1. Preliminary Design Review Patrick Weber, Eric Robinson, Dorin Blodgett, Michael Stephens, Heather Choi, Kevin Brown, Ben Lampe November 1, 2010 11/1/20101

2. 2 Mission Overview 1 2 3 4 5 6

3. Scientific Mission Overview o Primary: Collect space dust. o Provide a perspective of what is in our upper atmosphere. o Secondary: o Capture optical images of the Earth. o Measure thermal, seismic, and pressure effects throughout the duration of the launch. o Collect data for future projects. 11/1/20103 Presenter: Eric Robinson

4. Engineering Mission Overview o Engineer an extendable boom to mount a dust collector. o Use aerogel tablet as dust collector. o Engineer a water shield to protect dust collector. o Engineer modular electronic systems for: o Capturing and storing images from optical devices. o Recording thermal, seismic, and pressure data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry. 11/1/20104 Presenter: Eric Robinson

5. Theory and Concepts o Underlying Science and Theory o Attempt to capture space particles using telescoping boom and aerogel. o Quantification of varying flight parameters. 11/1/20105 Presenter: Eric Robinson

6. Theory and Concepts o Previous Experimentation o Previous flights have included multi-sensor packages. o Temperature, Humidity, and Pressure Sensors o Accelerometers / Seismic Sensors o Magnetometers o Data Storage (SD Cards) o Results provided a basis for improvement on future data collection and retrieval. o SD Cards impervious to low exposure to salt water o Payload orientation 11/1/20106 Presenter: Eric Robinson

7. Concept of Operations 11/1/20107 Presenter: Eric Robinson t ≈ 0 min Launch t ≈ 0.7 min End of Orion Burn t ≈ 1.7 min Shedding of Skin Boom Extends t ≈ 2.8 min Apogee t ≈ 4.0 min Boom Retracts t ≈ 8.2 min Chute Deploys t ≈ 15 min Splash Down

8. Expected Results o Successfully collect space dust o Space Dust Composition (10 -6 ) o Exhausted Rocket Fuel o Meteor / Metal Fragments o Other Miscellaneous Gases o Earth images o Detailed data throughout flight duration o Thermal Data o Seismic/Vibration Data o Atmospheric Pressure Data 11/1/20108 Presenter: Eric Robinson

9. 11/1/20109 System Overview 1 2 3 4 5 6

10. Subsystem Definitions o TB: Telescopic Boom o OC: Optical Camera o IS: Integrated Sensors o EPS: Electrical Power System o STR: Structure o MCU: Micro Controller Units 11/1/201010 Presenter: Eric Robinson

11. Subsystem Overview 11/1/201011 Presenter: Eric Robinson

12. System Level Block Diagram 11/1/201012 Presenter: Eric Robinson Buck Converter Boost Converter Microcontroller WFF Power Interface WFF Telem. Interface Motor Controller EPS TB OC STR Wallops PT Interfaces Low Voltage High Voltage Data/ Control Legend IS Camera Pressure S. Accelerometer Thermal Sensor

13. Critical Interfaces 11/1/201013 Presenter: Eric Robinson Interface NameBrief DescriptionPotential Solution TB/STR Telescoping boom will have to be integrated rigidly to the RockSat-X deck and designed carefully to be shielded tight in order to preserve the dust collected throughout the duration of the flight. The boom’s base is designed as part of the main structure, but must also be bolted to the top plate for extra support. EPS/STR The electrical system will need to be mounted to the RockSat-X deck rigidly to survive the thrust, vibrational, and impulse loading throughout the flight. Using bolt fixtures, the circuit boards should be mounted to the structure. IS/STR All the sensors have to be integrated rigidly to the RockSat- X deck to withstand flight conditions. The sensors should be mounted in the appropriate positions via epoxy or bolts. OC/STR The optical camera have to be mounted and shielded appropriately to survive throughout the flight. The camera mount should have minimal deflection and vibrations will not affect the short exposure times. Therefore, a bolted mount should be sufficient. TB/EPS The telescoping boom is controlled by an electric motor. At motor stall, peak current is drawn, so overheating and overdrawing of current is the critical failure mode. A standard cable should connect the motor controller to the EPS circuit board. All power connections will be fuse protected. IS/EPS All the data will be recorded and transmitted through provided telemetry. Telemetry failure is the critical failure mode. IS electrical leads will interface with the EPS circuit board. All power connections will be fuse protected. OC/EPS Optical camera will be controlled by electrical system. Short-circuiting and failure of the electrical communication is the critical failure mode. Internal power lines will be securely mounted using epoxy. External lines will be designed by NASA. All power connections will be fuse protected.

