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MOXA - ZARM

1. nennen 56 4 6 1 Microcontroller Design Mainboard PCB 56 4 6 2 Sensor circuits 61 4 6 3 Power design 63 4 6 Temperature 64 4 6 5 Sensor Boards uo iurc nee 64 46 6 CONNGCIOIS naar 64 4 7 Thermal DESIGN tec tactics fs He UR URDU bel wes eb a Eus 66 4 8 Power Systlem r 69 4 8 1 Power dissipation 69 4 8 2 Power System Design 70 4 9 Software Design a 71 4 9 1 Experiment Software Design 71 4 9 2 Microcontroller Placement Considerations 72 4 9 3 Software Flow Diagram 72 4 9 4 Implementation of a Minimalistic Operating System MOS 72 4 9 5 Data Communication Implementation 73 4 9 6 Data Protocol Implementation 73 497 OHtrol Loop za un epson ean uic paco EM de acces 74 4 9 8 Ground Station Software Design
2. 110 RX16 MOXA SEDv5 0 Page 6 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden PREFACE This Documentation describes the experiment and configuration of the MOXA experiment for the Rexus 15 16 sound rocket The idea followed the development of new sensors at the Institute for Aerospace Engineering Dresden University of Technology lead by Dr Tino Schmiel We want to thank the institute for all the support given to us and the DLR Esrange for this unique opportunity File Naming The naming convention for the SED is as follows e BX for BEXUS or RX for REXUS plus number of flight e MOXA for Measurement of Ozone and Oxygen in the Atmosphere e FIPEX Flux Phi Probe Experiments e SED plus version e g 3 for CDR and issue number beginning with 0 and increasing number when a new issue is sent e Date of issue in format ddmmyy Page 7 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden ABSTRACT The models of the distribution of residual gases varies widely For instance the atomic oxygen models results differ up to 400 To predict climate it is important to know the distribution of Oxygen in its various forms For instance atomic oxygen is a major influence on space borne objects resulting in degradation of exposed materials Therefore the MOXA experiment will measure ozone atomic
3. ST LrET PT EZZT 8z 800T tt ST6 oT TES E9 YSL 89 10 229 62 795 BL ZIS gs s9r TL Cty 6L EBE 9t Bre 9TE 2 187 08 092 6L IEZ 86 PTZ 6T S6T IZLET 06 OST 60 9 po ZET Et OzT ve 60 L 66 06 g8 T8 OE b 9p 9 Sz T9 T9 SS 6 05 v8 st z9 Ir BL LE TEPE ST TE Zeichnungsfl che input amp f 1 nach Random input amp f O vor Random Vibration Test Report Team MOXA Seite 22 27 REXUS 15 16 Team MOXA 16 01 14 Z Axis After the conversion of the shaker for the tests in direction of the Z axis eigen frequency test runs were conducted Due to the fact the first test runs couldn t be executed over the hole frequency spectrum section 8 1 the strain was changed from 0 25 to 0 50 still also in this case the test was conducted from 5 to 2000 Hz The following eigen frequencies were found Time Eigen frequency Eigen frequency Before After 00 00 02 Start at 5 00 Hz Start at 5 00 Hz 00 02 35 223 32 Hz 231 98 Hz 00 03 09 314 53 Hz 331 54 Hz 00 03 56 1156 97 Hz 00 04 00 1198 33 Hz 00 04 02 1278 04 Hz 00 04 03 1304 49 Hz 00 04 06 1483 79 Hz 00 04 14 1753 19 Hz 00 04 15 1886 28 Hz During comparison of the eigen frequency curves before and after the randomtest we noticed that the graves are similar but they are shifts in the values of the eigen frequencies
4. nn v9 tgv B LE SE 96E T8 BSE Z PZE S0 r6z 02 992 86 0rZ ST BIZ 6b 6T BLBLAT STIT es ovT ta zer 20 021 04 801 0t 86 80 68 vo9 og 00 60 99 8 6S OTS 0 6v 6 vt 8l 0t 8 9 6 2 8 62 66 92 v vc eVec 20 02 erst Test Sg vT St ET Let ZO TT 86 6 0 6 sts o s 0 9 0 9 6v S5 zHhun x a d o D 4 x o c a lt D z Vor Random x Achse 08 01 14 Diagrammbereich 35 Vibration Test Report Team MOXA Seite 20 27 REXUS 15 16 Team MOXA Y Axis 16 01 14 The search of the eigen frequency using 0 25g in the range of 5 2000 Hz in direction of the y axis leads to the following results Time Eigen frequency Eigen frequency before Random after Random 00 00 02 Start at 5 00 Hz Start at 5 00 Hz 00 03 16 414 14 Hz 414 14 Hz 00 03 21 435 17 Hz 435 27Hz 00 03 24 471 06 Hz 469 69 Hz 00 03 29 538 95 Hz 540 53 Hz 00 03 33 605 90 Hz 609 45 Hz 00 03 36 629 39 Hz 627 55 Hz 00 03 48 843 41 Hz 850 85 Hz 00 04 02 1146 86 Hz 00 04 04 1230 32 Hz 00 04 07 1312 15 Hz Also in this case the eigen frequency is quite high The comparison of the eigen frequency shows good match with the eigen frequencies gained under strain Vibration Test Report Team MOXA Seite 21 27 REXUS 15 16 Team MOXA 16 01 14 ZS 7B6T 86 6641 9z vE9T 6
5. traumexperiment E MW BLICK Nr 25 Ej TU Nachwuchsforscher erhebt Autobahn Maut in Transportsystemen Energiewende braucht Fahrplan mit klaren Zielen TERMINE A 55 17 01 2013 16 30 19 00 Branchentreff Informations amp Kommunikationstechnologie KONTAKT Dekan Prof Dr Ing habil Stelzer B ro des Dekans Ina Winkler Tel 49 351 463 32786 Fax 49 351 463 37735 Web tu dresden de mw m E Mail Kontakt Page 107 EuroLrunch Students Experiment Document MOXA Experiment RX 16 TU Dresden APPENDIX C ADDITIONAL TECHNICAL INFORMATION see PDF SED 2 2 APPENDIX C Page 108 EuroLrunch Students Experiment Document MOXA Experiment RX16 TU Dresden APPENDIX D REQUEST FOR WAIVERS Page 109 EuroLrunch Students Experiment Document MOXA Experiment RX16 TU Dresden APPENDIX E VIBRATION TEST REXUS 15 16 Team MOXA 16 01 14 REXUS MOXA Vibration Test Report Vibration Test Report Team MOXA Seite 1 27 REXUS 15 16 Team MOXA 16 01 14 Table of contens 1 A DTIC C M 3 LT Introduction cos etaed e ca pep basate opes erie rad cU EU Lp p TD Me 3 1 2 Aim Of a a E EES eS 3 ne tnn asum dace vat niet eons tut choca PO 4 2 1 Important points for the execution of the tests and strain levels
6. 4 2 2 Data sheets of fhe Fest equipment sedo suyana OR Eel hd ti e en MORSU 4 Test Or gam sa 0n sn a E EN 5 3 1 Cooperalors use 5 3 2 Ambience sinc S py cn Susa Sas 5 NSS EI SC cing isis ata ng a QS ate E aQ Ao a um clog Se sce ace a 6 Test Configuration ausser 9 5 Test CU PMERE 9 52 Adapter Ol VIDPILDL C e adalah tut eibi uu CMM ARD Scr 9 S 3 Test ROCESS ers cc cece a a E vam ak kaka SPS h Oa 10 5 4 Visualcontrol RR ee 10 3 9 Test reg irement kan dei ee 11 Test structure and sensor COMMBUTALION usage 12 6 1 Test str cutre on The shaker aaa 12 6 2 Monitoring of the incoming power flux enne 14 6 3 Sensors Positions Channeloccupation and Fixing 14 O apd etc Jg ks eee ene sa CD rc 17 6 4 1 Eigen frequencies searching poU ote 17 6 4 2 RandomstEdlif sec eoo a ED Te i ATO ER MI ann V sd da acme 17 FRCS d nomea T ta 18 E EP CC S Ime Bienen 18 oq M tea get act ace Fe een ep M m M 20 M 22 Evaluation on the test measurement and discussion eese ener 24 8 1 Z Axis Finding the eigen frequency using 0 28 4 24 8 2 Comparison of eigen frequencies une 24
7. presentation clarified several items o Additional team members should stand with the team not sit at the table o Some subjects were treated in too much detail some other like electronics haven t been covered enough o Graph showing the timeline of flight is very good SED Some information is hard to find not located in the standard places Use wording Exploded view not Explosion view Write CoG LoS etc lowercase o Document is not to be approved by Payload manager should be approved by professor etc Document ID does not follow the naming convention o 0 0 6 4 Panel Comments and Recommendations Requirements and constraints SED chapter 2 o F 2 F 3 word during is missing o Performance requirements are good Formatiert Deutsch Formatiert Deutsch Deutschland Deutschland Deutsch Deutschland o Design requirements have to be extended power usage weight data rate o Shortest design requirements list among all CDR SEDs Mechanics SED chapier 4 2 1 amp 4 4 Considerable progress since the last review Mechanical interface information should be collected in one place in the SED Hatch solution will still require improvement Consider using a linear actuator that would also allow closing of the hatch Solenoids may cause EMC problems has been considered by the team Consider
8. _ O 9 2 o0 2 d 0d o 2 9 N i II m N ee fw 133 Ww 8 3 1 3 w aay EEE 2 r s o 3 3 3 Eg 2 4 LS o o ss I s 4 Es 3 Es 43 E 3 Es 3 Es 3 Es 43 DS S l 48 N l 48 48 48 7 l 48 48 _ 4 r l _ l _ l C N 4 fig 8 Manpower 1 EuRoOLAUNCH ADLR and SSC cooperation Page 25 Students Experiment Document MOXA Experiment RX16 TU Dresden fig 9 Manpower 2 gt N elelelele gt elele 2 TS TS JS JS TS TS TS TS TS TS FO JO gt gt Bete my el AR S AR my Page 26 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Daniel___ susann__ Nathanael p Zee lexs le E www dw fw oo Too dw oo Foo foo oo Jw Jw Too foo Jw Jw Jw foo foo lu oo B ro f ro f ro Prof rof ajs fig 10 Manpower 3 Page 27 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Budget 3 3 2 The fabrication of the mechanic will
9. EUROLAUNCH A DLR and SSC cooperation SED Student Experiment Documentation Document ID 16 SEDv5 0 29 10 2014 Mission REXUS16 Team Name MOXA Experiment Title Measurement of Ozone and Oxygen in the Atmosphere Team Student Team Leader Team Members Issued by Approved by Name Alexander Mager Bastian Klose Patrick Geigengack Alexander Schultze Jonas Uhlmann Daniel Becker Fabienne Kinzelmann Susann Knapik Nathanael Warth Max Oswald Sebastian Weixler Team MOXA Alexander Mager Max Oswald Bastian Klose University TU Dresden TU Dresden TU Dresden TU Dresden TU Dresden TU Dresden TU Dresden TU Dresden TU Dresden TU Dresden TU Dresden RX16_MOXA_SEDv5 0 Change Record Version Date Changed chapters Remarks 0 2008 12 18 New Version Blank Book 2010 1 2013 02 28 All PDR 2 0 2013 06 06 2 2 Perform Req New pressure accuracy 1 4 2 3 1 3 3 New temperature range 4 2 8 5 1 5 2 6 1 1 6 3 6 4 CDR Appendix A B C 2 1 2013 06 17 3 3 3 5 4 1 4 8 4 9 10 2 2 2013 08 08 1 5 2 2 2 4 3 4 5 6 1 8 Version to pass CDR Changes resulting of CDR 3 0 2014 01 15 4 4 4 6 4 7 5 6 1 IPR 4 0 2014 03 14 1 5 3 5 4 3 1 4 4 4 7 5 1 Pre Campaign 5 3 6 7 1 4 1 2014 03 28 5 2014 10 29 All chapters Final report Abstract REXUS or BEXUS SED Student Experiment Documentation MOXA Measurement
