TEAM INFINITY AND BEYOND
CRITICAL DESIGN REVIEW
Adam Archuleta
Katie Cartee
Logan Farley
Patrick Klein
Kamron Medina
Catherine Villa
MISSION OVERVIEW
•
The objective of our mission is to test the practicality and capabilities of a satellite return vehicle prototype
as it falls away from our BalloonSat at an altitude of approximately twenty-six kilometers. Our secondary
objective is to use a micro video camera to create a video of the high altitude environment around the
BalloonSat from the point of view of the glider during the ascent, and also record the fall back to Earth after
detachment
•
We expect to prove the practicality of a glider-like vehicle that is designed to return a payload to Earth. A
satellite return glider can provide companies a means of safely recovering their de-orbited satellites. Our
paper airplane prototype will accomplish a task of the same nature.
•
We chose to carry out this experiment because the need for a satellite de-orbiting vehicle is prominent in
light of the decommissioning of the space shuttle.
•
Much like the decommissioned shuttles, which relied on steering jets and its aero surfaces to control the
vehicle for most of the re-entry, a paper glider relies on the aerodynamics in a continually densifying
atmosphere to control its rate of descent and directional velocity. Our BalloonSat model however, is limited
by weight constraints and a monetary budget; so it is incapable of carrying attitude correcting systems .
•
Hypothesis: Our return vehicle will successfully transfer the payload from our BalloonSat safely to Earth in
an affordable and efficient manner. Future developed products may implement a structure and simple
control systems based on our findings, using air jets for near space altitudes, and ailerons and flaps in a
lower altitude, higher density atmosphere.
FLOW DOWN CHART
Level
Requirement
0A
B
•
Detail
Transport paper airplane equipped with GPS technology to near-space conditions at approximately 26km
Incorporate an electromagnetic release mechanism into our satellite
C
Keep total weight under 850 grams
Requirements
Flow Down
D
Keep total cost under $250
• E Walk classRecover
through
your Level
0 and Level 1 requirements and how they flow down
GPS enabled
paper airplane
1 A1from the Mission
Design andStatement
construct BalloonSat that will reach 26-30km
Design and construct glider that will survive the ascent of the satellite through the atmosphere
• A2Refer to the
class slides from the RFP lecture
A3
Ensure the glider will support the weight of a cell phone and camera
A5
Construction and testing completed and turned in by Friday, November 4th
B1
Install magnet and wiring for magnet onto our BalloonSat
B2
Install magnet onto glider
B3
Install and test a timer to release the glider from the Satellite at a specific altitude
B4
Test integrated system before launch
C1
Research weights of all materials
C2
Measure individual parts once materials arive to check the accuracy of the aforementioned research
C3
Measure final design to ensure weight is under 850 grams
D1
Research costs of all materials
D2
Caculate total cost
D3
Current budget leaves $157.46 for unforeseen expenses
E1
Use Sprint Family Locator to locate paper airplane on Google Maps
• A4You may be
asked
to stop
andthe
move
anytime
by"Sprint
ChrisFamily Locator"
Set up
a connection
between
glider on
and at
ground
control via
DESIGN
•
The imperative of Project Falling With Style is to design a BalloonSat with a glider
payload that shall release at approximately twenty six kilometers. Its special feature is
most notably a high altitude glider carrying a payload of a GPS tracker and video
recorder. Through rigorous research and considerations of our proposal response, our
design process has been moderately revised to include several improvements, such as an
external paint layer to indicate stress points, and a specific timing circuit that will
determine the time of release of the glider. Team Infinity and Beyond now has a more
complete understanding of the satellite as the structure has already been built.
•
The payload on the glider itself is now set to carry only one video recorder facing
frontward. The deletion of the second camera is due to lack of meaningful information
provided, weight budget, and allows for a better camera model with more resolution. The
camera specifications allow for three hours of battery life, but whether this will hold up
during a continuous video will need to be determined during testing.
DESIGN
•
The other half of the payload on the glider is the LG Lotus cell phone that will act as a GPS
tracking unit. An accurate location of the GPS is essential for an easy recovery, and the cell
phone may be wrapped in a bubble wrap as an added layer of protection to withstand landing.
The placement of both devices are expected to be under the wings adjacent to the body, but
testing will determine ideal positions. As mentioned, the glider will feature a paint job that will
allow a visual inspection of minuscule cracks to be analyzed and see where the highest stress
points were located.
