it will indicate the aircrafts roll, pitch, and yaw rates, and accelerations in x, y and z. The IMU will also indicate the aircrafts orientation in space. It is needed to give this information to a flight control system to allow an aircraft maintain flight in a particular direction, altitude, and orientation. B.4.2 Design Specification The requirements for the IMU are to know the orientation of the aircraft while it is in flight as well as its horizontal, lateral, and vertical accelerations. The device that we 25 picked out is the ADIS16350 IMU from Analog Devices. The min/max voltage required for the IMU is between 4.75-5.25 volts. This IMU satisfies the requirements given to it because it is a six degree of freedom IMU that is designed to be used in guidance, control, and stabilization. The six degrees of freedom allows it to measure roll, pitch, yaw, and axial accelerations. These are all the accelerations that act on an aircraft. There are several ways to measure orientation and axial accelerations however they all revolve around the same type of devices: IMU’s, gyros, and accelerometers. A six degree of freedom IMU uses 3 gyroscopes and 3 accelerometers to measure roll, pitch, yaw, and accelerations in x, y, and z. Many IMU’s also contain a sensor that tells it in which direction gravity is pulling it so that it knows its orientation at all times. The IMU is the simplest solution to this problem because it combines all the sensors needed into one device. It would be possible to build your own IMU by buying 3 gyroscopes and 3 accelerometers and have them measure the required information. This method would require more work, in terms of setup time and programming. It might cost less in terms of dollars but it would cost more time to build your own IMU. For our project it made the most sense to buy an IMU. B.4.3 Pugh Analysis The IMU’s that looked the most promising were the Micro Strain’s and the Analog Devices. Micro Strain is one of the brands that NASA’s payload directed flight program uses to measure roll, pitch, yaw, as well as movement in x, y, and z. There were three IMU’s from Micro Strain we looked at the Inertia-link, 3DM-GX1, and 3DM-GX2. All three of these IMU’s were very similar in their capabilities with the main differences being price, power usage, and extra features that were not essential to our project such as wireless communication and magnetometers. The advantage of using one of the Micro Strain products is that it is familiar to the team, and is a proven technology. The main disadvantage with this brand is that all of their IMU’s are very expensive around $1400 and higher. This is where Analog Devices fits in. All of their IMU’s are relatively inexpensive at around $300. Like Micro Strain all of the Analog Devices IMU’s look the same in there specs and it was not really clear what the major differences were between them based upon their data sheets. The Analog Devices IMU that looked the best was the ADIS1650 do to its lower price. The advantages of the ADIS1650 to the Micro Strain IMU’s is that it is smaller, has about the same accuracy, it uses less power, and it is a lot less expensive. The main disadvantage of the Analog Devices is lack of experience with the product, and it has fewer input method options. The Pugh analysis was designed to help compare similar products to one another to compare chosen qualities against each other to see which one is the best. The first step of the analysis was to pick a sensor to be the baseline and compare several of the other makes and models against it, using +’s to indicated something better and –‘s to indicate areas where it was worse. Six models of IMU’s were chosen from three brands. Three from Analog Devices because all of them were in our price range, two from Micro Strain because NASA uses that brand for their UAV’s and one from Gladiator Technologies