10. 5 3 Opehing ot the a u prp ptr O ee phia esa ee DURER 25 jp rc AT 26 Vibration Test Report Team MOXA Seite 2 27 REXUS 15 16 Team MOXA 16 01 14 Outline Introduction This test report involves guidelines organisation execution and analysis to qualificate the REXUS MOXA experiment The vibration test was executed at the institution for light construction and plastics engeneering of the technical university of Dresden Test objective The aim of the vibration test is the safety case and the functional demonstration of the installation of the module and of the experimental set up in direction of the X Y Z axis with given vibration stain from the current REXUS User Manual Furthermore multiple tests with different experimental set ups were executed on the sensitive Pirani sensor Following tests were executed e Sinus eigen frequency search before Random conducted on each axis e Random strain test conducted on each axis e Sinus eigen frequency search after Random conducted in each axis e Figen frequency search with differently damped Pirani Sensors e Random tests in Z direction with instantly applied full load as flight simulation e Function tests of the mechanics Vibration Test Report Team MOXA Seite 3 27 REXUS 15 16 Team MOXA 16 01 14 Documents Important points for the execution of the tests and strain levels e Aktuelles REXUS User Manual Document ID RX_UserManual_v7 11_08Jan14 doc Data sheets of
11. 17 18 12V Supply Low Current 19 12V 20 12V 12V Supply Low Current 12V_BAT 24 12V_BAT 12 Volt from Battery Hih Current 29 RX_CHARGE 30 RX_CHARGE 28V connection TE Voltage between RX battery interface and battery charger 31 RX28V 32 GND_RX RX Interface to High Voltage Powerboard 33 RX28V 34 GND RX Interface to High Voltage Powerboard Page 60 EuroLaunch A DLR and SSC coopera Students Experiment Document MOXA Experiment RX16 TU Dresden Table 4 8 Power BUS pin configuration i Signal Signal2 used for Type GND GND I2C1 SDA I2C1 SDA of the Digital mainboards 1 or 2 I2C2 CLK CLK of the Digital mainboards 1 or 2 I2C2 SDA REX_SENS Current Sense 3 7V Analog Battery Connection BAT_HEATING Current Sense Analog a CEN Command _BAT_SENS 5V P Low Current 12V Supply Low Current 12V 12V Supply Low Current 24V Supply Low Current 12 Volt from Battery High Current 12 Volt from Rexus High Current 12V 12V BAT 12V RX 12V BAT 12V RX 58 EEE aE REE 28V connection High Voltage between RX battery interface and battery charger RX28V GND_RX RX_Interface to High Voltage Powerboard GND_RX RX Interface to High Voltage Powerboard Page 61 EuroLAuncH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Measure Bus This bus exists twice One between Mainboard A and Sensor board A the other between Mai
12. P 10 The pressure measurement shall be made between 10 bar and 1 5 bar Page 17 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden P 11 The pressure measurement shall be made with an accuracy of 8 P 11 The pressure measurement from 20 mbar to 3 bar shall be made with an accuracy of 1 5 P 12 The pressure measurement shall be made with an rate of 100 measurement per second P 13 The temperature measurement shall be made between 100 C and 100 C P 13 The temperature measurement shall be possible between 100 C and 200 C P 14 The temperature measurement shall be made with an accuracy of 1 C P 15 The temperature measurement shall be made with an rate of 100 measurement every second P 16 The pressure measurement from 0 001 to 20 mbar shall be made with an accuracy of 10 P 17 The experiment shall save and process the data at a rate of 10 Hz P 18 The experiment control loop shall process at 50 Hz 2 3 Design Requirements D 1 The experiment shall be designed to operate in the vibration profile of the RX rocket D 2 The experiment shall be designed in such a way that it shall not disturb and harm the RX rocket or other experiments D 3 The experiment batteries shall be qualified the rocket flights D 4 The experiment batteries shall be rechargeable to run the experiment during pre flight test flight preparation and flig
13. The experiment shall measure molecular oxygen on the outer shape of the RX during rocket the flight with two different electronic circuits F 4 The experiment shall measure pressure on the outer shape of the RX during rocket the flight with two different electronic circuits F 5 The experiment shall measure temperature on the outer shape of the RX during rocket the flight with two different electronic circuits 2 2 Performance requirements P 1 The ozone measurement partial pressure shall be made between 10 bar and 1 bar P 2 The ozone measurement partial pressure shall be made with an accuracy of 2 between an attitude of 30 to 90 km P 3 The ozone measurement partial pressure shall be made with an rate of 100 measurements per second P 4 The atomic oxygen measurement partial pressure shall be made Between 10 bar and 1 bar P 5 The atomic oxygen measurement partial pressure shall be made with an accuracy of 1 between an attitude of 30 to 90 km P 6 The atomic oxygen measurement partial pressure shall be made with an rate of 100 measurements per second P 7 The molecular oxygen measurement partial pressure shall be made between 10 bar and 1 bar P 8 The molecular oxygen measurement partial pressure shall be made with an accuracy of 196 between an attitude of 30 to 90 km P 9 The molecular oxygen measurement partial pressure shall be made with an rate of 100 measurements per second
14. and limit it o Note that REXUS is not flying to outer space o Include an atmospheric physicist in your team as discussed during selection o p 21 If most students stop by September this year find additional team members 5 Internal Panel Discussion PDR Result PDR passed Next SED version due o Version 2 two weeks before CDR BEXUS Experiment Critical Design Review Flight REXUS 15 16 Payload Manager Alexander Schmidt or Mikael Inga Experiment MOXA Location DLR Oberpfaffenhofen Date 26th June 2013 1 Review Board members Mikael Inga SSC Science Services Martin Siegl min DLR Institute of Space Systems Alexander Schmidt DLR MORABA Alex Kinnaird ESA Policies Dept Education and Knowledge Management Office Natacha Callens ESA Policies Dept Education and Knowledge Management Office Koen Debeule ESA Technical Directorate Mechanical Engineering Dept Test Centre Div Andreas Stamminger DLR MORABA Markus Pinzer DLR MORABA Frank Hassenpflug DLR MORABA Maria Roth DLR Space Administration Mark Fittock chair DLR Institute of Space Systems 2 Experiment Team members Alexander Mager TL Bastian Klose Daniel Becker Susann Knapik A Patrick Geigengack Alexander Schultze Formatiert Englisch USA Formatiert Deutsch Deutschland Formatiert 3 General Comments Presentation o
15. and molecular oxygen temperature and pressure during the flight The Institute for Aerospace Engineering at Dresden University of Technology has developed innovative sensors for oxygen and ozone with a very low response time and high measurement accuracy The atomic oxygen sensors of the experiment FIPEX have already performed successful measurements onboard the International Space Station and will be integrated in the experiment in a new miniaturized form The newly developed ozone sensor will be tested by comparing the measured data during the flight in dependence of the pressure with existing data In addition the data of the oxygen measurements give a hint on the ozone values and will help to verify functionality of the ozone sensor The development of accurate sensors for residual gases contributes to the survey of the atmosphere to correlate existing atmospheric models So it is possible to make precise prediction of residual gases This will support atmospheric science and improve the preparation of planned long term missions in the LEO The sensors are also applied in many other sections for example breathing gas analysis Page 8 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 1 INTRODUCTION 1 1 Scientific Technical Background Scientific background Earth is breathing The Atmosphere of earth is a dynamic and complex system which changes permanent and de
16. at launch site precise temperature and pressure data to correlate our measurements with atmosphere models Page 76 EurRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 5 EXPERIMENT VERIFICATION AND TESTING 5 1 Verification Matrix Table 5 1 Verification table ID Requirement text Verification Status The experiment shall measure ozone on the outer T R shape of the RX rocket during the flight with two orc different electronic boards The experiment shall measure atomic oxygen on T R i the outer shape of the RX rocket the whole flight m with two different electronic boards The experiment shall measure molecular oxygen T R on the outer shape of the RX rocket the whole a flight with two different electronic boards The experiment shall measure pressure on the T R done outer shape of the RX rocket the whole flight with two different electronic boards The experiment shall measure temperature on the T R outer shape of the RX rocket the whole flight with one two different electronic boards The ozone measurement partial pressure shall be R 4 possible between 10 bar 1bar The ozone measurement partial pressure shall be made with accuracy of 2 between an attitude FE of 30 to 90km The ozone measurement partial pressure shall be T R done made with an rate of 100 measurements every second The atomic oxygen measurement part
