MANUFACTURING STATUS REVIEW T I R

TELEMETRIC INTERPLANETARY REGOLITH EXPLORER FOR SEISMIC
INVESTIGATION OF ASTEROID SURFACES
MANUFACTURING STATUS REVIEW
Aerospace Engineering Sciences
University of Colorado
3 February 2014
Ian Barry
Rachael Collins
Jonathon Fraker
Patrick Haas
Tom Johnson
Austin Lillard
John Marcantonio
Scott Taylor
OUTLINE

Overview

Schedule

Manufacturing


Communications System

Power System

Mechanical System
Budget
2
OVERVIEW
PROJECT CONOPS



1.5 ft
Transmitter
3lb weight
Receiver
C&DH Board
Power

ADC

Thermistors
w/MUX
Internal
GeoPod
Structure
Heaters
During
this
time,
the
power
The
Board
continues
3-axis
accelerometer
Weight
dropped
near
fully
ADC
C&DH
converts
board
samples
6multiplexed
analog
and
internal
structure
must
GeoPod
detects
seismic
DataC&DH
from
the
Commands
Packetized
accelerometer
are
received
system
must
regulate
to
sample
both
the
measures
response
integrated
GeoPod
channels
stores
the
(2
digital
signals
data
for
from
each
integrate
the
components
waves
thermistors
(“housekeeping
over
and
thermistor
the
next
20data
minutes
isand
to
distribute
power
toat
all
of
accelerometer
data
and
the
the
ADC
at
500Hz
axis)
into
athe
and
the
system
into
data”)
ispower
sampled
500Hz
start
transmitted
transmissions
according
of
data
to
BASIX
mission
will
use
both
components
thermistors
for
15an
minutes
digital
signal.
the
GeoPod
shell
(provided
and
stored
at
80
bits/s
received
commands
a
GeoPhone
and
20
minutes
represents
a
by
Ball) window
Heaters
are not necessary
Accelerometer
contact
for
Ourground
projecttesting.
will sample each
Representative
loads will be
axis of the accelerometer
used
simulation
twice for
to simulate
the
GeoPhone, because
commercial GeoPhones are
too large, heavy, and
expensive for our project
 Ball is receiving a
custom GeoPhone
Accelerometer
1 ft
Overview
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4
DESIGN OVERVIEW
Overview
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Comm System
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5
FUNCTIONAL BLOCK DIAGRAM
6
DESIGN CHANGES
Overview
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7
CRITICAL PROJECT ELEMENTS
Element
Name
Description
MSN.1
Mass
Total mass of geopod shall be less than 5 kg
MSN.2
External Shell
Integration
All subsystems shall be integrated into existing 3000 mL
spherical external shell
MSN.3
Data
Collection
The GeoPod shall collect and store accelerometer and
housekeeping data
MSN.4
Transmission
The GeoPod shall be capable of transmitting all collected
data to the Ground Station Equipment (GSE) within the
mission duration
MSN.5
Thermal
Range
The GeoPod shall be kept within the operating
temperature range of GeoPod components
MSN.6
Power
The GeoPod shall be able to power itself for the mission
duration
MSN.7
Path to Flight
The designed subsystems shall have no critical
obstacles in their development toward a space-qualified
system
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8
SCHEDULE
WORK BREAKDOWN STRUCTURE
TIRESIAS
Project
Management
• CDR
• FFR
• Work Flow
Schedule
• Cost Budget
• MSR
• PFR
• SFR
Overview
Comm System
• Link Budget
• Transmitter
and Receiver
• Antennas
• Accelerometer
• Configured
ADC
• C&DH SW
Sketches
• Stored Data
• Spacecraft
Simulation
(GSE)
Schedule
Power System
• Power Budget
• Schematics
• Power
Distribution
PCB
• Temperature
Sensors
• ADC PCB
• Wiring Harness
Comm System
Power System
Mechanical
System
• CAD Models
• Thermal Model
• Mass and
Volume Budget
• Battery Pack
• Shell
Integration
Structure
• Subsystem
Mounting
Frame
Mechanical
System
Integration and
Test
• TRR
• Safety
Protocols
• Interface
Control
Documents
• As Run
Procedures
• Results
Documents
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10
CRITICAL PATH
Overview
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11
COMMUNICATIONS SCHEDULE
Overview
Schedule
Comm System
Power System
Mechanical
System
Budget
12
POWER SCHEDULE
Overview
Schedule
Comm System
Power System
Mechanical
System
Budget
13
MECHANICAL SCHEDULE
Overview
Schedule
Comm System
Power System
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14
COMMUNICATIONS SYSTEM
COMM REQUIREMENTS
Rotational
Period = 2.4hrs
freq < 50 Hz
Max. Amplitude:
0.2 g’s
Asteroid
Orbital
Period =
124.1hrs
60o
Requirement Flows From
Description
COM.1
MSN.3
6 channels of science data shall be sampled at 500 Hz.
COM.2
MSN.3
Science data shall be recorded such that a range of -2g to
2g is quantized with a resolution of 0.002g
COM.3
MSN.3,
MSN.4
The C&DH board shall interface with ADC, memory, power
board, and RF system.
COM.4
MSN.4
Uplink data rate shall ensure all stored telemetry is
transmitted during the 20 min contacts over 10 days
Overview
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16
COMM. ACQUISITION & STATUS