•
On the interior of the BalloonSat will be the HOBO data logger, heater kit, Canon stillframe
camera, timing circuit, and electromagnet. Each of these components will be held into place
with hot glue or additional internal structures made from the foam core. The HOBO is planned
to have the relative humidity and internal temperature sensors located within the cube, and the
external temperature probe will extend approximately two inches outside of the structure
through a snug opening. The heater kit is on the verge of being constructed, and proves little
challenge to implement on the inside of the satellite to warm the entire craft due to a small
volume. An external switch will allow the heater to be activated before launch. The Canon
camera will follow the specifications and requirements provided to take pictures on ten second
intervals starting from launch. The lens will protrude from another opening in the structure .
DESIGN
•
The electromagnet is planned to be in a series with a circuit board containing a 4060
CMOS chip. Another external switch will be added on this circuit to be activated before
launch. The chip is 14-bit binary, allowing for an accurate track of time in seconds. The
expected time of release is 76 minutes after launch, which is derived from the rate of
ascent and intended release altitude. When the electromagnet releases from the plane
(attached by a small metal disc that is to be determined with testing), the glider should
release cleanly.
•
The structure itself, which already has its first construction, is a fifteen centimeter cube
made of foam core. Hot glue and aluminum tape shall be used to hold the structure
together. Aluminum tubing running through the center of the cube will allow the string to
connect the satellite to the weather balloon. A paper clip and washer on the bottom of the
tube will prevent slippage of the line. The outside layer of thermal blanketing will add
insulation and is expected to keep the interior above freezing temperatures. Contact
information of SpaceGrant and the team leader will be visible on the outside, as well as
an American flag.
HARDWARE
•
Most of the required materials for Project Falling With Style are provided through SpaceGrant.
We ordered all of our hardware online and have already received our electromagnet. Separate
testing materials (dry ice, cooler, and extra batteries) will be purchased out of pocket from the
most affordable place we can find. From our $250 budget, we used $95.13. Out of our weight
budget is 850 grams and we are estimating our total weight will be approximately 834.9 grams.
(1) 2GB FPV Video Camera from Ebay for $49.35
(2) Tubular Electromagnet from ElectroMechanicsOnline for $35.89
(3) Timing Circuit Chip from reuk.co.uk for $0.40
(4) GP 12V Alkaline Batteries-23AE from Amazon for $9.89
(5) Components such as the HOBO, camera (SD780), heater, temperature sensor, foam core,
and accessories (hot glue, wires/ switches, batteries) are provided by SpaceGrant.
SCHEDULE
16-Sep
20-Sep
3-Oct
7-Oct
9-Oct
10-Oct
13-Oct
16-Oct
17-Oct
18-Oct
18-Oct
25-Oct
27-Oct
1-Nov
4-Nov
5-Nov
29-Nov
3-Dec
6-Dec
12:00 PM
7:00 AM
5:00-7:00
all day
5:00-9:00
5:00-7:00
7:00 AM
5:00-9:00
5:00-7:00
9:30 AM
2:00-5:00
2:00-5:00
9:30 AM
7:00 AM
2:00 PM
6:50 AM
7:00 AM
9:00-4:00
9:30 AM
Proposal Due
Conceptual Design Presentation Due
Foam Core Structure Prototype
Acquire All Hardware
Glider Prototype and Drop, Stairs, and Whip Tests
Freefall Test
Design Document Rev. A/B and Critical Design Presentation Due
Glider Complete Begin Testing and Foam Core Structure Complete
BalloonSat Construction Complete
MID-Semester Team Evaluations Due
Freeze and Release Mechanism Tests
Glider Camera and BalloonSat Testing Complete
In-Class Mission Simulation Test (bring “Ready to Go” BalloonSat)
LRR Presentations and Design Document Rev. C Due
Final Balloon Sat Weigh In and Turn In and LRR Cards Due
Launch BalloonSats
Final Presentations Due and All Data Due in Class
ITLL Design Expo (Design Documents Rev. D and Team Videos Due)
Hardware Turn In
Team meetings will be every Sunday from 5-9 PM and every Monday and Tuesday from 5-7 PM
Team meetings are tentative due to outside scheduling conflicts and potential necessity for more
meetings. Due dates are definite and all requirements will be completed at the designated time.