17. of our module is given Vibration Test Report Team MOXA Seite 25 27 REXUS 15 16 Team MOXA 16 01 14 Opening of the Hatch The independent opening of the Hatch during the Randomtest illustrates the problem which is multiple appeared For this the interlocking system was optimized between the tests We can conclude that this leads to an extension of the time which it takes to until it opens by itself This does not lead to a solution of the problem If the Hatch is opened to early the sensors can get contaminated or damaged due to particle from the rocket or air turoulences The Randomtest was executed without a power enhancement but with maximal vibration power of 0 018 g Hz and with duration of 30 seconds to analyze the behavior of the module during the flight The tests show that the hatchway opens itself around 3 5 seconds after start But the rotation of the rocket knits against this effect The centrifugal force which results of this effect knits in the same axis like the bolt of the electromagnet of the closing device Due to differences in storage life no defined vibration profile was found and therefore also the turn on behavior of each motor is different The position of the MOXA experiment on the rocket also decreases the impact of a to early opened hatch Only the experiment of the team HORACE is positioned along the axis of height above the MOXA module Furthermore no additional experiments are conducted by the team HORACE outside of
18. sensors Page 52 EurRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 4 5 Pressure sensors To measure the pressure we use the following sensors in the named subassemblies more information in the datasheets Hatch sensor box VSP63 Internal sensor box Keller 21Y The VSP63 sensor will not be mounted directly where the measurement is taken because of space problems We use a flexible tube to connect the sensor with the position of measurement To mount the flexible tube at the hatch and at the sensor we will be using hose band clips over a screwable adapter The flexible tube will have an inner diameter of 9 mm The sensors themselves have suitable connectors The VSP63 pressure sensor will be fixed as shown below pressure sensor VSP63 rubber mat fixation clip mounting plate vibration dampers fig 33 sensor fixation Page 53 y amp EuroLruncH DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden The sensor will be fixed by a clip which will be screwed down A rubber mat will be placed between the sensor and the clip to prevent damage to the sensor The clip will be held by two screws which connect the clip with the mounting plate The plate will be mounted on three vibration dampers These will decouple the sensor from vibrations The dampers will be installed on top of the spacers to creat
19. the airstream that will be 120 C outer shape of the rocket measured on RX 11 Therefore the hatch has to guarantee functionality between 20 and 120 C During reentry the hatch is open hot gases hitting the parts which are looking in the airstream At this state of the flight we don t want to measure anymore and we don t care if a sensor breaks But hot gases must not come in the module itself For that every way into the module is secured by heat resistant components Therefore the hatch has to guarantee leak tightness from 20 to 200 C Because the hatch is the only assembly group with moving parts there is a dilatation calculation in appendix C Table 4 11 temperature profiles of components of hatch Part Temperature in C In house production AlMgSi1 melt at 585 operating at 25 to 55 protected by hatch during hot flight phase Solenoid Operating temperature up to 300 Gas sensors Work on up to 500 i 12 Pressure tube Operating up 5 1209 Operating temperature 40 to 120 springs Medium thermal expansion coefficient at 200 C is shane 12 5x10 m K slide bush Operating temperature 100 up to 250 Sealing compound Operating up to 300 Page 67 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Temperature of the inner chamber The inner chamber has a very small inlet 2 54mm hole but the air could stre
20. up before the TO Therefore the highest power dissipation will occur before the launch if all the sensors get heated up at once 6x 5 Watts A lower power dissipation is expected during the first flight phase 0 30km and the lowest at around the top 6x1 Watts The maximum power dissipation during low pressure atmosphere will be estimated around 31 Watts in total by using battery supply and around 37 Watts by using the REXUS power interface Table 4 16 Overview Dissipation Power Total Voltage Current Dissipation Count Dissipation uController 3 300 V 29 mA 95 mW 2 190 mW uC peripherie 3 300 V 10 mA 33 mW 2 66 mW Fipex sensor heat 7 000 V 673 mA 4711 mW 6 28266 mW Shunt 0 020 V 673 mA 13 mW 6 81 mW MOSFET 0 020 V 673 mA 80 mW 6 480 mW Measurement Peripherie current side 12 000 V 10 mA 120 mw 6 720 mW Measurement Peripherie voltage side 12 000 V 10 mA 120 mw 6 720 mW Pressure sensore 12 000 V 20 mA 240 mW 1 240 mW Temp sensor 12 000 V 20 mA 240 mW 1 240 mW DC DC Loss 6000 mW Total Dissipation 37082 mW To avoid excessive power usage two possible designs can be implemented The alternative switched heating might be implemented but can only be used before the actual measurement The second design includes batteries to lower the power withdrawal of the REXUS I F 4 8 2 Power System Design High current batteries will be used to provide additional energy A space certified Li lon battery
21. will be used For safety it will be placed in a separated compartment inside of the boardbox Assuming an average consumption of 20 Watts and a safety factor of 2 the required battery capacitance results to W Q U W 20W h Q tt gygy min 2 2 133 mAh Page 71 EuRoOLAUNCH A DLR and SSC cooperatio Students Experiment Document MOXA Experiment RX16 TU Dresden The battery charging and handling will be implemented using an MAX8814 charging IC The Charging line of the RX Interface will be used 4 9 Software Design 4 9 1 Experiment Software Design Each experiment will have their own Microcontroller and data system to create independence The Experiments are controlled manually before LO and by Timeline after LO According manual command for the Sensors Heating can be sent by the ground station Automatic flight events like Measurements Data Acquiry Shutdown are controlled by an timeline The opening of the hatch is controlled by MORABA In case of any reset the LO Signal will be analysed first and with LO present the measurements and data acquiry will immediately start The timing will be synchronized to the LO signal and data capture and acquiry will be performed The timeline corresponds directly with Table 4 1 Table 4 17 Software Timeline 900 Height Heating Measurement Hatch Shutdown Manual Events PowerON Heating Power OFF Software State IDLE HEATING O FLIGH
22. with 2 x EN ISO 2010 2x6 The cover will move between the light beam of the sensor when it is opened so we get a feedback of the position of the hatch Page 48 EurRoLAUN A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden open state closed state fig 27 open and closed hatch Page 49 EurRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 4 4 Inner chamber fig 28 inner chamber The principal task of the inner chamber is to offset air of the fluid flow streaming on the rocket This requires that the inlet geometry wont heat up too much the inlet should not disturb the aerodynamic of the rocket and the gas exchange should be very fast without stressing the gas sensors to much A N X e nicht gebrochene Kante x o N Do 1 A 10 A A fig 29 ramp Because the ramp is very flat the fluid flow has little contact points for friction so the ramp wont heat up so much Also because the ramp is so flat it has little contact area for the fluid flow to disturb it Page 50 f EuroLAuNcH A DLR and SSC coope Students Experiment Document MOXA Experiment RX16 TU Dresden oblique compression shock fig 30 compression shock The break for the fluid flow caused by the ramp leads to an oblique compression shock Across this shock the pressure temperature and air
23. 1 Mechanical Inner chamber Ramp Battery Absolute pressure sensor Fly your message to space box Electronic box Pirani pressure sensor Hatch fig 15 Top view of experimental module The bulkhead is mounted with 11x EN ISO 4762 M5x12 e The hatch will be mounted with 4x EN ISO 7046 1 M5 screws from outside e The inner chamber is split into parts inside and the ramp outside The ramp will be mounted on the outer shape of the module with 4xDIN965 M4 counter sunk screws The inside parts mounted together with screws will be attached with the adhesive OMEGA Bond 300 which provides an safety of 272 Additional it will be mounted with one M4 counter sunk screw e There will be a thread in a drill hole at the inner chamber to mount the piezo pressure sensor e The Pirani sensor will be mounted with a screwed clip on top of an aluminium plate which is connected to the bulkhead via tree screws three vibration Page 38 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden dampers and tree spacers There are several configurations for the rubber dampers A final setting was chosen after the vibration tests e The electronic box will be mounted with 6xDIN 912 M4 screws on the bulkhead e The fly your message to space box will be mounted with 2x DIN 912 M3 screws on the bulkhead e The battery will be pinched with two plates that will be fixed with two M3 nuts on