2 major design changes from CDR
 Selected different ADC due to misinterpretation of data sheet
 Selected different receiver and transmitter due to interface issue
Component
Acquisition Method
Status
Arduinos
Purchased
Received
PCB Components
Purchased
Received
PCB
Ordered/Manufactured
Shipped
Temperature Sensors
Purchased
Shipped
Accelerometer
Provided by Ball
Waiting on customer
Transmitter and
Receiver from Ball*
Provided by Ball
Waiting on customer
Transmitter
Purchased
Expected Delivery = February 24th
Receiver
Purchased
Expected Delivery = February 24th
*only necessary for backup system
Overview
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17
RF SYSTEM COMPARISON
Req.
Req. Description
DT-15
DR-75
FMT-1
FSR-1
COM.3
TTL (3.3 V logic for direct
interface with Arduino Due)
RS-422
RS-422
TTL 3.3V
TTL 3.3V
COM.4
Data Rate > 32 kbps
10 Mbps 10 Mbps 115 kbps
115 kbps
EPS.2
Current Draw < 275 mA
600 mA
275 mA
130 mA
100mA
Previous Component
New Component

Other concerns related to the new radios
 Power connector
 DF-13 is provided
 RF output of 20mW
 Smaller form factor
 Virtual wire
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18
ADC CHANGE
Previous ADC
Voltage Description
Input
Minimum
Typical
Maximum
Our Design
Unit
AVDD
Analog Supply
4.5
5.0
5.5
5.0
V
BVDD
Buffer I/O Supply
2.7
3.0
5.5
3.3
V
HVDD
Input Positive Supply
5.0
10.0
16.5
9.0
V
HVSS
Input Negative Supply
-16.5
-10.0
-5.0
0.0
V
Analog signal input must remain between (HVSS + 0.3V) and (HVDD – 0.3V)
 HVSS requires negative voltage  requires a voltage inverter
 Added noise and complexity
Representative analog signal bounded by HVSS and HVDD
HVDD – 0.3 V

V
HVSS + 0.3 V
Time
Overview
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19
ANALOG DEVICES AD7606-6
Req.
Description
Satisfaction
COM.1
6 channels sampled at
500 Hz
6 channel simultaneous ADC
Maximum rate of 200 kSPS
COM.2
-2g to 2g data range
with .002g resolution
1.5 to 8.5 V signal input range = -5 to 5g data range
14 bit resolution = 0.0006g resolution
COM.3
Interface between ADC
and Arduino
Communicates over SPI
Uses 3.3 V logic
ONLY 1 input voltage required to power ADC 5 V 3.3 V Digital Logic
SPI
(MISO, SCLK, CS)
0.5 – 8.5 V
Analog Input
New ADC
(ANALOG AD7606-6)
Settings
(CONVST, REFSELECT,
RESET, PAR/SER SEL)
3.3 V (reference)
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20
C&DH BOARD
2.5”
Status



Overview
Schedule
Comm System
3.125”

PCB has been shipped
All components for the board
have been obtained
ADC test circuit (for the new ADC)
has been constructed
 Being tested simultaneously
with software validation
DataFlash test circuit completed
and validated
Power System
Mechanical
System
Budget
21
C&DH SOFTWARE
Status

Data collection software developed and currently in test
Testing


Unit testing performed on component interface functionality
 DataFlash for storage of data collection
 Write array of data to specified page in main memory through buffer
 Read specified page in memory and store in array
 MUX for temperature sensors
 Read analog value from selected channel (8 sensors)
 Convert value to temperature
 ADC for accelerometer sampling
 Erroneous values returned - currently eliminating possible short on board
Entire algorithm tested for execution flow and timing
Overview
Schedule
Comm System
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22
SOFTWARE TIMING
Collect Data
Driver

