Airframe Measurements P09233 – Detailed Design Review

Team Structure Team Lead: Michael Skube – Mechanical Engineer Co-Team Lead: James Hunt – Mechanical Engineer Electrical Lead: Joseph Peters – Electrical Engineer Kevin Li – Electrical Engineer William Atkinson – Mechanical Engineer Heidi Morgan – Electrical Engineer John Isely – Mechanical Engineer

Power – Airframe A On-Board Supply

Airframe Measurement System

Power – Input Voltages Device Minimum Vin Maximum Vin Vin Used Micro-controller* 4.5V 10V 5V GPS 3.3V Pitot Static Tube 3.0V 16V IMU 5.5V Altimeter 3.7V *LM1117 – Linear Regulator

Power – Calculation Device Vin Min Current Max Current Min Power Max Power Micro-controller 5V .06 mA .11 mA .06 mW .55mW GPS 33 mA 55 mA 109 mW 182 mW Pitot Static Tube 20 mA 30 mA 100 mW 150 mW IMU 57 mA 165 mW 285 mW Altimeter 13 mA 16 mA 65 mW 80 mW Total Power Consumption: : .439 W – .697 W Airframe A Battery: 14.4 V 2.5 Ampere-hour 36 W-hour Can supply power for 52 – 82 continuous hours ~100x our expected flight time (40 minutes)

GPS Variable update rate 32 Parallel Channels High Accuracy Small Size 1-5 Hz 32 Parallel Channels High Accuracy ~3.3m Small Size 30x30x8.5mm Software: GPS Locator Utility

GPS – GPS Locator Utility

GPS – Accuracy Test

GPS – Accuracy Test

GPS – Accuracy Test

GPS – Accuracy Test Observations Number of Satellites: Max: 13 Min: 9 Avg: 10 Percentage of available satellites used: ~83% Altitude (example from starting point) Google Earth: 524ft GPS: 517ft ~1% error

GPS – Accuracy Test Speed (MPH) Sample Number Stop Signs

GPS – Accuracy Test Red Barn Altitude (m) Sample Number

GPS –Test Plan Test #1: Accuracy Test Test #2: Time Satellite Fix Test #3: Material Interference Test #4: Orientation effects

Microcontroller Atmel: AT91SAM7S Various I/O SD Card 2x UART 10 bit ADC SPI SD Card

IMU Analog Devices: ADIS16350 6 degrees of freedom Tri-axis accelerometer X, Y and Z linear acceleration Tri-axis gyroscope X, Y and Z angular acceleration Serial Peripheral Interface (SPI) master (MCU) –slave (IMU)

IMU – Output Registers Adapted from ADIS16350 Datasheet

IMU – Timing Diagram Adapted from ADIS16350 Datasheet

SPI Communication: IMU Example code: x-axis gyro Chip Select is driven low Address written to DIN to determine what register is read Data is read off by MCU The gyro needs to be calibrated while the plane is stationary. This is done to eliminate drift and compensate for the temperature dependence. The code below initialized the gyro.

UART Communication: GPS UART (parallel to serial) controlled Interrupt to inform MCU new data is available Prevents the processor from being bogged down

ADC Communication: Initialization Measure analog voltages and assign digital values to store. 10 bit ADC 1024 digital measurements possible

Measurements Box Design The design space inside Airframe A required that the MCU be cut down, the change in size is shown below full size board cut down board

Measurements Box Design GPS IMU Altimeter Microcontroller Ultrasonic

Measurements Box In Airframe A

Component Constraints & Dimensions IMU Requires Specific Mounting Direction Ultrasonic Sensor Mounting on the Exterior Altimeter Requires Static Pressure Inside = Static Pressure Outside GPS Requires Specific Mounting Direction GPS Requires No Dense Obstructions Pitot Static Tube Mounting Outside of Boundary Layer Pitot Static Tube Sensor Must be Easy to Remove

Pitot Static Tube Analysis The Pitot Static tube works off of two very simple principles, Bernoulli and the Ideal Gas Equation Bernoulli Equation Ideal Gas Equation From this, the speed of the aircraft through the air can be found directly.

Pitot Static Tube Testing Test #1 – Wind Tunnel Testing in RIT Wind Tunnel Test #2 – Car Test with Anemometer Test #3 – Time Delay Test on tubing Test #4 – Flight in Airframe A Test #5 – Compare Velocity with GPS Velocity

Pitot Tube Test Results Test #1 – Small Wind Tunnel at RIT Anemometer ETS Pitot-Tube m/s mph 1.0 2.20 0 ~ 2 1.3 2.86 1 ~ 3 1.5 3.30 3 ~ 4 2.0 4.40 4 Spec from ETS states lower limit of 2 mph

Test #1 – Large Wind Tunnel

Test #2 – Car Test

Pitot Tube Test Results (cont.) Test #3 – Time Delay Theory This is based off Pneumatics with a Capacitance and a Resistance Then a system model can be setup with a step input to find the time delay to the sensor.

