Western Aerostat Fliers Critical Design Review Western Technical

Western Aerostat Fliers Critical Design Review Western Technical College LSI’s: Jon Grotjahn, Travis Haugstad, Joel Nielsen Mentor: Dr. Mike Le. Docq 4/13/2015 Tethered Aerostat Program Critical Design Review

Mission Statement: Our goal is to safely and reliably fly an aerostat and payload package to test and discover the application and limitations of Ka band power beaming technology. Tethered Aerostat Program Critical Design Review

Mission Overview Joel Nielsen Tethered Aerostat Program Critical Design Review

Mission Overview: • Prove effectiveness of Ka band power beaming over a variety of distances • Use to beam power to and from balloon • Immediately benefits NASA as a way to provide power to satellites • Eventually may benefit mankind as alternative energy distribution Tethered Aerostat Program Critical Design Review

Mission Overview: Mission Objectives • Prove concept of Ka band power beaming • Repeatable power transmission at variety of altitudes • Power instrument package indefinitely • Beam harvested power from aerostat to ground • Determine efficiency over distance, time, and with varying atmospheric conditions • Develop range of conditions where consistent measurable results can be achieved • Understand limitations due to varying conditions Tethered Aerostat Program Critical Design Review

Organizational Chart Industry Mentor David de Bruyn - Entacore Faculty Mentor Dr. Michael Le. Docq Industry Mentor Mike Wilson – KMA Sales Data Transfer, Build Team Lead Jon Grotjahn Power System Team Lead Travis Haugstad Ka Band Team Lead Joel Nielsen Software/Hardware Landon Rudy Battery Power Nicolas Watson Radar Beaming Josh Wagner Fabrication Lor Xiong Solar Power Brian La. Plante Radar Reception James Beier Tethered Aerostat Program Critical Design Review

Mission Overview: Theory and Concepts Radar Frequency Bands 24. 05 -24. 5 GHz X-band Ka Band K-band 10. 5 -10. 55 GHz 33. 4 -36. 0 GHz • Ka band covers 33. 4 -36. 0 GHz • Primarily used in vehicle speed detection and satellite communication • XISP developing “beaming” power to small Cube. Sat from ISS Tethered Aerostat Program Critical Design Review

Mission Overview: Concept Aerostat of Operations Ka Radar Antenna AIM XTRA Variable DC Power Supply Logging Laptop Base Unit Generator 0 V Tethered Aerostat Program Critical Design Review Ground 30 V + - Ka Beaming Radar

Mission Overview: Concept of Operations At 152. 4 m (500 ft) Every 15. 3 m (50 ft) Pre-launch 1) Ka band power transmission test 2) Switch to backup power 3) Collect data from all instruments 4) Hold altitude and run power efficiency tests 1) Ka band power transmission test 2) Switch to backup power 3) Collect data from all instruments 1) Safety check 2) Arm payload 3) Instrument and communication test Tethered Aerostat Program Critical Design Review

Mission Overview: Expected Results • Ka band power beaming successful, but ability to beam power could be lost between 15. 3 m and 152. 4 m • Switching to backup power will be successful • Successful collection of data from instrument payload • Weather conditions likely to influence results Tethered Aerostat Program Critical Design Review

Design Description Name of Presenter Tethered Aerostat Program Critical Design Review

De-Scopes and Off-Ramps • XISP no longer a viable partner, all Ka technology will be prototyped and developed by our team • Payload platform may eventually be produced using 3 -D ABS printer Tethered Aerostat Program Critical Design Review

Mechanical Design Elements Tethered Aerostat Program Critical Design Review

Ka Radar Detection Design Elements Signal from Radar Detector Op-Amp - Comparator Tethered Aerostat Program Critical Design Review Voltage Regulator

Fractal Antenna Design Elements • First, second, and third order of fractal antenna • Dimensions subject to specific radar frequency • Antennas will be developed in the event that signal cannot be obtained from radar detector antenna Source: http: //www. hindawi. com/journals/ijap/2012/361517/ Tethered Aerostat Program Critical Design Review

Signal Rectifier Design Elements Voltage Doubler Current to Voltage Converter • Signal from Antenna fed through voltage doubler (likely order of 7) • Schottky diodes used for high frequency application • Op-amp used to convert current to voltage signal • Will need +/- Vcc voltage of 5 V • Goal is to develop circuit where a known value of current will produce a known value of voltage Tethered Aerostat Program Critical Design Review