24. 10022 3 r 3iuon 3 21004323 3 z 3iuon 3 1 132 a 1 quinN Page 28 EuROLAUNCH A DLR and SSC cooperatio Students Experiment Document MOXA Experiment RX16 TU Dresden 3 3 3 External Support Dresden University of Technology Institute of Aerospace Engineering Space Systems Prof Dr Martin Tajmar o Dr Tino Schmiel Head of research group of the sensor development AO 02 03 o Dr Christian Meyer responsible for the ozone sensor Chair of Fluid Dynamics o Dr Frank R diger Shallow water analogy 3 4 Outreach Approach 3 4 1 Social Media MOA 00 MOXA Team Dresden Atmosphere Measurements on a REXUS Rocket ft d Raumfahrt Verteidigung This page is all about the students MOXA Team for the REXUS 15 16 rocket project in Dresden Our goal is the measurement of ozone and oxygen in the atmosphere on a REXUS rocket flying up to 90 km Info fig 11 Facebook site In January 2013 we launched a Facebook page to inform industry insiders journalists classmates and friends about our project s progress and other news www facebook com REXUS MOXA Page 29 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 3 4 2 Website HOME TEAM ABOUT REXUS BEXUS MEDIA SPONSORS Home Overview of our Experiment Overview of our Experiment The models of the distribution of residual gases in the atmosphere vary widely for instance the at
25. 2000 Hz is to increase the strain level Alternatively we wouldn t gain any information in the frequency range of 1500 to 2000 Hz The fact that all axis had been investigated in the range of 5 to 2000 Hz and no problems for the other measurements were found the decision was made to increase the strain level to 0 5 gramm Comparison of eigen frequencies Due to the fact that the shifts of the eigen frequency of the X and Y axis had been very small it can be assumed that no measurement errors concerning the stiffness occurred The visual control and the check during demounting showed no measurement errors The visual control after the test of the z axis measurement showed no signs of stability problems The only thing which was suspicious was a rattling noise occurring during the last tests During the following demounting we noticed that the screws of the cap of the electronic box became loose and these screws are responsible for the irregular noise and for the displacement of the graphs But this isn t a problem for the experiment because all screws are secured before the final mounting with screw locking Furthermore the screws of the electronic box were already strained by many tests in X and Y direction before and due to this fact loosening occurred An unwanted loosening of the screw connection during the flight can be excluded if the mounting with done properly and screw locking is used Therefore the necessary safety concerning the stability
26. 74 4 10 Ground Support Equipment 75 5 EXPERIMENT VERIFICATION AND TESTING 76 5 1 MenfiGatlor Matix nina ink 76 SIME Mi pH 79 5 3 Mibration ob Ea Db c ebat 81 5 4 Thermal e or Ete rer ERR SSS ER E 82 5b Test POS US uA et detta LEMMA st 82 5 5 1 T5 Software Tests nur 82 5S2 TANibfation Toskana 82 6 LAUNCH CAMPAIGN 83 6 1 Input for the Campaign Flight Requirement Plans 83 6 1 1 Dimensions and mass 83 RX16 MOXA SEDv5 0 p 12 Safety SKS ct iet a nad NU ups MU 83 6 1 3 Electrical interfaces 85 6 1 4 Launch Site Requirements 85 6 2 Preparation and Test Activities at Esrange 86 6 3 Timeline for countdown and llight 87 6 4 Post Flight Activities sesesssseseeeeeeeeeneennnnnnn 87 6 4 1 After Recovery 87 6 4 2 After launch campaign 87
27. A 16 01 14 jus 4 SY NN Wy 77 RN ZN Lu Channels 5 6 7 Picture 8 Sensor arrangement X Axis Cable feedthrough Channels 2 3 4 C5 The 3 Axis sensor is arranged in the box Vibration Test Report Team MOXA Seite 16 27 REXUS 15 16 Team MOXA 16 01 14 Picture 9 Sensor arrangement referencesen or Channel 1 Referencesensor in Vibration Test Report Team MOXA Seite 17 27 REXUS 15 16 Team MOXA Testlevels 16 01 14 The test procedure and the test levels were set and defined on the bases of intense discussions and consultations with Mr Dieter Bischoff ZARM Bremen prior to the execution of the experiments Eigenfrequencies searching Sinus Eigenfrequencies searching Axis Frequency spectrum Input level X Y 5 2000 Hz 0 259 2 5 2000 Hz 0 59 Sweep Rate 2 Oct min Randomstrain Random Axis Frequency spectrum Input Level All Axis 20 2000 Hz 6 34gRMS 0 0189 Hz Duration 10s 10s 10s 60s Input 25 50 75 100 Vibration Test Report Team MOXA Seite 18 27 REXUS 15 16 Team MOXA 16 01 14 Results In the following subsection the eigen frequencies of the respective axis are given Concerning the structural investigations only eigen frequencies lower than 1000 Hz are of interest The data of measurements conducted under higher frequencies would not be very precise due to smaller amplitudes Because of this fact the software finds e
28. M model predicts a higher density for the beginning and end of the year and the in NRLMSISE model are no significant variations visible The values differ a lot from day to day Page 10 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 7 00E 12 6 50E 12 6 00E 12 5 50E 12 5 00E 12 4 50E 12 NRLMSISE 4 00E 12 DTM 3 50E 12 MET 3 00E 12 2 50E 12 2 00E 12 fig 2 Prediction of atomic oxygen In the prediction of atomic oxygen every model shows a clear influence of the seasons This comparison shows that these models are insufficient for a clear prediction It is necessary to take time resolved measurements of the densities of the gases in the atmosphere That is a reason why these sensors have been developed The aim is to correlate one model or prospect up to now unknown influences and create a new model for calculating a precise prediction Page 11 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden The sensors First time resolved measurements of atomic and molecular oxygen were taken by the Flux Q Phi Probe Experiments FIPEX It operated 572 days on European Technology Exposure Facility EUTEF on the International Space Station ISS fulfilled its primary objectives and collected complete reasonable data iit fig 3 FIPEX These AO and O2 sensors and in addition the new ozone
29. Reynolds numbers by the Experiment of Spalart Direct simulation of a turbulent boundary layer up to RO 1410 from 1998 The calculations of the issues occur with the Shear Stress Transport Modell SST and most likely with the Reynolds Stress model RSM Here the SST Model requires much less computation time as the RSM and combines the advantage of the k w model near the module boundary with the advantage of the k w model for the free surface boundary The RSM owns higher model accuracy but with the disadvantage of higher effort and no guarantee of more precise results The outcome of the SST Model is acceptable so the RSM is not really necessary Page 56 EurRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 6 Electronics Design 4 6 1 Microcontroller Design Mainboard PCB To handle measuring and data handling for each sensor control board one ARM7 microcontroller of the type STM32F103RB will be used A customized PCB with supplementary ADC DAC SD Card and USART level converters with be used sensor U ref D A Rexus Controller Measurement Data Interface measure data output Sensor Microcontroller _RS 232 Module testing programming JTAG SD Card Interface fig 37 Simple schema of our microcontroller architecture For better understanding all modules are explained in this chapter Very important modules are listed with a connection table for
30. T FLIGHT FLIGHT STOP Table 4 18 List of Implemented States Moxa Experiment State FLIGHT STATES Description 0 SETUP X Used at Controller Startup 1 IDLE X No Action is taken 2 HEATING ONLY X Heating is Active PreLaunch 7 TESTPINS All Output Pins will blinks Page 72 EurRoLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 9 2 Microcontroller Placement Considerations Two autonomous measurement environments Supplemental data transmission 1 s from 1 out of 2 measurement devices Rocket Bus SIDE clea Sensors 1 3 1 M3 digital fig 43 Microcontroller Placement Considerations 4 9 3 Software Flow Diagram SOE T 900s Open Latch Heating amp Measure ment fig 44 Software Flow Diagram 4 9 4 Implementation of a Minimalistic Operating System MOS Minimalistic Operating System with continuous scheduler and basic task overview The different flight states are represented in the microcontroller using a state machine to perform the according tasks The following figure shows the basic flow of the onboard microcontroller software The control loop and the scheduler housekeeping tick rate confirm to real time operation as described in the requirements 10Hz by using interrupts Other components are driven with the lowest achievable latency Page 73 EuroLrauncH A DLR and SSC cooper Students Exp
31. These values are within the range of 5 and details are shown in section 8 2 Vibration Test Report Team MOXA Seite 23 27 REXUS 15 16 Team MOXA 16 01 14 00 8r6T gv E941 Et 96ST TZ StrT ZE SOET 6 2 0 9 046 69848 9t 564 024 68 159 PT 06S vC PES po esr SE 96E T8 8SE 73 pz S0 r6z 02 992 86 0tz ST BIZ 6t 61 8L 841 SB TOT ZS 9PT 9 zer 20 021 0 801 Ot 86 80 68 v9 og 00 60 99 8 6S OT bS 0 6 8 9 E6 CE 18 672 66 92 Ev vc cT ec 0 02 erst Test Sg vT St ET VT ZO TT 86 6 0 6 Ot 04 9 0 9 6v S zu iun x input amp f O nach Random input amp f 1 vorRandom Vibration Test Report Team MOXA Seite 24 27 REXUS 15 16 Team MOXA 16 01 14 Evaluation on the test measurements and discussion Z Axis Finding the eigen frequency using 0 25g As mentioned in Section 7 3 during the test measurement which should determine the eigen frequency in the direction of the Z axis a measurement error occurred The shaker did start the search for the eigen frequency but stopped the measurement to early at 1500 Hz After an intense searching for errors and multiple restarts of the measurement using different measurement parameters it was obvious that the problem in not solvable in easy manner The only possibility to enable the measurement of the frequency response of the device to