14. System/Project Level Requirement Verification Plan 11/1/201014 Presenter: Eric Robinson Requirement Verification Method Description The telescopic boom shall extend no more than 12” from the Payload’s outermost dimension and then seal itself shut upon retraction. DemonstrationBoom will extend to its full length and be retracted to verify all mechanical components function properly and gaskets effectively seal the interior from water. The payload structure will survive 50G forces with minimal deflections during launch. AnalysisSolidWorks will be used to subject our payload structure to a 50G uniform acceleration to measure deflections. The payload structure and gasket seals must survive the impact of splashdown completely intact and stay sealed during submersion. TestingPayload structure with boom, motor, and locking mechanism will be impact tested and left submerged underwater to ensure structural soundness and gasket functionality.

15. User Guide Compliance 11/1/201015 Presenter: Eric Robinson TypeQuantitative Constraint Physical EnvelopeCylindrical Diameter: 12 inches Height: 6 inches Weight15 lbf ± 0.5 lbf Center of Gravity (COG)±0.5in from axial center of RockSat-X plate Power and Telemetry8x 0-5V 16-bit A/D Lines 1x Asynchronous Line at 15.36 kBd (19.2 kBd nom.) One GSE Activation Line Three timer controlled power lines One redundant timer controlled line High VoltageNo high voltage lines required.

16. Sharing Logistics o Who are we sharing with? o University of Northern Colorado o Re-entry Experiment Sat: Recover a reusable deployable, attempt to dynamically control the descent of the payload, and gather data during the return trip. o The possibility of a communication system between the AstroX payload and the UNC Re-entry Experiment Sat payload is being considered. o Plan for collaboration? o Email, phone, road-trips to Greeley and Boulder o Communication with Max Woods on a weekly basis. o Grant UNC access to the AstroX private website. 11/1/201016 Presenter: Eric Robinson

17. 11/1/201017 Subsystem Overview 1 2 3 4 5 6

18. Subsystem A: Telescopic Boom 11/1/201018 Presenter: Patrick Weber

19. Subsystem A: Telescopic Boom o Functional Block Diagram 11/1/201019 Presenter:

20. Subsystem A: Telescopic Boom o Telescopic Boom, Spring Loaded o Safe o Inexpensive o Reliable o Strong 11/1/201020 Presenter: Patrick Weber TypeScoreSafetyCostStrengthReliabilityWeightFeasibilityComplexity Weighting Factor3899898 Spring Loaded3998878588 Retractable Tray32910576566 Robotic Arm2478365543

21. Subsystem A: Water Shield 11/1/201021 Presenter: Patrick Weber

22. Subsystem A: Water Shield o Aluminum o Easily machined o Inexpensive o Reliable (no surprises) 11/1/201022 Presenter: Patrick Weber TypeScoreSafetyCostStrengthReliabilityWeightFeasibilityComplexity Weighting Factor5889998 Aluminum44010879499 Composite33410289833 Plastic39410547987

23. Subsystem B: Power System (EPS) 11/1/201023 Presenter: Michael Stephens

24. Subsystem B: Power System (EPS) o NASA Power o Reliable o Inexpensive o No weight penalty o Safe 11/1/201024 Presenter: Michael Stephens TypeScoreSafetyCostStrengthReliabilityWeightFeasibilityComplexity Weighting Factor5679799 NASA Power52010 Battery Packs1994343165 Solar Panels24710128625