Science data sampled at 500Hz
Solution



0.2ms
Write to DataFlash
0.2 ms
Define Packet Headers
Computations of data collection
algorithm critical path must
execute within 2ms
Limiting factors
 84 MHz CPU clock
 DataFlash transfer speed
based on 66MHz clock
 Sampling the ADC and MUX
Algorithm has been developed
with timing determined to be
within time constraints
 CDR Prediction = 1.22 ms
 Actual = 1.6 ms
Overview
0 ms
Schedule
Sample ADC and
Store in Buffer
Sample MUX and
Store in Buffer
Calculate Checksum
12μs
27μs
1.4ms
13μs
125μs
Write Packets to Flash
Comm System
1.6 ms
Process Complete
0.4ms
Computational Margin
Power System
Mechanical
System
Budget
2 ms
23
POWER SYSTEM
POWER REQUIREMENTS
Critical Components
 Batteries
 Mass and Volume (Complexity)
 Power Regulation and Distribution
 Efficiency
Requirement Flows From
Description
EPS.1
MSN.3,
MSN.4
The power system shall output voltage lines at 5, 9, 20,
and 12 volts
EPS.2
MSN.5
The batteries shall supply power for 12 days of operations
EPS.3
MSN.1
Power Distribution board shall fit on 4x4 PCB
EPS.4
EPS.1,
EPS.2
The Power Distribution board must be >90% efficient
Overview
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25
POWER STATUS
Component
Order Status
Component Status
Power Distribution
Board
Ordered
Being shipped.
Expected delivery date = February 3rd
Battery Pack
Ordered and
delivered
In process of manufacturing battery pack
Power discharge test has been performed
Connectors
Overview
Ordered and
delivered
Schedule
In process of soldering and assembling
connectors
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26
CHANGES TO POWER DESIGN
New 9V
Switching
regulator
Related Req.
Reason For Change
EPS.1
(Voltage
Lines)
Initial battery test showed
New design handles wider
higher than expected voltage input voltage range
(~15 V > 13 V expected)
Additional MSN.4
PCB
(Data
connectors Transmission)
What changed
Output with some loads at
less than 9 V outside limit
for TX and RX
New targeted output of 9.5
V to handle small drops
Power board must handle
either TX/RX set
Added header connection
for RS422 for old TX/RX set
8 channel Hirose connector
for new TX/RX set
Overview
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27
POWER PCB
Initial revision of power
distribution board
 Sent off to
Advanced circuits
for construction
Switching
Regulator
4000 mil

TX/RX
Connections
4000 mil
Overview
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Budget
28

Most recent revision of
power distribution PCB
 Added mounting holes
 Board size larger to
accommodate mounting
holes
 Further changes may be
made after electrical
testing of current PCB
4150mil
POWER PCB
4350 mil
Overview
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Budget
29
MECHANICAL SYSTEM
MECHANICAL REQUIREMENTS
Requirement Flows From
Description
MCH.1
MSN.2
The internal structure shall integrate with the
manufactured GeoPod shell
MCH.2
MSN.2
The power and electrical subsystems shall be accessible
for extraction without the removal of other components
MCH.3
MSN.5
A thermal model shall be created to ensure subsystems are
within operating temperatures in the testing environment
MCH.4
MSN.7
All internal structural components shall be manufacturable
using on campus resources
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31
MASS BUDGET


27% Mass Margin
(17% at CDR)
Mass Removal


Overview
Schedule
Comm System
Power System
Decreased overall
form factor size
Transmitter/Receiver
weight decrease
Mechanical
System
Budget
32
STRUCTURE CHANGES
CDR
Current
Major Changes
Sphere Size
12 in
10 in
Epoxy
y
z
Battery pack
Plastic Harnesses
x
Size Comparison
z
x
Overview
y
Schedule
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33
MANUFACTURING OVERVIEW