32. Zoc DADIASNALYSISPLDBIN asien au 88 TT Data AnalysisPlanzsssess ae 88 7 2 Launch Campaign socer eret EIER DH EH EHE EN ERES 88 Z 3 ROS UNG iu oet di Ot mua a u qax RR RN eee 88 7 3 Main goal a u 88 7 32 EIGKITOITQ uu auqa naa is ugh bade 89 133 OM ANG ss pana u e NEP uei 89 Mechanic eei eee Ehe as bte UR adu oat tutis 89 acid MT IEEE 89 nmmercORar berbu u uu M HY 89 Pirani pressure sensor xai EE PH ee a 90 Eleelronic BOX a d sco tutis ndo T s Ee CES 90 7 4 First Data Hes lls P 91 7 5 Discussion and Conclusions dos ara a 93 7 6 LESSONS Leaned uu ot Net E rr Eo Sb ns 93 8 ABBREVIATIONS AND REFERENCES sse 95 8 1 Abbreviation S oan ecoute c e RA de dpi UR aidati da 95 8 2 HOlOl Gl OS Do de edited webs wale ciao le taam ia aes 97 Appendix A Experiment Reviews ssssessseeeeeeeeeennnenennn nnns 98 Appendix B Outreach and Media Coverage 104 Appendix C Additional Technical Information 107 Appendix D Request for Waivers 108 Appendix E Vibration nennen nnn 109 Appendix F Preparation and Test Activities at Esrange
33. act rexus maxa de zu k nnen Das Projekt erm glicht Dir einen Einblick in den gesamten Entwicklungsprozess eines Welt raumprojektes Wir sind stets auf der Suche nach motivierten Mitgliedern f r die Bereiche Public Relations Facebook Website Sponsoring Elektrisches Design Software Design Microcontroller Java Mechanical Design sowie Fluiddynamik Str i eae Studentisches Gute Englischkenntnisse sind eine wichtige Vor A rasan Projekt UNIVERSITAT zz 8 fig 54 MOXA Flyer EuRoLAUNCH ADLR and SSC cooperation Page 106 Students Experiment Document MOXA Experiment RX16 TU Dresden fig 55 UNIVERSITAT DRESDEN E DIE FAKULTAT gt Fakult t Maschinenwe MOXA Buttons Studierende der Luft und Raumfahrttechnik starten weiteres Weltraumexperiment FAKULTAT MASCHINENWESEN O Startseite Leitung und Kontakt Leitbild Zentrale Einrichtungen Geschichte der Fakultat Alumni Interne Informationen Links CAD Labor der Fakultat Labor und Versuchsfelder Suchmaschine Fakultat Maschinenwesen fig 56 STUDIERENDE DER LUFT UND RAUMFAHRTTECHNIK STARTEN WEITERES WELTRAUMEXPERIMENT v l n r Alexander Mager Bastian Klose Patrick Geigengack Foto Klose Marz 2014 in Schweden Informationen f r Journalisten Alexander Mager Projektleiter ta contact rexus moxa de Tel 0152 28981521 facebook com rexus moxa article on TU Dresden homepage Zum zweiten Mal
34. agnet Magnet 10 Control JST SH 4 Mainboard 1 JST SH 4 Control 200mm 4AWG28 14 11a Temperat Tempera c ure LM75 JST SH 4 Mainboard 1 JST SH 4 turesens 100mm 4AWG28 42 11d Temperat Tempera f ure LM75 JST SH 4 Mainboard 2 JST SH 4 ture sens 100mm 4AWG28 42 Temperat ure Solder to Sensor go PT1000 Thermod 1 Mainboard 1 JST SH 4 1 Hatch 200mm 4AWG28 14 Temperat ure Solder to Sensor 13 PT1000 Thermod2 Mainboard 2 JST SH 4 T2 Cavity 300mm 4AWG28 14 Crimp Magnet Crimp 2 min 14 CAP H lse Control H lse CAP 150mm AWG10 25 Mainboa 15 Photo Solder Photosens JST SH 4 rd 300mm 4AWG28 14 ARM Magnet 16 PLUG Solder ARM PLUG Solder Control 180mm 5AWG28 25 Magnet Crimp Magnet 2 min 17 Power H lse Control Solder Solenoid 200mm AWG10 25 Total Mass g 3352 Page 66 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 7 Thermal Design The thermal design is split in four parts The temperature in the hatch the inner chamber the parts which are mounted in the module and these which are not in contact with the ambient air stream The fourth part is the interplay between the electronic boards and the electronic box Temperature of the hatch The hatch will not open until an altitude of 30 km is reached Because of the low density in this altitude the friction on the lower edge of the now opened cavity is very low That means that the hatch has to handle the temperature of
35. air by demand The sensors will be protected from exhaust gases at the launch That will be realized by a hatch plate that is closed and fixed by thin steel wire in the initial position This wire is clamped with a plate and 4 screws on the movable hatch and again with a clamping plate and 4 screws on the underneath bottom plate of the hatch housing By cutting the thin wire with a pyrotechnical cutting cylinder we open the hatch with springs that push the hatch up In the pictures below you see schematics of this mechanism Steel wire Hatch TT Y Pyrocutter Clamping plate fig 21 hatch function EuRoLAUNCH ADLR and SSC cooperation Page 44 Students Experiment Document MOXA Experiment RX16 TU Dresden fig 22 Detail view clamping mechanism Part overview of the hatch mechanism 4x ISO 4762 M4x8 1x 015 cover fotosensor page Seite 10 2x 006 X6FM 0608 06 Fa IGUS 2x 005 SPJ6 70 SC6 Fa Misumi 1x 007 sensorplate page Seite 6 2x D 115H Gutekunst 2x ISO 4762 M3x8 1x 003 hatch page Seite 1x 010 plate page Seite 7 2x ISO 4762 M3x8 2x ISO 4762 M4x12 2x ISO 2338 6x20 fig 23 hatch exploded view 1x 001 box page Seite 3 1x 012 photodiode Fa Conrad 2x ISO 4762 M3x8 1x 015 Flange Fa Pfeiffer 8x ISO 4762 M4x6 1x 013 sensorplatine Fa Fischer Leiterplatten 4x 004 sensor R TU Dresden 3x ISO 4762 M4
36. am very fast So in worst case the inner chamber has to handle 250 C This is an assumption because real behavior of the airstream is very hard to calculate The pressure difference between in and outlet could be up to one bar but many influences like wall near effects and inaction of the stream prohibit a good calculation We estimate the highest temperature with up to 250 C The inner chamber and the bond should be able to handle temperatures of 20 to 250 C The Ramp outside should handle 20 to 600 C to be sure that the ramp wont separate from the module and damage the rocket Table 4 12 temperature profiles of components of inner chamber Part Temperature in C In house production AlMgsi1 melt at 585 Medium thermal expansion coefficient at 500 C is 18x10 Ramp X5CrNi18 10 m K Gas sensors Work on up to 500 piezo sensor process attachment Operating 25 up to 85 Sealing compound Operating up to 300 High temperature adhesive Operating up to 982 Page 68 EuRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Parts mounted in the module except electronic box Inside the module we know that the temperatures measured on the transmitters having their maximum at 43 C All parts inside the module should be able to handle temperatures of 20 to 50 C Table 4 13 temperature profiles of components in module Par
37. are missing o BDetails tests to be performed on the hatch Safety and risk analysis SED chapter 3 4 Safety risk of steel wool combustion Risk register Rating of 5 partly unrealistic Risk ratings are not consistent List of risks really limited Personnel budget risks and project risks are not included Hot surface risk not properly mitigated e g safety covers etc 000000 Launch and operations SED chapter 6 o Oscilloscope requirement Note that no development work can be performed at Esrange Organisation project planning amp outreach SED chapters 3 1 3 2 amp 3 3 o Availability of team members critical after the summer serious problem Webpage Include sponsors In a blog news list the newest entry should be on top Clarify the meaning of the word start should be launch Include the Final Report in the project plan Commitment work hour percentages have to be properly defined Include a sponsorship column in the budget overview 000000 Formatiert Schriftartfarbe Hellblau Formatiert Schriftartfarbe Hellblau Provide a complete budget Include all team members also on the Facebook picture Fly your message will be 2 3 A4 pages Appendix B add more information add link to PDF copies 5 Internal Panel Discussion Summary of main actions for the experiment team see bold print CDR Result pass conditional pass fail o Con
38. at success Problems None on electrical side 7 3 3 Software The Software was full working we lost two of 14000 measured values so we can say this is a great success too The ground station gave us live feedback for all sensors so we saw much more of the rocket flight even though the others stood on the radar hill and we sat next to a computer in the control room It was quite a lot of gratification to watch the sensor graphs varying in dependence of the rocket height 7 3 4 Mechanic Hatch During the flight the pyro cutter fired after it received the signal from the RX bus The cutter sliced the steel wire which holds the hatch down and then the springs could push the hatch up That the hatch really opened is confirmed by a photo sensor in the hatch the vibration measurement of another experiment FOVS and you can hear it in the flight video GoPro looking outside the rocket Inner Chamber The design of the inner chamber should enable to take samples of the ambient airstream around the rocket slow the air down and make it so suitable for our gas sensors The design based on simplifications of the airstream Tumbling caused by the rotation stabilized flight and the resulting dynamic boundary layer couldn t be predicted But especially the boundary layer around the rocket leads to much lower fluid velocity which the inner chamber was not designed for In conclusion we assume very little air exchange in the chamber but thi