to see how it compared. All three Analog Devices and both Micro Strain’s made it through 26 the first screening. Next we weighted the earlier used criteria to compare the products directly to see which got the best score. The weights were as follows: cost 20%, Size 3%, weight 3%, Resolution 18%, interface 29%, Power Consumption 7%, and Sampling Rate 20%. It was found that the ADIS16350 got the highest score due largely to its low cost. The second best was the ADIS16354. The third best was the Inertia-link though we will not follow up on this one because of its high cost. It received third position due to the comparison chart. B.4.4 Components Specification The IMU interfaces with the MCU through a serial interface and breakout board. It is mounted in the box though two 1.588mm holes on its base. The IMU will be vibration isolated using a rubber dampening sheet attached to its base. Vibration dampening is very important for IMUs in order to read there orientation and accelerations as accurately as possible. Detailed Specs of the IMU The IMU requires between 4.75 and 5.25 Volts There are three sensitivity setting for this IMU ±300o/s, ±150o/s, and ±75o/s. The data output rate is 350Hz. The IMU costs about $500, the one selected for this project was inexpensive compared to most others. The IMU will likely need to be calibrated/ zeroed every time it is used to increase its accuracy; this is to prevent errors in its calculations. There is no/very little maintenance needed for the IMU other than to keep it away from too much moisture and not to drop it. It is a robust device but it is a very expensive piece of hardware, and should be treated with care. B.4.5 Test Plan We will come up with a test cycle with the MAV team that will test both of our IMU’s. This test cycle will allow for a direct comparison between our two IMU’s. The IMU’s will be tested on a test stand that is being designed by the MAV team that will be able to rotate along two axes. The angular rotation rates of what the IMU’s read will be compared to that of the test stand cycle as well as against each other. B.4.6 Test Results Verification of IMU error while stationary: Between time 27 and 276 and between 522 and the end of the test the IMU was stationary on a work bench and was unmoved. The IMU did pick up some changes in its position; however these fluctuations are within the device specifications of ~+/- 3. The reason for these fluctuations could be due to vibrations that it picked up through the desk or simply minor errors in the device. To close this test showed that the IMU while stationary works as specified. 27 B.5.1 Microprocessor B.5.2 Design Specification B.5.3 Pugh Analysis B.5.4 Components Specification B.5.5 Test Plan B.5.6 Test Results 28 B.6.1 Components Box The box design was based off of the sensors that were purchased to fulfill the needs of the project, as well as maintain low weight and ensure that the final design would fit within the confines of the fuselage of Airframe A. The external memory source needed to be removable from the exterior of the airframe without removing the box enclosure. To meet these requirements the box was constructed out of light aircraft plywood and the components were attached to the box with 4-40 bolts and t-nuts. To ensure that the box fit completely within the confines of Airframe A, a model of Airframe A was used while modeling the box and mock ups of the sensors were used to ensure that the components would fit in and out of the box. Because of the size constraints for fitting into Airframe A, some components, specifically the MCU needed to be modified to fit. Because of the requirement that the IMU be near the Cg of the Airframe, its mounting was pre determined, and the box design accommodates for this. Picture 1 - Measurements Box The box was designed in Pro/E Wildfire 3.0 and prototyped in the laser cutter in