Electrical Design Changes • Since the PDR • Relays have replaced optoisolators • More efficient switching circuits developed Tethered Aerostat Program Critical Design Review

Electrical Design Elements Tethered Aerostat Program Critical Design Review

Electrical Design Elements – Section A • The relay will be energized by the Arduino. • When not energized the normally closed switch will pass current to the batteries, “ 1”, and the normally open switch will act as electrical “open” passing no current to the batteries, “ 2”. • When the relay is energized, the normally closed switch will open and stop current flow to batteries, “ 1”, and the normally open switch will close and allow current to flow to batteries, “ 2”. • The diode will prevent any voltages from returning back to the Arduino when the current changes quickly in the coil. Thus preventing damage. Tethered Aerostat Program Critical Design Review

Electrical Design Elements – Section B • The Zener regulator will receive between 7. 4 -14. 8 volts from the battery source. • The Zener diode will always drop 5. 1 volts. The rest of the voltage will be dropped across the resistor R 1. • The Aim Xtra will then get its voltage across the Zener diode and ground, insuring it will always receive 5. 1 V during voltage spikes. Tethered Aerostat Program Critical Design Review

Electrical Design Elements – Section C • The photocell consists of a fixed 10 k ohm resistor and a variable resistor set up in a voltage divider configuration • The variable resistor will vary between 1 K-10 K ohms depending on the amount of light it is receiving • We will apply 3. 3 volts to the top of the fixed resistor and take voltage measurements between the fixed and variable resistors • These voltage readings will be sent to the Arduino where it will be sent through an algorithm to be computed into useable data. Tethered Aerostat Program Critical Design Review

Power and Data Control Design Elements • If time, X, > time, W, && light sensor is high then && Pin 1 is Low: • Make Pin 1 high on Arduino • If Pin 1 goes high wait time, Z, and switch Pin 2 high. • Reset time X • Else If time, X, >time, W, && light sensor is high then && Pin 1 is High: • Make Pin 1 low on Arduino • If Pin 1 goes low wait time, Z, and switch Pin 2 low. • Reset time X • Else If light sensor is low then: • • Make Pin 1 low Reset time, X, If time, X, >= time, T, then make Pin 1 high. Tethered Aerostat Program Critical Design Review

Software Design Elements • The Arduino will save all data from the weather sensors and control the power source. • The AIM XTRA will collect the radar data in the air and live feed it to the AIM Base were it will sent to the laptop for live viewing and storage. Tethered Aerostat Program Critical Design Review

Prototyping/Analysis Name of Presenter Tethered Aerostat Program Critical Design Review

Prototyping Results • EPS prototyped relay and voltage regulator circuit on Multi. Sim (electrical simulation software) • Upcoming prototyping • • Payload platform Bread board circuits Fractal antenna Radar gun modifications Tethered Aerostat Program Critical Design Review

Analysis Results • EPS relay and voltage regulator • Tests showed that our calculations for the Zener regulator were able to hold 5 V to the Aim Xtra from a 7. 4 V-14. 8 V. • Tests showed that our relay can be switched with 3. 3 V and less than 40 m. A. Tethered Aerostat Program Critical Design Review

Future Prototyping • Prototype the relays without the Arduino. We will monitor the switching current. • Prototype the solar panel and charge controllers to monitor the charging current • Prototype our Arduino and Aim Xtra with just a battery to ensure it will power the system. • Finally Prototype the whole system before soldering where we will monitor the currents through the system, especially the sourcing/sinking currents from the Arduino. • We must do all our current readings now before soldering the system. Tethered Aerostat Program Critical Design Review

Detailed Mass Budget Description Mass (g) Platform* 800 Rectenna* 20 Sensors* 100 Power Terminal (2) 60 Batteries (4) 203 Solar Panel 225 Bread Boards (2) 60 Wiring* 100 Mounts/Hardware* 500 Kestrel 125 Total Mass 2193 • Platform weight includes T-bar • * denotes estimation • Continuous mass testing will be performed throughout the building process • Platform weight may increase is vane is required to stabilize • 2193 g = 4. 8 lbs Tethered Aerostat Program Critical Design Review