39. ates are fixed with self sealing 3x EN ISO 10642 M3x8 The top plate is fixed with 6x EN ISO 10642 M3x8 directly with the spacers from the upper mainboard Front backside and side plates are form closed by the top plate and in addition the side plates get stabilization by flaps of the front and backside plate The board box is not designed to be gastight It is just designed to cover the boards and to prevent the income of small aluminium chips Air flow will be enabled through five holes diameter 10mm These holes are covered with a 45x45mm filter net to prevent the boards from aluminium chips and thereby eventually caused short circuit The net is fixed between a small 45x45mm plate also with 5x 10mm holes to enable air flow the plate is fixed on the top plate with 4xM4 screws and nuts The whole board box is affixed on the module with 6x EN ISO 10642 M4x12 All plates will be manufactured of aluminium EN AW 6082 T6 Page 43 ee EurRoLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 4 3 Sensors box with hatch fig 20 hatch assembly This is one of two assemblies which include sensors the other one is the inner chamber in chapter 4 4 4 The included sensors will measure atomic oxygen molecular oxygen ozone and temperature so there are 4 sensors inside The main task of the hatch is to mount the sensors in the module and give them access to the ambient
40. be described using SART acc Hatley87 The experiment system design implements two similar independent designs Page 35 Ta UROLAUNCH Students Experiment Document MOXA Experiment RX16 TU Dresden 4 1 1 System Model Ground Station deni diens eg Module Inner Chamber l l Measure Board A Sensors 1 3 I l l 4 Control Measure Board B Sensors 4 6 fig 14 System Model Table 4 2 Module Specifications Hardware Software Function Measurement Board STM32F1 ARM7 Measurement Saving Transmission Measurement STM32F1 ARM7 Measurement Board B Saving REXUS BUS Data Transmission Ground Station Java Windows Data Receiving or Linux and Saving Page 36 EuRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 1 2 Modules The MOXA experiment electronics will be designed modular The two modules similar structure will be stand alone They will be developed on standardized 4 layer Euro size circuit boards An additional circuit board will be designed for the power system All systems will be housed in Electro Magnetic Capability EMC shielded segments of the box to avoid EMC troubles Table 4 3 Data lexicon Data Flow Description Heating U 0 3 3 Volt Page 37 T f EuRoLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 2 Experiment Interfaces 4 2
41. be taken by our university Table 3 1 Mechanical and Electric Parts Cost Estimate 30S 3 LE OLT 3 76 529 3 6 EL 30 3 1 98 30 30 3 0 601 30 c9 ovt OL 6ET 3 S8 91 3 LE ev 3 0c 3 187 3 00 6v 30 30 30 3 0v 14 3 SC c0 8vT 3 90 30 3 c0 8vT 9 ds 18430 2 104 3509 g 4sosuods 2 ja 3 99 9 c Jer uid 1 3900 uenseg Ead e Bal Ba JOSUBS ozald JOSU3S IueJld syed Inpoyy uononpoud esnou ui jnpoyy sued xog 21004323 3 uononpoud xog 21u04329 3 uononpoud Jaqwey sued u31eH uononpoud u31eH sjes wayy SAA919S WIS syed uias onauZeyy siosu s 10 99 sped 82d yms sJosuag 2usuas 82d paeoqiamog sued pyeoqiosuag Wd preoqiosuss Syed pyeoquiejg spieoqoloid 82d piAeoqu elW uoin sqns 3lueu3 W Sc 3Iueu2 W vz QUeYIIN EZ 3IuBu3 lN e 3lueu3 W TZ Sueyaay oz 3lueu2 W 61 ST 3lueu3 W Lt 3Iueu3 W 91 Sueyaay ST 210022 3 vt 2100293 ET 210022 3 zt 3iuon 3 IT 21001323 3 OT 3iuon 3 6 31004329 3 8 3iuon 3 L 1 9 3iuon 3 S 2
42. d amp saved onto an SD Card e 0 5 The RX I F is implemented and working using upstream commands and downstreaming of measurement data e 0 6 The Experiment can be deactivated automatically Timeline The Test using a RS232 connection has been successful and proven that the necessary software parts are implemented as required beforehand both on the experiments microcontroller as well on the groundstation 5 5 2 T4Vibration Test see APPENDIX E Page 83 42 9 EurRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 6 LAUNCH CAMPAIGN PREPARATION 6 1 Input for the Campaign Flight Requirement Plans 6 1 1 Dimensions and mass Table 6 1 Experiment mass and volume Attribute Dimension Experiment mass in kg 8 973kg including module and bulkhead Experiment dimensions in m 0 348 x 0 130 Experiment footprint area in m 0 0657 Experiment volume in m 0 012 Experiment expected COG centre of x 137 y 106 z 0 191 gravity position 6 1 2 Safety risks Hot surface of one of the sensors 500 C when heated The risk occurs between t 900s and t 600s during flight and during active tests which include heating of the sensors Before launch and during testing the surface will be covered by the hatch and are not touchable After Power off the sensors cool down within seconds and are not hazardous during recovery For additional safety a warning sign mark
43. detailed information All other modules are connected as recommended in the data sheet You can find the pdf document for circuits and board layout as well as the part lists with a hyperlink to the distributor in Annex C Microcontroller Our main unit Pin connections are described here Table 4 6 Connections PIN Function MOXA Signal Type PAO ADC ADC1 1 A D sensor 1 PA1 ADC ADC1 2 A D sensor 1 PA2 ADC ADC1 3 A D sensor 1 PA3 ADC ADC1 4 A D sensor 1 PA4 SPI DA AD NSS D A external DAC and ADC EuROLAUNCH ADLR and SSC cooperation Page 57 Students Experiment Document MOXA Experiment RX16 TU Dresden PA5 PA6 PA7 PA8 PA9 PA10 PA11 PA12 PA13 PA14 PA15 PBO PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12 PB13 PB14 PB15 PCO PC1 PC2 PC3 PC4 5 PC6 PC7 PC8 PC9 PC10 PC11 SPI DA AD SPI DA AD SPI DA AD Measure I O Measure 1 0 JTAG JTAG JTAG ADC ADC JTAG JTAG I2C1 TEMP I2C1 TEMP LED SOE LED STATUS USART3 RS232 RS422 USART3 RS232 RS422 SPI2 SD Card SPI2 SD Card SPI2 SD Card SPI2 SD Card ADC ADC ADC ADC ADC ADC PGA1S1 152 251 252 PGA3S1 PGA3S2 SCK D A MISO MOSI CS_DAC CS_ADC HATCH_ON HATCH_IN1 HATCH_IN2 TMS TCK TDI ADC2 1 ADC2 2 HATCH_DONE TDO RST LO SCL SDA SCK MISO MOSI ADC2 3 ADC2 4 ADC351 ADC3 2 ADC3 3 ADC3 4 000000 externa
44. ditional pass under the prerequisite that a new version of the CDR SED is submitted within 4 weeks addressing all above points Next SED version due o Resubmission of SED within 4 weeks Page 104 EuroLAUNCH A DLR and SSC coopera Students Experiment Document MOXA Experiment RX16 TU Dresden APPENDIX B OUTREACH AND MEDIA COVERAGE LIST OF APPEARING ARTICLES e HI TECH CAMPUS e atp edition e Die Welt e TU Dresden 1 Main Homepage 2 Hompage of mechanical engineering 3 Twitter 4 Facebook e Sachsische Zeitung e Kanal8 e Dresdner Neuste Nachrichten e Bild online e Unijournal e Freie Presse e CAZ e LVZonline e Mein Infodienst INTERVIEWS e MDR Figaro e Campusradio http campusradiodresden de 2013 01 31 vom horsaal ins all more 5740 MEDIA Website www rexus moxa de Facebook www facebook com rexus moxa Other Buttons Posters Flyer Send your Message to space Page 105 EuRoLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Das Team Kontakt www rexus moxa de REXUS Web http www rexus moxa de http www rexusbexus net Das MOXA Team besteht aus Studenten aus ver schiedenen Fachrichtungen darunter Maschi n i http www facebook nenbau Mechatronik und Informatik Wenn Du NIE TREE dich f r die Mitarbeit interessierst w rden wir Kontakt uns sehr freuen dich in unserem Team begr en cont
45. e 97 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 8 2 1 2 3 4 5 6 7 8 9 10 11 12 References Books Paper Proceedings Tino Schmiel Entwicklung Weltraumqualifikation und erste Ergebnisse eines Sensorinstruments zur Messung von atomaren Sauerstoff im niedrigen Erdorbit 2009 S Dikty H Schmidt M Weber C von Savigny and M G Mlynczak Daytime ozone and temperature variations in the mesosphere a comparison between SABER observations and HAMMONIA model 2010 Interface for atmospheric models http www spenvis oma be Database of geomagnetic indicies and solar indicies as input parameters for atmospheric models http www swpc noaa gov ftpmenu indices old indices html KYOUNGSIK CHANGAnalysis of the flow and mass transfer processes for the incompressible flow past an open cavity with a laminar and a fully turbulent incoming boundary layer 2006 EuroLaunch BEXUS User Manual 2012 REXUS User Manual 2012 European Cooperation for Space Standardization ECSS Space Project Management Project Planning and Implementation ECSS M ST 10C Rev 1 6 March 2009 SSC Esrange Esrange Safety Manual REAOO E60 23June 2010 European Cooperation for Space Standardization ECSS Space Engineering Technical Requirements Specification ECSS E ST 10 06C 6 March 2009 European Cooperation for Space Standardizati
46. e enough place for the electric connector The spacers will be screwed directly on the bulkhead Detailed information about the dimensions will be found in the drawings 4 4 6 Position and fixation of the Battery Inner chamber Ramp Absolute pressure sensor Fly your message to space box Electronic box Pirani pressure sensor Hatch fig 34 top view of the experiment The picture above shows the position of the battery It will be fixed by two screwed metal strips at the bulkhead 4 4 7 fly your message to space part The messages that will fly to space will be printed on two or three sheets of paper These sheets will be inside a closed box with an venting hole so its not air tight To ensure that the paper will not block the hole we will push it down with a screw and clip them together The box will be mounted by two screws in the bulkhead Page 54 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 5 Fluid Mechanic For the implementation of measuring ozone atomic oxygen and molecular oxygen we choose two experiments for different height ranges For ranges higher than 30 km we use a cavity which opens its hatch a few seconds after lift off and reveals the sensors Because of decreasing density and the high velocity of the rocket we use an inner chamber for representative measurements up to an altitude of 30 km To analyze the flow over the cav