25. Subsystem C: Integrated Sensors o Telemetry o Reliable o Least Expensive o No weight penalty o Least Complex o Cannot handle large data 11/1/201025 Presenter: Michael Stephens TypeScoreSafetyCostStrengthReliabilityWeightFeasibilityComplexity Weighting Factor3479598 SD Card4051088999 Telemetry45010 Eye-Fi32410587967 o SD Cards o Reliable / Redundant o Solid State o Impervious to salt water o Lightweight o Can handle large data

26. Subsystem C: Integrated Sensors 11/1/201026 Presenter: Michael Stephens

27. Subsystem C: Integrated Sensors 11/1/201027 Presenter: Michael Stephens

28. Subsystem C: Integrated Sensors 11/1/201028 Presenter: Michael Stephens

29. Subsystem D: Optical Camera o Optical Still Camera o Least Expensive (already own) o Lightweight o Least complex (circuits pre-engineered) 11/1/201029 Presenter: Michael Stephens TypeScoreSafetyCostStrengthReliabilityWeightFeasibilityComplexity Weighting Factor2898598 Infrared35510276888 Optical37110 76888 Stereoscopic30110178467

30. 11/1/201030 Mathematical Models 1 2 3 4 5 6

31. Telescopic Boom o Launch/Reentry o Centrifugal Loading o Static Tension o Assumptions o The maximum centrifugal force will occur directly before Orion burn out. o Internal forces are equal to zero. o Centrifugal masses are treated as point masses at their COG. 11/1/201031 Presenter: Patrick Weber

32. Telescopic Boom o Apogee o Spring Force o Friction o Dynamic Tension o Assumptions o The maximum frictional force will occur between the base and mid sections. o Internal forces are zero. o Gravity at apogee will be negligible, beam theory does not apply. 11/1/201032 Presenter: Patrick Weber

33. Payload Structure o Launch o Uniform Thrust Loading o Vibrations o Impulse o Fatigue (~0.7 minutes) o Pressure Vessel Effects (neg.) o Assumptions o Loading can be applied as body forces. o Payload internal supports are fixed connections. o Payload has uniform material properties. o Vibrations treated as static loads at peak amplitude. 11/1/201033 Presenter: Patrick Weber

34. Payload Structure o Reentry o Impact o Pressure Vessel o Shear Loading (Plate Lip) o Assumptions o Perfectly rigid and joints have no clearance o Uniform material properties o Gravity is constant 11/1/201034 Presenter: Patrick Weber

35. Finite Element Analysis o Simplified Governing Equations 11/1/201035 Presenter: Patrick Weber

36. Finite Element Analysis o Launch Assumptions o Vibration loads will be treated as static loads at peak amplitude. o Base of each longeron is fixed and immovable. o No surface forces are present other than contact forces. o Vibration and thrust loads are applied as body forces. o Loading conditions are continuous over each part. o All materials are linear isotropic. 11/1/201036 Presenter: Patrick Weber

37. Finite Element Analysis o Reentry Assumptions o Payload falls directly onto surface. o Surface is perfectly rigid. o Payload can deform. o No surfaces forces are present other than part contact forces and surface/payload contact force at impacting location. o Drag and impact loads are applied as body forces. o All materials are linear isotropic. 11/1/201037 Presenter: Patrick Weber

38. 11/1/201038 Prototyping Design 1 2 3 4 5 6

39. Subsystem: Risk Matrix/Mitigation o Risk Matrix / Mitigation o STR/TB.RSK.1: Canister seals fail at splashdown and aerogel is saturated with water. o TB.RSK.2: Boom jams when skins are shed. Boom fails to open and mission objectives are not met. o IS.RSK.1: Telemetry or SD cards fail and data to be collected for next year’s team is lost. Secondary mission objectives are not met. o EPS.RSK.1: Should the NASA telemetry or Timed Event circuits fail, the boom may prematurely extend causing failure of the UW payload as well as possible damage to the rocket. 11/1/201039 Presenter: Patrick Weber Consequence EPS.RSK.1 STR/TB.RSK.1 TB.RSK.2 IS.RSK.1 OC.RSK.1 Possibility