the Aero Design Lab at RIT. The box consists of 7 parts all cut out of light aircraft plywood. The original design was refined after the first prototype to accommodate changes in mounting as well as added access holes to make the assembly of the components easier. Drawings of each of the parts as well as 3-D models of the box can be found on our EDGE website, as well as complete instructions for assembling the box and the components into the box. 29 Picture 2 - Measurements Box Inside Airframe A The Pitot-tube and its sensor were placed in the wing tip, because the Pitottube needed to be outside of the prop wash, and outside of the wings boundary layer, and turbulence created by the fuselage as the aircraft flies through the air. The sensor was placed on a removable plate in the wingtip as shown below, so that the sensor could be moved from wing to wing without having to re-run the wires and tubing required to be the input into the sensor for every wing. Because of the sensors moderate cost, it was chosen to make this sensor easily accessible. By mounting the sensor in the wing tip, we have cut down the time delay seen in the tubing between the sensor and the Pitot-static tube. Picture 3 – Pitot Static Tube Inside Airframe A 30 Appendix 1.1 31 1.2 32 1.3 Time Delay Calculations 1 P1 P2 Psensor 0.9 0.8 0.7 0.5 0.4 0.3 0.2 0.1 0 0 1 2 Time (sec) 3 4 -11 x 10 Figure 1.3.1 Time Delay Calculations -4 x 10 2 Mass Flow Rate (kg/s) Magnitude 0.6 1 0 0 20 40 60 80 100 Pressure Drop (Pa) 120 140 160 180 200 Figure 1.3.2 33 Time Delay Calculations 200 180 160 Pressure Drop (Pa) 140 120 100 80 60 40 20 0 0 10 20 30 velocity (mph) 40 50 60 Figure 1.3.3 Small Wind Tunnel Test Anemometer m/s 1 1.3 1.5 2. mph 2.2 2.86 3.3 4.4 ETS Pitot-Tube mph 0~2 1~3 3~4 4 Table 1.3.4 34 Pitot Static Tube vs. Anemometer (Automobile Test) 60 50 40 20 10 Airspeed Sensor Anamometer 0 0 10 20 30 40 50 60 70 Data Collection Event Figure 1.3.5 Pitot Tube Large Wind Tunnel Test Hot Wire Probe 140 120 100 Speed (mph) Speed (mph) 30 80 60 40 20 0 0 2 4 6 8 10 12 14 16 18 Event Figure 1.3.6 35 Pitot Tube Time Delay 1.6 1.4 Voltage (V) 1.2 1 0.8 0.6 0.4 0.2 0 0 0.2 0.4 0.6 0.8 1 1.2 Time (sec) Figure 1.3.7 36 2.1 37 2.2 38 2.3 Figure 2.3.1 Figure 2.3.2 39 GPS GPS vs Altimeter Altimeter test Zlog 600 500 Altitude (ft) 400 300 200 100 0 0 100 200 300 400 500 Time (s) Figure 2.3.3 Vacuum Chamber Pressures 1800 1600 Zlog 1400 Eagle Tree Pressure Sensor Altitude (Ft) 1200 1000 800 600 400 200 0 0 5 10 15 20 25 30 Data Collect Event Figure 2.3.4 40 3.1 41 3.2 42 3.3 Speed 20 18 16 14 Speed (MPH) 12 10 8 6 4 2 0 0 20 40 60 80 100 120 140 160 Sample Number Figure 3.3.1 Altitude 175 170 Altitude (m) 165 160 155 150 145 0 20 40 60 80 100 120 140 160 Sample Number Figure 3.3.2 43 Figure 3.3.3 Figure 3.3.4 44 Figure 3.3.5 Figure 3.3.6 45 25 Speed (mph) 20 15 10 5 0 0 20 40 -5 60 80 100 120 80 100 120 Sample Number Figure 3.3.7 170 Altitude (m) 165 160 155 150 145 140 0 20 40 60 Sample Number Figure 3.3.8 46 Figure 3.3.9 Figure 3.3.10 47 Figure 3.3.11 Figure 3.3.12 48 Cold start up time Time (seconds) 300 250 200 150 100 50 0 0 2 4 6 8 10 12 14 10 12 14 Sample number Figure 3.3.13 Warm start up time Time (seconds) 250 200 150 100 50 0 0 2 4 6 8 Sample number Figure 3.3.14 49 Hot start up time Time (seconds) 250 200 150 100 50 0 0 2 4 6 8 10 12 14 sample number Figure 3.3.15 GPS - Satellite Time to Fix 250 25th Percentile 200 Time (sec) Minimum 150 Mean 50th Percentile 100 Maximum 50 75th Percentile 0 Cold Warm Hot Start-up mode Figure 3.3.15 50 4.1 51 4.2 52 4.3 X-Axis Angular Rate vs. Time 12 9 6 X-Axis Angular Rate 3 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 -3 -6 -9 -12 Time Figure 4.3.1 53 X-Axis Angular Rate vs. Time 12 9 6 X-Axis Angular Rate 3 0 14 16 18 20 22 24 -3 -6 -9 -12 Time Figure 4.3.2 54 5.1 55 5.2 56 5.3 57 6.1 58 6.2 59 6.3 60 6.4 61 7.1 62 7.2 63