47. ectronics Board development in a student research project Patrick Geigengack Aerospace engineer student CATIA V5 Dual studies of construction engineering bachelor of science Jonas Uhlmann Mechanical engineering student Designed a test stand in a student research project Traineeship in the area of designing mobile processing machine Student staff at Institute for Fluid Mechanics at TU Dresden SOLID WORKS CATIA Daniel Becker Aerospace engineer student Bachelor of engineering CATIA Fabienne Kinzelmann Philosophies and catholic Theology Trained as a journalist Page 23 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Susann Knapik Chemical engineer student SOILD WORKS Max Oswald Aerospace engineer student Internship at Astrium Satellites Friedrichshafen Student staff at Institute of Aerospace Engineering involved in the software development for the next student picosat of the TU Dresden SOMP2 CATIA SOLID WORKS Nathanael Warth Aerospace engineer student SOLID WORKS Sebastian Weixler Mechanical engineering student SOLID WORKS Page 24 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Exams 5 Other Vacation etc gt Bastian Patrick AlexS exM EEE O E T 3 usann Nathanael Fabienne Sebastian D er o
48. en or don t fit Delayed Fabrication of the university workshop Detect design failure during the fabrication Bad communication and misunderstandings between the team and the workshop Experiment Software Synchronization Loss LO SD Card Failure RX I F Failure A B B C B B B B A A Calculate and test before CDR Function Test Select connectors that are resistant to vibration Allocate responsibilities Use flow chart and time schedule Communication Share tasks in work packages Time schedule Time schedule Schedule buffer time Adhere strictly to the time schedule Schedule buffer time Schedule buffer time Schedule buffer time Appoint a contact person Synchronize Data after Landing Redundancy RX I F Redundancy SD Card Page 33 EuroLauncn Students Experiment Document MOXA Experiment RX16 TU Dresden Experiment Restart during A Instantly start Flight Power Line Cut collecting data Experiment Stuck S X 05 Critical Module Failure DAC A Extensive Preflight ADC Quartz Tests S XXX Software is not Ready at A Time schedule Launch E Electronics M Mechanics P Personal L Logistic F Fabrication S Software Page 34 EuROLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 EXPERIMENT DESCRIPTION Due to the interesting higher concentratio
49. ensive data to create a new model which allows a more precise prediction of the distribution of residual gases This will support atmospheric science and improve the preparation potential of material etc for long term low earth orbit missions fig 12 Website Our website can currently be visited via www REXUS MOXA de The website generally informs about the REXUS program our MOXA team and of course about our experiment Furthermore we there collect and present all published articles and posts about MOXA In future every visitor of the website will have access to press material press releases photos etc Page 30 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 3 4 3 Classic PR work TECHNISCHE UNIVERSIT T DRESDEN Startseite gt uar Studenten der TU Dresden starten ein weiteres Weltraumprojekt AKTUELLES STUDENTEN DER TU DRESDEN STARTEN EIN WEITERES WELTRAUMPROJEKT Startseite Aktuelles Zum zweiten Mal hat ein studentisches Forscher Team am Institut f r Luft und Raumfahrt der TU Dresden die Ausschreibung f r einen der begehrten Raketenstartplatze im REXUS Programm des Deutschen Zentrums f r Luft und Raumfahrt DLR gewonnen Publikationen Fotos der TU Dresden Mediathek Nachdem schon im November 2012 ein Experiment von Dresdner Studenten mitfliegen durfte startet nun das MOXA Team in den Weltraum Nach einem mehrt gigen Auswahlver
50. ensor Module This is a separate PCB Board All connections are provided by the Power Bus and Measure Bus systems A D Controller We use an external ADC for additional AD Ports and because of higher resolution Because of precise pressure sensors onboard we need to support an higher resolution than the internal 12 Bit Additional we get feedback about power consumption and battery voltage level SD Card The SD Card is for data storage We are not able to send all data down while flying so data is kept on a SD Card The reject mechanism of the SD card socket is good but for safety it has to be locked by some glue additionally Page 59 EuroLrauncH DLR and SSC coopera Students Experiment Document MOXA Experiment RX 16 TU Dresden Power Bus We use a Power bus that connects all boards and provides the different voltage levels where needed High current or critical voltage levels as well as the GND are at least doubled on this bus There are some uncritical Signals on this bus system like I2C powering the battery and measuring of voltage too Table 4 7 Power BUS pin configuration Pin Signal Pin Signal2 used for Type 3 I2C1_SDA 4 I2C1_CLK SDA ofthe Digital mainboards 1 or 2 I2C2_SDA 6 I2C2 CLK CLK of the mainboards Digital 10r2 9 REX SENS 10 3V7 Current Sense 3 7V Analog Battery Connection 11 BAT SENS 12 HEATING Current Sense Analog Heating Command 13 SAD 14 GND 15 16 a 5V Supply Low Current
51. eriment Document MOXA Experiment RX16 TU Dresden Pressure Temperature Sensors Sensors ET 2 Mainboard Control Loop Scheduler Loop bOHz 10Hz 2 r en Be m eee eee Hardware External Software I T Realtime X Component Hardware Controller fig 45 Implementation of a Minimalistic Real Time Operating System RTOS 4 9 5 Data Communication Implementation Active time of flight measurement during 300s with 10Hz will results in 3000 Measurements By efficient compression of data all packages will be send down to the ground station as redundancy for SD card failure The overall measurement data per measurement is roughly 150 Byte and hence 1500 Byte s 4 9 6 Data Protocol Implementation According to the REXUS experiment documentation a data protocol has been implemented A 16Bit CRC CCIT OxFFFF algorithm has been implemented at ground station at all communication participants to check for bit errors The upstream and downstream protocol use different package sizes since upstream is solely required for commanding and does not carry many data Each message consists out of a 6 Byte header containing the identifying Message ID MSGID as well as a consecutive message number In addition a 2 Byte CRC is included containing the CRC for all data after SYNC Page 74 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresde
52. est organisation X Axis Vibration Test Report Team MOXA Seite 12 27 REXUS 15 16 Team MOXA 16 01 14 ESWI Wy Picture 6 Test organisation Y Axis Vibration Test Report Team MOXA Seite 13 27 REXUS 15 16 Team MOXA 16 01 14 Picture 7 Test organisation Z Axis Vibration Test Report Team MOXA Seite 14 27 REXUS 15 16 Team MOXA 16 01 14 Monitoring of the incoming power flux The incoming power was measured for each test by an acceleration sensor type PCB 353B03 The sensor was mounted on the Hatch close to the module always in the direction of the axis which was under investigation The Hatch perfectly suites for this application due to it s rigid fixation Sensors Positions Channeloccupation und Fixing Sensor Type Measuring Channel Position Function Fixing Nr direction A 1 PCB 353B03 Uniaxial 1 Vibration desk oscillation bin in Screwed each direction of excitation Referencesensor for the power output M 1 Br el amp Kjaer X Y Z 2 X 3 Y In the electronic box of the third Sticked hot glue 4505A triaxial 4 Z platine from below CCLD M 2 Br el amp Kjaer X Y Z 5 X 6 Y On the hose clamp of the Pirani Sticked hot glue 4505A triaxial 7 Z Sensors CCLD R 1 PCB 353B03 Uniaxial 8 Hatch in each direction of Sticked wax excitation referencesensor for the power input Vibration Test Report Team MOXA Seite 15 27 REXUS 15 16 Team MOX
53. f power budget required Carefully describe the use of the on board charging system if required Hatches might be required to open with a short time difference to avoid high overall currents 00000 Thermal SED chapter 4 2 4 amp 4 6 o Consider thermal design of the hatch Software SED chapter 4 8 o Software section is well developed o Communication protocol might have to be refined Verification and testing SED chapter 5 o Note that several tests will be scheduled prior to launch o Consider the use of safe arm devices Safety and risk analysis SED chapter 3 4 o Include project risks in the risk register o DC DC converter related risk a ranking of 4 is enough o Risk of hot surface of sensor mitigated by low thermal capacity o Hatch opening related risk Not critical to rocket only experiment ranking of 4 is sufficient Launch and operations SED chapter 6 o Power on of experiments is at 600s Consider how a hold in the countdown affects the experiment Change of sensors after testing and before roll out is recommended Extensive late access of rocket on the launcher is to be avoided by all means If required a foil covering the hatches could be pulled off the rocket skin before launch o Consider flushing with nitrogen 0000 Organisation project planning amp outreach SED chapters 3 1 3 2 amp 3 3 Table 6 1 1 is empty please fill it o Fly your message Paper will get heavy try to make it light