Power Discussion Tethered Aerostat Program Critical Design Review

Build Plan Name of Presenter Tethered Aerostat Program Critical Design Review

Mechanical Build Elements • Platform obtained from Dan Hawk, additional modifications made as necessary • Need T-bar to perform structural tests • Component mounts and enclosures created with 3 -D ABS printer Tethered Aerostat Program Critical Design Review

Mechanical System Schedule • May 15, 2015 – Platform base completed • May 22, 2015 – Structural testing completed • May 31, 2015 – Tethered testing completed • June 14, 2015 – Components attached to payload base, full system testing begins Tethered Aerostat Program Critical Design Review

Ka Power Beam Elements • RF amplifier to be installed in radar gun • Radar gun converted to DC power supply • Fractal antennas need to be developed and tested • Monitoring circuitry needs to be prototyped and tested Tethered Aerostat Program Critical Design Review

Ka Band Schedule • May 15, 2015 – All components aquired • May 22, 2015 – Radar gun converted to DC power supply • May 31, 2015 – Fractal antenna patterns etched, if necessary • June 5, 2015 – Fractal antenna tests completed • June 12, 2015 – Amplifier installed in radar gun • June 14, 2015 – Amplified radar signal testing completed • June 14, 2015 – Antenna and resistor circuitry attached to payload, full system integration testing begins Tethered Aerostat Program Critical Design Review

Electrical Elements • 2 lithium-ion rechargeable battery packs • Zener regulator • Solar panel wired to charge controllers • Charge controller feeds through relays • Relays controlled by Arduino • Arduino software controls charging/discharging of batteries • All circuits will be prototyped using Multi. Sim and the prototyped on breadboards, then custom PCBs will be developed Tethered Aerostat Program Critical Design Review

Electrical System Schedule Week Task Begin Finish Week 1 Get Components April 27 th May 1 st Week 2 Prototyping May 4 th May 11 th Week 2 Write Code May 4 th May 8 th Week 3 -4 Build May 11 th May 25 th Week 3 -4 Individual Test May 11 th May 25 th Week 5 System Test May 25 th May 29 th Tethered Aerostat Program Critical Design Review

Software Elements • Open-source Arduino Software (ARDUINO 1. 6. 3) • AIM XTRA Tethered Aerostat Program Critical Design Review

Software Development Schedule • 04/26/2015 – Programing begins • 05/15/2015 – Begin software testing • 06/15/2015 – Complete all software programming and testing Tethered Aerostat Program Critical Design Review

Testing Plan Name of Presenter Tethered Aerostat Program Critical Design Review

Mechanical Testing • Weight verification • Ensure loaded payload platform is below specified weight • Scale • Balance testing • Verify placement of components allows stable balance of payload platform • Suspend payload from prototyped tether system • Aerodynamic testing • Will aerostat airfoil provide sufficient stabilization, or will additional wind vane on payload be necessary? • Consult with manufacturer of aerostat • Tethering testing • Determine how to attach payload to aerostat to prevent tangling of lines • Suspend payload, subject to wind testing Tethered Aerostat Program Critical Design Review

Ka Band Generation and Rectenna Testing • Develop 3 fractal antenna patterns • Test efficiencies of each with unaltered radar gun and RF test meter • Install TGA 516 RF amplifier and repeat tests with addition of radar detector to ensure radar signal is present • Convert radar gun from battery operation to power supply operation • Continue testing efficiencies, modify fractal pattern depending on results Tethered Aerostat Program Critical Design Review

Electrical Testing • We will develop a dummy load equal to the other systems and place the system outside in the sun. • We will also monitor voltages, with a volt meter, at relay transitions to ensure they we do not get spikes in voltage and that we do not go below the components minimums. • We will also be checking to make sure nothing is over heating. We will do that by touch. • We will do testing throughout the build process, weeks 3 & 4, to ease troubleshooting incase of an issue. • We will do a full test after we have the Electrical Sub-System finished, week 5. • All components will be added and tested individually Tethered Aerostat Program Critical Design Review