Budget &
Specifications
Hardware
Component
Quantity
Source
HOBO H08-004-02
Canon SD780 IS
Heater
Temp Sensor (1' cable) TMC1-HD
LG Lotus Cell Phone
1
1
1
1
Gateway
Gateway
Gateway
Gateway
1
Adam’s cell
phone
2 Lithium 9V, 2 Lithium
AA, 3 Alkaline 9V
Batteries
FPV Video Camera 2GB
7
Gateway
1
Tubular Electromagnet
1
Velcro
Wiring and Switches
Aluminum Tape
GP 12V Alkaline
Batteries-23 AE
Timing Circuit Chip
Balloon Sat Structure
Foam Core Structure
1
1
1
1 pack of
20
1
Insulation
Glider Structure
Foam core
Tape
Hot Glue
Testing
Dry Ice and Cooler
1
Total
Weight (g) Dimensions
(mm)
30
68 x 48 x 19
130
18 x 55 x 88
100
10 x 50 x 50
14
.5 x 2.5 x 30
105
84 x 61 x
17.8
ebay.com
27
Electromechan
icsonline.com
31
28 DIA x 82
L
21 DIA x 20
L
Company Contact Info
Provided
Provided
Provided
Provided
$49.35
$35.89
Provided
Provided
Provided
$9.89
$0.40
Provided
Gateway
80 (230g/
sheet)
>1
1
1
1
Gateway
Gateway
Gateway
175
>1
>1
Provided
Provided
Provided
4
King Soopers
1
Part Number
Donated by
Adam (worth
$85)
1 Lithium 48.5 x 26.5 x
Provided
9V-38.8
17.5
Gateway
>1
Gateway
>1
Gateway
>1
Amazon.com 1 Battery - 10 DIA x 2.8 H
7.5g
reuk.co.uk
1
19 x 6.3
Gateway
Cost
834.9
grams
Provided
$5.16 @ $1.29/
lb
$95.13
2608574 00161
Enjoy Secret
Address: N/A
ELMATU021020 Address: 6901 Woodley
Avenue
Van Nuys, California
91406, USA
Telephone: (818) 785-6244
(888) 785-9444
facsimile: (818) 785-5713
e-mail:
info@ElectroMechanicsOnline.
com
B004SK9P0O
MYBATTERYSUPPLIER
Address: N/A
reuk.co.uk
Functional Block Diagrams
BalloonSat
Glider
TESTING
•
Testing is one of the most important procedures that must be performed on any mission based program
because testing is the single most effective method in identifying design and/or build problems. Along with
identifying the problems, testing the device gives a simulation of how the BalloonSat will perform in each
tested condition. Each system will be rigorously tested individually for all questionable upcoming conditions
on the flight. Not only will each system be tested individually, all systems will be combined in the BalloonSat
and will be tested extensively to ensure each system works together. The tests that will be performed
include: freeze tests, camera tests, drop tests, whip tests, free-fall tests, release tests, stress tests, and
aerodynamics tests.
•
For the freeze test, each system will be placed in a cooler containing dry ice. While not in direct contact with
the ice, each system will experience similar temperatures (-10°C approx.) to expected internal flight
temperatures and will be examined for functionality at these temperatures to simulate the temperature
inside the BalloonSat near the edge of the troposphere, when the temperature is the coldest. This test will
have duration equal to that of our flight, about 2.5hrs while the BalloonSat is operating. During this test, we
can make sure we will have sufficient battery life for our cameras. However, the release mechanism needs
to be tested at even colder temperatures (-50°C approx.) because the release will be taking place outside of
the insulated BalloonSat and will experience much lower temperatures: the same test will be carried out for
this system because the dry ice used will produce temperatures cold enough to simulate this condition.
TESTING
•
The cameras on board have a unique set of requirements that must be met. The still frame camera must
take pictures at specific time intervals (every 10 seconds) for the entire flight. This means the camera must
be tested to ensure it will take the pictures as programmed for the entire flight, as well as ensuring battery
life. To run the test, the camera’s specific programming will be run while the camera undergoes the freeze
test so the team can ensure proper functionality throughout the most difficult conditions. The video camera
will be tested on the same terms as the still frame camera but with some extra testing included: determining
the angle to mount the camera to ensure an appropriate field of view from the glider. To do this, the video
camera will take a short video while attached to the glider during a test flight, and the resulting video will
provide a reference for proper adjustment
•
Structure of the BallonSat is a crucial element of our BalloonSat because it protects all of the systems and
the mission itself. Because of this, the structure will undergo two tests for durability. The first is known as
the drop test, where the structure will be dropped from a height of two stories (~6 meters) to simulate a
rough landing. Another version of the drop test that will be conducted is dropping the BalloonSat down a
flight of stairs so ensure the structure can withstand any number of variable landings, such as bouncing,
rolling, or dragging upon landing. The final structural test is the “whip test”, where the BalloonSat will be tied
to a string and then swung around to simulate extreme g-forces experienced soon after the balloon burst.
