Individual Subsystem Testing Report Patrick Weber Michael Stephens

Individual Subsystem Testing Report Patrick Weber, Michael Stephens, Heather Choi, Kevin Brown, Ben Lampe, Anne-Marie Suriano, Eric Robinson, Dorin Blodgett February 24, 2011 2/24/2011 1

Mission Overview 3 4 2 5 1 6 2/24/2011 Presenter: Dorin Blodgett 2

Mission Overview Scientific Mission o Primary: Collect space dust. o Particle size = nano and micro level o Space Dust Composition (10 -6) o o Exhausted Rocket Fuel o Meteor / Metal Fragments o Other Miscellaneous Gases Donate collected aerogel tablets to UW Geology Department for further analysis Secondary: o 2/24/2011 o Capture Detailed data throughout flight duration o Thermal Data o Seismic/Vibration Data o Earth images/video Presenter: Dorin Blodgett 3

Mission Overview Engineering Mission o Engineer an extendable boom to mount a dust collector. o Use aerogel as dust collectors. o Engineer modular electronic systems for: 2/24/2011 o Capturing and storing images from optical devices. o Actuating Telescopic Boom o Recording thermal and seismic data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry. Presenter: Dorin Blodgett 4

Mission Overview Concept of Operations t ≈ 1. 7 min Shedding of Skin Boom Extends via First Timed Event t ≈ 2. 8 min Apogee t ≈ 4. 0 min Boom Retracts via Arduino Controller Boom Power Shut Down t ≈ 0. 7 min End of Orion Burn t ≈ 8. 2 min Chute Deploys t ≈ 0 min Launch Systems Power On (t = -2 min) -Collection of Sensor Data Begins 2/24/2011 Presenter: Dorin Blodgett t ≈ 15 min Splash Down Payload Power Down 5

Design Description Subsystem Overview Telemetry PWR Wallops OC/STR Interface EPS/STR Interface Temp. Sensor Accel. Sensor IS/STR Interface Optical Camera Boom Optical Camera MCU STR Motor Aerogel Arm Control TB/STR Interface EPS TB Control Box OC OC/EPS Interface TB/EPS Interface Boom IS IS/EPS Interface Motor Optical Camera Temperature Sensor Accelerometers 2/24/2011 Presenter: Dorin Blodgett 6

Design Description/ Design Changes 3 4 2 5 1 6 2/24/2011 Presenter: Dorin Blodgett 7

Design Description New Design Parameters o Full Canister Available o o 30 ± 1 lb weight requirement Payload material changed to Steel o Payload – 16. 7 lb o Ballast – 13. 3 lb o Higher centrifugal forces o More powerful motor needed - holding torque of 57. 6 lbin o Load increased on tape reel 2/24/2011 o Loading Stress – 16. 5 ksi o Axial Deflection – 5. 93 E-4 in o Boom Seal o Tapered Seal o O-ring (Durometer Shore A: 70) Presenter: Dorin Blodgett 8

Design Description New Design Parameters o o Skin Ejection o Clam-like skin shed after motor burn-out o Payload section will not be pressurized Temperatures at Reentry o Max of 350 o. F – well after apogee o Bearing material changed to Teflon o o 2/24/2011 Higher operating temperature is 500 F, melting of 635 F Radial thermal expansion, Δ T of 273 F o Teflon = 3. 3 E-2 in o Steel = 3. 3 E-3 in o High temperature o-ring (A: 70) o Aerogel cover electric components Presenter: Dorin Blodgett 9

Design Description New Design Parameters o Boom Vacuum o Boom will be pre-vacuumed prior to launch o Atmospheric pressures will ensure internal vacuum during reentry o Vacuum will aid in holding boom closed o Aerogel Contamination o Aerogel tablets will be inserted in clean room o Boom will be vacuumed o Aerogel Properties o Pore Network is open 2/24/2011 Presenter: Dorin Blodgett 10

Design Description Program Management o No Changes Project Manager Shawn Carroll Engineering Faculty Advisor Physics Faculty Advisor Dr. Carl Frick Dr. Paul Johnson Team Leader Patrick Weber Telescopic Boom (TB) Electrical Power System (EPS) Integrated Sensors (IS) Optical Camera (OC) Patrick Weber Eric Robinson Dorin Blodgett Michael Stephens Ben Lampe Michael Stephens Heather Choi Kevin Brown Nick Roder 2/24/2011 Presenter: Dorin Blodgett 11

Design Description Program Management o Team Picture 2/24/2011 Presenter: Dorin Blodgett 12