Manufactured





Purchased


Overview
Schedule
Comm System
Top and bottom brace
plates
Brace plate clips
Vertical pylons
Electronic mounting plates
Battery harnesses
Hex standoffs
Power System
Mechanical
System
Budget
34
MANUFACTURING PROGRESS
Task Type
Item
Method
Completion
CNC/Knee Mill
100%
CNC
100%
Vertical pylons
Bandsaw/Knee Mill
30%
Electronic mounting plates
Bandsaw/Knee Mill
30%
Mount plates to sphere
Hand drill (match drill)
90%
Battery Pack
Tape/Velcro/Harnesses
50%
Battery harness
N/A
100%
Standoffs
N/A
50% (on order)
Fasteners
N/A
50% (on order)
Brace plate clip
Brace plate
Manufacture
Purchase
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35
BUDGET
PROCUREMENT STATUS
Financial Plan
Part
Cost
Breakout Boards and Prototyping
Arduino’s (Cables and Board)
$161
$132
Mechanical Supplies
$382
Batteries
PCBs
$230
$167
Electrical Components (Ics/Res/Caps/Cables)
$232
Transmitter and Receiver
Total
Budget
Current Budget
Overview
Schedule
Comm System
Power System
$1,831
$3,135
$5000
$1,865
Mechanical
System
Budget
37
COST PLAN
Financial Plan
Part
Cost
Contingency
Total
Arduino
$132
$20
$20
$111
$47
300%
300%
30%
30%
0%
$528
$80
$26
$144
$47
Batteries
$20
20%
$24
Attenuator
Testing Equipment
$115
$20
0%
30%
Total
Budget Left
Final
Margin
$115
$26
$990
$1,865
$875
18%
PCBs
IC’s
Resistor, Capacitors, Inductors, Diodes
Cables/Adapters
Overview
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38
ACKNOWLEDGMENTS
Customer – Ball Aerospace

Joseph Hackel
Course Coordinator

Dr. Dale Lawrence
Faculty Advisor

Dr. Scott Palo
Principal Investigator

Dr. Daniel Scheeres
39
QUESTIONS?
APPENDIX
RF SYSTEM LINK BUDGET
PARAMETER
Data Parameters
Bit Error Rate / Probablility of Bit Error
Data Rate
Minimum Pr/No
Range
Link Budget:
Transmitter Power
Effective Isotropic Radiated Power
Propagation Losses
Antenna Gain (Both Ends)
Received Power
System Noise Power
Carrier to Noise Ratio Density
Minimum Pr/No
Link Margin
DOWNLINK
(FROM PROBE) UNITS
(TLM & DATA)
Reference
10-6
[-]
32,000 bps (Hz)
57.75
dB-Hz
1
m
Input: design requirement
Input: based on mission / objective
Eb/No + Z + RDM in dB
Testing Range
20
mW
--27.08
dBW
-25.98
dB
-10.09
dB
-63.1
dBW
-200.47 dBW-Hz
137.76
dB-Hz
57.75
dB-Hz
79.60
dB
FMT-1 Output Power
Pt + Gt
Ll + Ls + La + Lpt + Lpr + Lp
Gr
EIRP + L + Gr
k Ts
Pr - kTs
42
RF SYSTEM SIZE
FMT-1 / FSR-1
DR-75
DT-15
*Relative sizes
Overview
Schedule
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Mechanical
System
Budget
43
NEW RF SYSTEM INTERFACE


4 lines being used during operation
 VDC Input, Ground (Power), TTL Data, Ground (Data)
 Behaves like a “virtual wire”
Reprogrammable carrier frequency and baud rate
 15 presets can be saved
 Requested custom presets for TIRESIAS project (in backup slides)
Overview
Schedule
Comm System
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Budget
44
RF SYSTEM PRESETS
Preset
Frequency (MHz)
Baud Rate (bps)
0
N/A (Programming)
N/A (Programming)
1
434.70
2400
2
434.70
4800
3
434.70
9600
4
434.70
19200
5
434.70
38400
6
434.70
57600
7
434.70
115200
8
437.35
2400
9
437.35
4800
10
437.35
9600
11
437.35
19200
12
437.35
38400
13
437.35
57600
14
437.35
115200
45
ANTENNA CHARACTERISTICS
Voltage Standing Wave Ratio (VSWR)




Ball antenna tuned to 437.5 MHz
Freq. (MHz)
2 transmission frequencies available
to TIRESIAS
GS Antenna
 Licensed (Palo):
437.35 MHz
437.50 (Ball)
 ISM Band:
434.79 MHz
437.35 (Palo)
437.35 (Palo)
 Acceptable VSWR
434.79 (ISM)
 VSWR could be acceptable
 Decreased performance likely
VSWR
Return Loss
(dB)
1.19
21.0
1.19
21.2
2.91
6.3
437.50 (Ball)
1.75
11.3
437.35 (Palo)
1.65
12.2
434.79 (ISM)
3.57
5.0
434.79 (ISM)
S/C Antenna
Operational: VSWR < 2
Maximum: VSWR < 20
Overview
Schedule
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46
BATTERY DISCHARGE RESULTS
Direct Sunlight
Heats Up Batteries
Conservative Capacity:
530 ± 20 Wh
Required Capacity:
248 Wh
BATTERY DISCHARGE SETUP
8 x 1.5
V AA
cells,
10-14 V
248.3 Ω
(2 x 100 Ω,
1 x 50 Ω)
Voltage
Probe
Point
DISCHARGE INTEGRATION
BATTERY DISCHARGE POWER