Throughout the structural testing, an equal mass inside the BalloonSat will be achieved using weights or
rocks that will be positioned similarly to our systems positioning to account for the center of gravity and
overall mass.
TESTING
•
Dropping a glider from a BalloonSat is one of the most difficult operations that could be performed. Because
of this, the glider, release mechanism, and the total apparatus must be tested thoroughly to ensure proper
function. At launch of the BalloonSat, the glider will be attached to the side of our BalloonSat. This brings up
the matter of launch and ascent survival. As the BalloonSat ascends, it will experience average speed of
about 5.5 m/s. We will test the apparatus in the wind tunnel to ensure the glider will not release during the
climb. Once at altitude, the release of the glider is crucial. We will test the release mechanism at very low
temperatures (around -50°C) to ensure the release of our glider in the appropriate environment. The final
test the glider needs to undergo is what we are calling the “freefall test”. The main reason for this test is to
observe how the glider will react after release. When released, the glider will be facing the ground with very
little air present. We will be dropping the glider from approximately 21 meters in the same fashion that the
glider is going to release from the BalloonSat in order to observe whether or not the glider will stabilize and
glide as required by the mission.
•
Finally, the team will be executing simple stress tests on the glider to analyze and further the proposed
design. To do this, the glider will be painted in a thin coat of white paint for the aerodynamics tests as well
as the maiden voyage. The reason behind conducting the test on the actual mission along with during
testing is because the actual stress under the exact conditions experienced is impossible to identify and
therefore test. By conducting the stress tests, areas of high stress will yield cracks in the paint. These
results will provide evidence of dangerous stress levels to be assessed in future glider designs.
EXPECTED RESULTS
•
Since a space glider would enter the atmosphere at a predetermined angle, this prototype
must also try to level the plane out before it loses too much altitude, and an analysis of
the upper atmospheric flight can be made from the descent video.
•
We expect the release mechanism to release at 24-30 km. The goal is for it to release at
26 kilometers. The intended path of the glider is a straight line of flight relative to the air.
Wind is expected so an actual straight line path relative to the earth is likely unachievable
and would require corrective directional systems. We would like a high ratio of distance
travelled to altitude dropped to minimize the vertical speed of landing. There are no
mechanisms to control horizontal velocity other than drag so the nose of our glider is
expected to meet a rough landing if it encounters a landing zone other than a flat open
field.
•
While the camera is expected to record during the entire flight, there is a chance that
force of impact could crack the lens or damage the camera. This should not be a problem
because all that needs to survive and be recovered is the microSD card.
EXPECTED RESULTS
•
If we see a large view of earth then can determine the pitch is low, and it is falling too quickly;
alternatively if there is a shot that consists more of the horizon and/or sky then we will know it is
maintaining a lower rate of altitude loss. The angle of the horizon/earth directly in front the the
glider will give us an idea on how much roll the plane is experiencing. The yaw can also be
determined if the camera is facing in the same direction as velocity, which may indicate winds
affecting the flight path.
•
The condition of the glider will be analyzed to determine stress on the glider during the flight.
During testing we will find a paint-like material in which to cover the glider. After flight there will
be be small cracks where the wings bend and other areas that were stressed.
•
Testing of data retrieval will be done thoroughly before launch. Data retrieval from the flight
video will be plugging the microSD into an adapter and into a computer. A test in which the
video is recording and the battery is suddenly removed will be used to determine if the video
will be corrupted and can even be played on a media player. This might occur as the glider hits
the ground and the camera is destroyed while the video is still recording.
•
The GPS will be tested before the flight to ensure it's accurate. Since the GPS is not in realtime, we will need to constantly refresh the website to get the location and take screenshots to
get a semi-accurate flight path. When the GPS location stops moving, we can assume the
eagle has landed.
TEAM ORGANIZATIONAL CHART
Name
Title
Responsibilities
Adam Archuleta
Team Leader and Testing Specialist
Design and execute tests, manage team tasks,
and integration of individual projects.
Katie Cartee
Design and Planning
3D modeling and scheduling
Logan Farley
Troubleshooting and Electronics
Aid with testing and construction issues, check
that all electronics are functioning properly.
Patrick Klein
Technician
Fabricate necessary parts and assist in
construction
Kamron Medina
Structural Engineer and Scheduling Manager
Construction of BalloonSat and glider structures
and managing deadlines
Catherine Villa
Budget Manager and Solderer
Keep track of a detailed budget as well as solder
circuit boards
BIGGEST WORRIES…
• Timer/Release (too early/failure)
• Battery life
• Camera malfunctions
• GPS (service/destruction)
• Glider stabilization
• Phone destroyed on impact