40. Prototyping Plan o Most mechanical prototyping will be done and tested using Finite Element Analysis. o Drop tests o Launch simulations o Once the payload is manufactured, extensive testing will be performed on the payload as it is assembled. o Circuits tests o Pool submersion tests on the canister as well as drop deflection tests on the sealing around the boom. 11/1/201040 Presenter: Patrick Weber

41. 11/1/201041 Project Management Plan 1 2 3 4 5 6

42. Organizational Chart 11/1/201042 Presenter: Patrick Weber Project Manager Shawn Carroll Team Leader Patrick Weber Physics Faculty Advisor Dr. Paul Johnson Engineering Faculty Advisor Dr. Carl Frick Integrated Sensors (IS) Michael Stephens Heather Choi Electrical Power System (EPS) Michael Stephens Ben Lampe Telescopic Boom (TB) Patrick Weber Eric Robinson Dorin Blodgett Optical Camera (OC) Kevin Brown Nick Roder Charles Galey

43. Mechanical Schedule o Major Mechanical Milestones: o Design Freeze at CDR (Friday, November 19, 2010) o Blueprints submitted for manufacturing by CDR o Mechanical prototype constructed mid-January, 2011 o Mechanical prototype fully tested by end of January, 2011 o Impact and submersion testing o Aerogel testing 11/1/201043 Presenter: Patrick Weber

44. Electrical Schedule o Major Electrical Milestones: o Electrical Schematics completed by CDR o Components ordered by end of Fall Semester (December, 2010) o Electrical assembly and testing done by Mid February o Control function test o Telemetry and SD card output test o Fully functioning payload by end of February 11/1/201044 Presenter: Patrick Weber

45. Budget o Mass Budget (15±0.5 lbs) o Structure (9 lbs) o Boom (2 lbs) o Water Shield (4 lbs) o NASA Structure (3 lbs) o Camera (1 lb) o Other Sensors (1 lb) o Modular Electrical System (1 lb) o Ballasting (~3 lbs) 11/1/201045 Presenter: Patrick Weber

46. Budget o Monetary Budget (~$1300) o Structure ($600) o Boom ($200) o Aerogel ($300) o Water Shield ($100) o Camera ($100) o Other Sensors ($110) o Modular Electrical System ($200) o Correcting Factor (+$25%) 11/1/201046 Presenter: Patrick Weber

47. Work Breakdown Structure 11/1/201047 Presenter: Patrick Weber Integrated Sensors (IS) Electrical Power System (EPS) Telescopic Boom (TB) Optical Camera (OC) Finalize Design Design Freeze at CDR Submit Work Request Manufacture Boom Parts Assemble Boom and Structure Finalize Schematics Design Freeze at CDR Order Parts by End of Fall Semester Build Circuits Program Microcontrollers Test Systems Integrate with Boom Finalize Schematics Design Freeze at CDR Order Parts by End of Fall Semester Build Circuits Program Microcontrollers Test Systems Recover previous year’s camera Test functionality of camera If functional: Integrate with Electrical Power System and Integrated Sensors If non-functional: Assess alternatives and proceed in the most appropriate path

48. 11/1/201048 Conclusions 1 2 3 4 5 6

49. Scientific Mission Overview o Primary: Collect space dust. o Provide a perspective of what is in our upper atmosphere. o Engineer a water shield to protect dust collectors. o Secondary: o Capture optical images of the Earth. o Measure thermal, seismic, and pressure effects throughout the duration of the launch. o Collect data for future projects. 11/1/201049 Presenter: Patrick Weber

50. Engineering Mission Overview o Engineer an extendable boom to mount imaging equipment and dust collector. o Use aerogel to collect space dust. o Engineer modular electronic systems for: o Capturing and storing images from optical devices. o Recording thermal, seismic, and pressure data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry. 11/1/201050 Presenter: Patrick Weber

51. Questions?