Design Description Program Management o Schedule Update o Manufacturing delay (approval for construction) o Electrical manufacturing is on schedule and has begun assembly o Resolve Issues o Final drawings will soon be submitted to machine shop o Manufacturing should be done in two weeks o Concerns o 2/24/2011 Will a vacuum/ clean room be available at Wallops? Presenter: Dorin Blodgett 13

Design Analysis Subsystem Updates 3 4 2 5 1 6 2/24/2011 Presenter: Eric Robinson 14

Design Analysis Subsystem List o Telescopic Boom (TB) o Optical Camera (OC) o Integrated Sensors (IS) o Electrical Power System (EPS) 2/24/2011 Presenter: Eric Robinson 15

Design Analysis - TB Boom Force Parameters o Forces on Boom - Testing on Earth 2/24/2011 Force Equations Value UC Unit FN, extension =mboom*32. 2 = 5. 80 ± 0. 03 lbf FN, retraction =mboom*32. 2 = 76. 01 ± 0. 03 lbf Ffriction, static, extension =μstatic*FN, extension = 0. 23 ± 0. 01 Ibf Ffriction, static, retraction =μstatic*FN, reaction = 3. 04 ± 0. 01 Ibf Fvacuum, sea-level =14. 7 psi*SABoom. End 141. 4 ± 0. 03 lbf Ftapereel, launch =Fcentrifugal, launch + 25 G*mboom*32. 2 ft/s 2 - Fvacuum, sea-level= 165 ± 0. 20 Ibf Ftapereel, extension =Ffriction, static, retraction-Fcentrifugal, apogee = 0. 82 ± 0. 04 lbf Ftapereel, retraction =Fcentrifugal, apogee+Ffriction, static, retraction = 5. 26 ± 0. 04 lbf Ftapereel, reentry =Fcentrifugal, reentry - Fvacuum, sea-level = -55. 6 ± 2 lbf Presenter: Eric Robinson 16

Design Analysis - TB Boom Force Parameters o Forces on Boom – Throughout Launch 2/24/2011 Force Equations FN, extension =mboom*32. 2 = FN, retraction =mboom*32. 2 = Value UC Unit 0 ± 0. 03 lbf Ffriction, static, extension =μstatic*FN, extension = 0 ± 0. 01 Ibf Ffriction, static, retraction =μstatic*FN, reaction = 0 ± 0. 01 Ibf Fvacuum, sea-level =14. 7 psi*SABoom. End 0 ± 0. 03 lbf Ftapereel, launch =Fcentrifugal, launch + 25 G*mboom*32. 2 ft/s 2 - Fvacuum= 23. 3 -165 ± 0. 20 Ibf Ftapereel, extension =Ffriction, static, retraction-Fcentrifugal, apogee = -2. 22 ± 0. 04 lbf Ftapereel, retraction =Fcentrifugal, apogee+Ffriction, static, retraction = 2. 22 ± 0. 04 lbf Ftapereel, reentry =Fcentrifugal, reentry - Fvacuum = -55. 6 - 85. 9 ± 2 lbf Presenter: Eric Robinson 17

Design Analysis -TB Boom Force Parameters Force Ranges through Launch through Reentry Altitude (miles) Force Ranges Force (lbf) Presenter: Eric Robinson 18

Design Analysis -TB Motor Parameters o Torque Load on Motor Throughout Launch Torques Tmotor, launch Equations Value =Ftapereel, launch*rtapespool = Unit 8. 14 - 57. 6 ± 0. 05 lbin Tmotor, extension =Ftapereel, extension*rtapespool = -0. 78 ± 0. 05 lbin Tmotor, retraction =Ftapereel, retraction*rtapespool = 0. 78 ± 0. 05 lbin -19. 4 - 30. 1 ± 0. 1 lbin Tmotor, reentry =Ftapereel, reentry*rtapespool = 2/24/2011 UC Presenter: Eric Robinson 19

Design Analysis -TB New Payload Design 2/24/2011 Presenter: Eric Robinson 20

Design Analysis - TB New Payload Design 2/24/2011 Presenter: Eric Robinson 21

Design Analysis -TB Payload Boom Lengths o Retracted – o 11. 4 in boom o Extended – o 27. 1 in boom o 14. 6 in reach 2/24/2011 Presenter: Eric Robinson 22

Design Analysis -TB Telescopic Boom - Stress Key Results Loading of 50 G in all directions and 100 G vertical impulses o Stress o Peak von Mises o ~1350 psi at Motor Support o Verified with Empirical Models 2/24/2011 Presenter: Eric Robinson 23