Software Testing • May 2, 2015 – Complete testing of software without hardware • May 15, 2015 – Complete testing of software with individual hardware • May 31, 2015 – Complete testing of software with each subsystem • June 5, 2015 – Complete testing of software with all hardware • June 14, 2015 – Complete testing of software with flight simulation Tethered Aerostat Program Critical Design Review

System Level Testing • Test antenna and rectifier circuit for power transfer • Ground testing with dummy load attached and oscilloscope for data logging • At this point, stable power transfer of 1 W will be expected • Resistor circuit will be developed depending on voltage acquired from Ka signal • Test logging capabilities of Aim XTRA • Ground testing with software modifications complete • Use multiple signal generators to simulate data and compare results • Testing starts as soon as software is acquired from Aim • Test power system for efficiency • Extended ground testing using dummy load, eventually Aim XTRA will be tested to log data • Testing starts as soon as system is constructed • Test Arduino redundant data collection • Log data with Aim XTRA and write data to SD card on Arduino and compare results • Testing starts as soon as system is constructed Tethered Aerostat Program Critical Design Review

Risks Name of Presenter Tethered Aerostat Program Critical Design Review

Risk Walk-Down KA. RSK. 1 Consequence FDC. RSK. 1 EPS. RSK. 1 Possibility • FDC. RSK. 1 : First flight will be delayed if Aim XTRA is not received by May 14, 2015 • KA. RSK. 1 : Mission objective will not be met if rectenna cannot be developed • EPS. RSK. 1 : Data collection will be minimized if indefinite power is not produced Tethered Aerostat Program Critical Design Review

New Risk Walk-Down • Aim XTRA is backordered • Much of our data collection depends on the use of the Aim XTRA, especially real time data logging • Alternative is SD card on Arduino • Borrow Aim XTRA from Dan Hawk • Ka Rectenna • Unknown technology at this point, will be trial and error • EPS requirements are unknown • Some power specs have been estimated, will not know until testing Tethered Aerostat Program Critical Design Review

Project Management Plan Name of Presenter Tethered Aerostat Program Critical Design Review

Project Schedule • May 15, 2015 – Payload mockup completed, prototyping for mounts begins • June 14, 2015 – Payload mounting completed, full scope ground testing starts • June 20, 2015 – Tenative First launch • July 25, 2015 – Tentative second launch • August 1, 2015 – All data analyzed, begin white paper • August 7, 2015 – White paper completed, finalize presentation, practice • August 14, 2015 – EAA presentation Tethered Aerostat Program Critical Design Review

Budget Item Lithium Ion 3. 7 V 10400 m. AH (Battery) 6 V 5. 6 W Solar Panel USB/DC/Solar Lithium Ion Charger (Charger Controller) Circuit Board (Breadboard) 1 N 4004 (Diodes)(10 Pack) DPDT Relay 1 N 4733 A 5. 1 V Zener Diodes ROYAL MARINE A-A FIR PLYWOOD Whistler XTR-140 (Radar Detector) RF Amp (TGA 4515)(Radar Amplifier) 1 NA 160 IC (Current Sensor) Stalker ATR (Radar Gun) PCB Etch Kit (Circuit Board Etching Kit) Ka Fractal Antenna Reciever Schottky Diodes Terminal Block (Power Strip) Comparator op-amp Cost $ 33. 59 $ 67. 50 Quantity $ 17. 50 $ 1. 76 $ 1. 50 $ 5. 69 $ 0. 25 $ 31. 88 $ 31. 48 $ 107. 00 $ 9. 95 $ 149. 00 $ 5. 67 $ 149. 00 $ 0. 44 $ 4. 95 $ 0. 43 Tethered Aerostat Program Critical Design Review 4 1 2 5 1 1 1 3 1 10 1 4 2 1 Total Item Total $ 134. 36 $ 67. 50 $ $ $ $ 35. 00 7. 04 1. 50 11. 38 1. 25 31. 88 31. 48 107. 00 29. 85 149. 00 56. 70 149. 00 1. 76 9. 90 0. 43 825. 03

Project Summary • Potential donation of radar equipment from local law enforcement • Extensive ground testing required • Methods of data collection may change depending on success of data logging Tethered Aerostat Program Critical Design Review

Conclusion • Data collection waiting on backordered flight controller and software development • Power system waiting for components to start building and testing • Radar system waiting for components to start building and testing Tethered Aerostat Program Critical Design Review