Pitot Tube Test Results (cont.) Test #3 – Time Delay Theory R = 1.322e-6 m*s C = 9.332e-7 m*s^2

Pitot Static Sensor Mounting

Pitot Static Tube Mounting

Pitot Static Tube Mounting (cont.)

Altitude Stair Test 1

Altitude Stair Test 2

Altimeter cont… Future tests Vacuum Chamber Altimeter vs GPS Use a vacuum chamber to simulate the pressure drop of high altitude ~10,000 ft Altimeter vs GPS Compare the GPS and Altimeters readings

Vibration Dampening Softness Ratings for our Application Vibration Damping helps to reduce vibrations and shocks to sensors and components Softness Ratings for our Application 5 - 9 for Foams 35 - 75 for Rubbers Good or Excellent compression recovery was also selected as it will allow the dampener to have quick energy dissipation. Sensors and the MCU will use Vibration Foam Sheets The Boxes Mounting Bolts will use Vibration Grommets

Vibration Dampening Images from McMaster.com

Expenses To Date $ 910.73 Item Model Altimeter ZLOG 3 Data Recorder # Item Model Manufacture Part Number QTY Price Shipped   1 Altimeter ZLOG 3 Digital Products #ZLOG3 $ 89.95 $ 93.74 2 Data Recorder eLogger V3 Eagle Tree Systems MPRV3-LEADS-100 $ 69.99 $ 77.99 3 MicroSensor V3 ALTIMETER-V3 $ 37.99 $ 37.99 4 Airspeed AIRSPEED-V3 $ 42.99 $ 42.99 5 Pitot-Static Tube Pitot-Static Tube Kit PITOT-KIT-V3 $ 9.99 $ 49.95 6 Microprocessor SAM7-256 Board Spark Fun Electronics DEV-00774 $ 71.95 $ 153.69 7 GPS 32 Chan San Jose Nav. GPS-08266 $ 99.95 $ 99.95 8 Ultrasonic Range Finder SEN-08504 $ 27.95 $ 27.95 9 GPS Break Out Board Lassen iQ Eval Board - USB GPS-00168 $ 34.95 $ 48.88 10 3/16" X 12" X 12" Foam w/ Adhesive Back, SOFT McMaster 86375K151 $ 8.17 $ 24.51 11 1/8" X 1/2" 39' 93275K12 $ 15.84 $ 15.84 12 .25" Dia, .057" Thick Vibration Grommet 9311K138 $ 10.27 $ 20.54 13 1/8" X 12" X 12" Foam w/ Adhesive Back, FIRM 86375K163 $ 6.94 $ 20.82 14 1/16" ID, 1/8" OD Silicone Tubing 51135K11 50 $ 0.41 $ 20.50 15 4-40, 1/8" H Barrel Thread Plate 90975A002 $ 9.01 $ 9.01 16 1/16" Single Barb Tee Fitting 5116K11 $ 2.38 $ 2.38 17 7mm OD, 3.2mm ID Fiber Washer 95225A315 $ 8.35 $ 8.35 18 4-40, 1/2" Length Socket Cap Screw 92196A110 $ 4.26 $ 4.26 # Item Model Manufacture Part Number QTY Price Shipped   19 4-40, 3/4" Length Socket Cap Screw McMaster 92196A113 1 $ 4.52 $ 4.52 20 4-40, 1" Length 92196A115 $ 5.78 $ 5.78 21 1/32" X 12" X 12" PTFE Sheet Gasket 1063T21 2 $ 7.05 $ 14.10 22 1/16" X 12" X 12" 1063T22 $ 13.94 $ 27.88 23 IMU Analog Devices $ - $ - 24 BOX - MOD01 Initial Release of BOX P09233 - $ 29.50 $ 29.50 25 4 Pack of Bateries AA Radio Shack $ 2.50 $ 5.00 26 AAA 27 Battery Holder 4X AA $ 1.79 $ 1.79 28 Battery Clips 9V $ 2.69 $ 2.69 29 2X AA $ 1.69 $ 1.69 30 3X AAA 31 Adapter Plug M 32 AC Adapter 6V 800Ma AC $ 22.99 $ 22.99 33 SD Memory Card 1Gb Sandisk $ 12.99 $ 12.99 34 Binder 1.5" OFFICE DEPOT $ 7.79 $ 7.79 35 Ready Index 5 Tabs $ 2.59 $ 2.59 36 1.5" (2-Pack) $ 5.29 $ 5.29 $ 910.73