Design Analysis - TB Telescopic Boom – Deflection Key Results Loading of 50 G in all directions and 100 G vertical impulses o Deflection o Peak Deflection o 0. 24 thousandths of an inch o Occurs at center of boom. 2/24/2011 Presenter: Eric Robinson 24

Subsystem Testing 3 4 2 5 1 6 2/24/2011 Presenter: Patrick Weber 25

Subsystems Testing Tests to be Performed o TB o 2/24/2011 Mechanical Test o Tape – reel buckling test Completed o Vibration test Not Completed o Drop impact test Not Completed o Water seal test Not Completed o Thermal expansion test Not Completed o Cyclic extension/retraction test Not Completed Presenter: Patrick Weber 26

Subsystems Testing Tests to be Performed o EPS/ IS/OC o o 2/24/2011 Electrical Test o Temperature sensor functionality test In Progress o Accelerometer functionality test Not Completed o Optical camera functionality test Not Completed o Thermal loading on electronics test Not Completed Software Test o Asynchronous data capture test Not Completed o Motor control test Not Completed o Integration test Not Completed o Data recovery test Not Completed Presenter: Patrick Weber 27

Subsystems Testing - TB Tape-reel Buckling Test Bucking Load with respect to Key Results (14” Tape – reel) Tape – reel Length o Extension load - earth 25 o 0. 23 lbf 20 o 16. 28 lbf Lenght (in) o Buckles loading of 15 10 5 0 0 2/24/2011 Presenter: Patrick Weber 100 200 300 400 500 600 700 800 900 1000 Loading (lbf) 28

Subsystem Integration 3 4 2 5 1 6 2/24/2011 Presenter: Patrick Weber 29

Subsystem Integration Plan o Based on where you are now, how will you ensure the subsystems will be integrated and tested for the Subsystem Integration and Testing Report? o Manufacture Payload o Assembly Payload o Test Payload o What are the major hurdles going to be? 2/24/2011 o Approval for Construction/ME Faculty o Part Backorder/Wait Time Presenter: Patrick Weber 30

Subsystem Integration Lessons Learned o What have you learned about subsystem testing and engineering so far? o The payload is over-engineered o What would you do differently? o Push ME Faculty harder for approval for construction o What has worked well so far? o 2/24/2011 We have analytical justification for all models Presenter: Patrick Weber 31

Fabrication and Assembly 3 4 2 5 1 6 2/24/2011 Presenter: Patrick Weber 32

Fabrication and Assembly Mechanical Fabrication o o Payload Frame – 1018 Carbon Steel o CNC machined o Bolted down to base Telescopic Boom – 1018 Carbon Steel o Boom Housing o o 2/24/2011 Tubing epoxied into frame Intermediate Arm o Threaded tubing and bearing mounts o Teflon bearing Aerogel Arm o CNC machined o Aerogel Purchased Tape Reel housing o CNC machined o Bolted to frame Presenter: Patrick Weber 33

Fabrication and Assembly Mechanical Assembly o Manufacturing Instructions 2/24/2011 Presenter: Patrick Weber 34

Detailed Mass Budget o Total Mass Budget (30± 1 lbs) o Structure (16. 7 lbs) o Boom (13. 7 lbs) o Circuit Trays (2. 99 lbs) 2/24/2011 o Camera (0. 25 lb) o Other Sensors (1 lb) o Modular Electrical System (1 lb) o Ballasting (13. 3 lbs) Presenter: Patrick Weber Boom Circuit Trays Camera Other Sensors Modular Electrical System Ballasting 35

Monetary Budget o Monetary Budget (~$1300) o Structure ($675) o Boom ($300) o Aerogel ($375) 2/24/2011 o Camera ($100) o Other Sensors ($110) o Modular Electrical System ($225) o Contingency (+$15%) Presenter: Patrick Weber Boom Camera Other Sensors Modular Electrical System Aerogel Correcting Factor 36

Conclusions 3 4 2 5 1 6 2/24/2011 Presenter: Patrick Weber 37

Conclusions o New Design Parameters Effects on Design o Reentry temperatures of 350 o. F – Teflon Bearings o Boom vacuum created before launch and at reentry o Prevent aerogel contamination o Full canister available o Payload made of 1018 Carbon Steel – o Less ballasting but greater centrifugal forces o Motor must withstand a holding torque of 57. 6 lbin o New tape reel and frame design will survive loadings o Fabrication and Assembly o Vacuum/Clean room availability 2/24/2011 Presenter: Patrick Weber 38

Questions? 2/24/2011