Bill of Materials TOTAL $ 1,100.79 # Item Model Manufacture Part Number QTY Price Shipping Shipped   1 Altimeter ZLOG 3 Digital Products #ZLOG3 $ 89.95 $ 3.79 $ 93.74 2 Airspeed MicroSensor V3 Eagle Tree Systems AIRSPEED-V3 $ 42.99 $ - $ 85.98 3 Pitot-Static Tube Pitot-Static Tube Kit PITOT-KIT-V3 $ 9.99 $ 19.98 4 Microprocessor SAM7-256 Board Spark Fun Electronics DEV-00774 $ 71.95 $ 9.79 $ 81.74 5 GPS 32 Chan San Jose Nav. GPS-08266 $ 99.95 $ 99.95 6 Ultrasonic Range Finder SEN-08504 $ 27.95 $ 27.95 7 GPS Break Out Board Lassen iQ Eval Board - USB GPS-00168 $ 34.95 $ 13.93 $ 48.88 8 3/16" X 12" X 12" Foam w/ Adhesive Back, SOFT McMaster 86375K151 $ 8.17 $ 8.17 9 1/8" X 1/2" 39' 93275K12 $ 15.84 $ 15.84 10 .25" Dia, .057" Thick Vibration Grommet 9311K138 12/25 $ 10.27 $ 4.93 11 1/8" X 12" X 12" Foam w/ Adhesive Back, FIRM 86375K163 $ 6.94 $ 6.94 12 1/16" ID, 1/8" OD Silicone Tubing 51135K11 20 $ 0.41 $ 8.20 13 4-40, 1/8" H Barrel Thread Plate 90975A002 17/100 $ 9.01 $ 1.53 15 7mm OD, 3.2mm ID Fiber Washer 95225A315 31/100 $ 8.35 $ 2.59 16 4-40, 1/2" Length Socket Cap Screw 92196A110 7/100 $ 4.26 $ 0.30 17 4-40, 3/4" Length 92196A113 $ 4.52 $ 0.32 18 4-40, 1" Length 92196A115 $ 5.78 $ 0.40 19 IMU ADIS 16350 Analog Devices $ 550.00 $ 550.00 BOX - MOD01 Initial Release of BOX P09233 - 1/4 $ 29.50 $ 7.38 21 AC Adapter 6V 800Ma AC Radio Shack $ 22.99 $ 22.99 22 SD Memory Card 1Gb Sandisk $ 12.99 $ 12.99 TOTAL $ 1,100.79

Projected Project Costs Building a second Measurements Box: Total Project Cost: $1900 (includes IMU cost ~$500) Total Project Cost: $1400 (assumes donated IMU) Measurements Box BOM: $1100 (includes IMU cost ~$500) $600 (assumes donated IMU) The Current Project Cost: $910

Current Risks Ability to Program the MCU Ability to Interface with the IMU Ability to Test the IMU – MAV Test Stand GPS Calibration Airframe A Flight Testing

Action Items Program MCU IMU Testing Further Sensor Testing Pitot Static Tube Mounting Design Part Drawings Assembly Instructions Component Documentation

Part Design Test Pitot Static Tube Program MCU Test Altimeter Schedule - SDII Team Member WEEK 11 FINALS BREAK WEEK 12 WEEK 13 WEEK 14 Michael Skube (TEAM LEAD) Review Project Status, Meet with team leads, Update EDGE, Individual Sensor Review, Order new Parts, Finalize SD I Documents Complete Documentation, Write Instillation Instructions Meet with Team Leads, Update EDGE, System Integration Review Test complete system on Ground Station James Hunt (TEAM / MECHANICAL LEAD) Prepare for Individual Sensor Review, Revisit Sensor Selection if needed, Continue Testing, Meet with team leads Begin Testing Complete Measurements System, Meet with Team Leads Joseph Peters (ELECTICAL LEAD) Complete Documentation, Program Microcontroller Program Microcontroller Begin Complete System Integration, Meet with Team Leads Kevin Li Prepare for Individual Sensor Review, Revisit Sensor Selection if needed, Continue Testing, present testing results Begin Complete System Integration Heidi Morgan John Isely Complete Documentation, Test Sensors William Atkinson Program MCU Test Altimeter Document BOX Build Test Pitot Static Tube Part Design Phase I System Testing

(TEAM / MECHANICAL LEAD) Schedule - SDII Team Member WEEK 15/17 WEEK 16 WEEK 18 WEEK 19 WEEK 20/21/22 Michael Skube (TEAM LEAD) Review/Fix/Re-test Complete Measurements System on Ground System, Meet with other Team Leads Test complete system on Airframe A, Prepare for IMAGINE RIT, Begin Design of SD Poster Update Documentation, Meet with Team Leads, Update EDGE, Fly Measurements System and Document Flight, Prepare for IMAGINE RIT IMAGINE RIT FESTIVAL Finalize All Documentation, Update EDGE, Team Lead Meeting James Hunt (TEAM / MECHANICAL LEAD) Joseph Peters (ELECTICAL LEAD) Kevin Li Review/Fix/Re-test Complete Measurements System on Ground System, Update Documentation, Update EDGE, Fly Measurements System and Document Flight, Prepare for IMAGINE RIT Finalize All Documentation, Update EDGE Heidi Morgan John Isely William Atkinson Refine Programming Documentation Drawings Phase II System Testing Final Documentation