54. fahren entschied das siebenk pfige Studententeam die Ausschreibung des REXUS Programms f r sich o Archiv der Pressemitteilungen Pressespiegel Messen Das deutsch schwedische REXUS Programm kurz f r Rocket borne EXperiments for University Students bietet eine Experimentierplattform f r Studenten im Bereich der Raumfahrt J hrlich werden zwei Raketen mit bis zu zw lf Experimenten gestartet die von studentischen Teams entwi den Die Experimente werden auf einer k Orion Motor mit 290 Kilogramm Brennmasse durchgef hrt Die Rakete erreicht eine H l MOXA Measurement of Oxygen in the Atmosphere will auf der Forschungsrakete REXUS 15 16 genaue Messungen in der Erdatmosph re durchf hren Gemessen wird mit neuentwickelten Sensoren des Instituts f r Luft und Raumfahrt der TU Dresden REXUS 15 16 startet im M rz 2014 in Schweden Informationen f r Journalisten Alexander Mager Projektleiter fig 13 MOXA on TU Dresden On the 8 of January the TU Dresden s press office sent out our first press release under the heading Studenten der TU Dresden starten ein weiteres Weltraumprojekt http tu dresden de aktuelles newsarchiv 2013 1 REXUS About ten magazines and papers took it out in either print or online Moreover we published a detailed article in our University s Journal This article appeared on the front page on the 14 of January PDF http bit Iy Y1A8Bv Throughout the very first pre
55. flow velocity change The velocity will go down and the temperature rises but the most important fact is that the pressure rises too So the pressure at the ramp is higher than the pressure next to the ramp air inlet air outlet fig 31 Ramp on module with air in and outlet Page 51 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Between the drill holes of the in and outlet the air flow generates a pressure differential which leads to an air flow through a chamber with sensors for pressure temperature ozone atomic and molecular oxygen spacer i gt outlet pressure sensor N air inlet air inlet for pressure sensor ramp fig 32 air stream through inner chamber After the air flows through the inlet in the chamber it hits the spacer scatters there and expands because of the profile extension Because of the pressure differential the air flows over the sensors to the outlet and leaves the inner chamber The ramp made of X5CrNi18 10 will be mounted with 4 x DIN965 M4 counter sunk screws The adaption which is made of AlMgSi1 will be glued from the inside on the shape with a safety of 272 and positioned with one DIN 7991 M4 counter sunk screw Then the spacer is fixed with two M4 screws on the adaption The sensor board with the soldered sensor clips is fixed with six M3 screws The sensor board is easy to disintegrate for an easy exchange of the
56. genfrequencies Table 5 9 Sinusoidal frequency vibration Axis Frequency Input Level X Y 5 2000Hz 0 258 Z 5 2000Hz 0 25g Table 5 9 Random frequency vibration Axes Frequency Level Remark All Axes 20 2000 Hz 6 34gRMS 0 018 g Hz Duration 10s 10s 10s 60s Input 25 50 75 100 Page 82 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden During the Bench Test at Oberpfaffenhofen a second vibration test was performed by DLR at a 12gRMS level to ensure the safety of the Hatch Test results are documented in the Appendix E 5 4 Thermal test The thermal test consistent with the expected maximum and minimum of temperatures on each assembly group or measure the produced and emitted heat flow during operation electronics During a test the emitted heat due to the operating electronics was measured In the end the produced heat was harmless to the experiment Single components have been tested to their thermal sensitivity But tests of the electronic box with the boards or the sensors were not possible due to the state of development of these parts 5 5 Test Results 5 5 1 5 Software Tests e P 6 P 9 The software is fast enough to control 100 Measurements Second e 0 9 O 1 O 2 Timeline events can be performed e 0 3 The experiment can be deactivated by RX I F State Change e 0 4 Data can be capture
57. ght using the RX simulator After passing all tests the experiment will be assembled and secured with Loctite in the module After the flight we will start a rough estimation in Kiruna if the Sensor works or not 7 3 Results 7 3 1 Main goal The main outcome of MOXA is that we built an experiment that is able to fulfil the scientific goal we announced in the proposal for the REXUS campaign We wanted to measure primary ozone atomic and molecular oxygen and secondary local pressure and temperature during the whole flight But what has to be discussed is the quality of the measurements Mainly the thermodynamic flight environment was a cause for unexpected quality penalty of the data This has to be discussed in detail with the gas sensor provider ILR at TUD Page 89 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 7 3 2 Elektronic Up to the moment we received the signal Start Of Experiment SOE all electronic systems worked well The sensors did heat up properly and we received a status of our experiment every second via the ground station Because of two similar ground stations we saw all 6 sensors the temperature sensors and the pressure sensors everything worked as expected and already tested at the bench test This did not change at liftoff and during the flight except the sensors but more about that later on On the point of view of an electrician it was a gre
58. h the guides which will support a fluent movement of the hatch The springs push the hatch up when the wire is cut While beeing stressed the springs each have one a force of 16 38 N So a force of 32 76 N pushes the hatch to open the recess in the module completely so that air can get to the sensors The steel wire which keeps the hatch in its inital position is cut at an altitude of around 30 km by a pyrocutter It is fired by an electric current of at least more than 0 4 A To fire it in any case there have to be a current of 1 2 A The triggerring of the explosive inside the pyrocutter lies by MORABA Mobile Raketen Basis DLR The replacement of the pyrocutter and the wire due to tests requires an unscrewing of the hatch box out of the module and a disintegration of the clamping plates and the pyrocutter mounting Page 47 EurRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Owing to the fact that the pyrocutter contains explosives there have to be some security constraints To prevent early ignition and damage to men or material the electric circuit have to be capsuled and seperated from other cords Positioning photo sensors nl gt Hatch closed Sensor gives no signal Hatch open sensor gives signal fig 26 photo sensors To know whether the hatch is closed or open we use a photo sensor mounted with 2 x EN ISO 4762 M3 x 6 and a cover mounted on the hatch
59. h time resolved Page 92 EuROLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden In Figure 53 the time resolved ozone measurement is shown The sensor in the hatch didn t work and the other one in the inner chamber slowly rise and jump to zero at 110 s This trend could have several reasons mentioned below The ozone sensors are prototypes that where finished two weeks before launch In laboratory environment the sensors worked very well but a rocket launch is a very harsh stress test for these sensors O3 Sensor Current fig 53 Ozone time resolved The ozone sensor needs to be filled with a water carrying fluid to guarantee a permanent humidification of special foil This foil and two electrodes measure incoming ozone If the humidification is not stable or not available anymore the sensor does not work The sensor itself and especially fluid inside could be influenced by varies factors e High velocity of the rocket up to 1400m s and resulting airstream conditions that hits the sensor e High acceleration 18g e Boundary layer effects on the rocket e Different environments after inflation integration hall Launchpad flight e High variations of local pressure and temperature during flight e Mistakes during inflation or bonding The sensors were installed protective as possible but the extreme airstream conditions during flight couldn t be simulated In Concl
60. hat ein studentisches Forscher Team am Institut f r Luft und Raumfahrt der Fakult t Maschinenwesen der TU Dresden die Ausschreibung f r einen der begehrten Raketenstartpl tze im REXUS Programm des Deutschen Zentrums f r Luft und Raumfahrt DLR gewonnen Nachdem schon im November 2012 ein Experiment von Dresdner Studenten mitfliegen durfte startet nun das MOXA Team in den Weltraum Nach einem mehrt gigen Auswahlverfahren entschied das siebenk pfige Studententeam die Ausschreibung des REXUS Programms f r sich Das deutsch schwedische REXUS Programm kurz f r Rocket borne EXperiments for University Students bietet eine Experimentierplattform f r Studenten im Bereich der Raumfahrt J hrlich werden zwei Raketen mit bis zu zw lf Experimenten gestartet die von studentischen Teams entwickelt werden Die Experimente werden auf einer Forschungsrakete mit einem verbesserten Orion Motor mit 290 Kilogramm Brennmasse durchgef hrt Die Rakete erreicht eine H he von etwa 90 Kilometern MOXA Measurement of Oxygen in the Atmosphere will auf der Forschungsrakete REXUS 15 16 genaue Messungen in der Erdatmosph re durchf hren Gemessen wird mit neuentwickelten Sensoren des Instituts f r Luft und Raumfahrt der TU Dresden REXUS 15 16 startet im English Suche FAKULT T MASCHINEN WIESEN AKTUELLES A RSS Deutsch Japanischer Nano Workshop initiiert Austauschplattform Studierende der Luft und Raumfahrttechnik starten
61. ht D 5 The experiment batteries interface shall be accessible for recharging D 6 The experiment sensors shall be accessible for a late exchange D 7 The experiment sensors shall be put on the outer shape of the rocket for a convenient approaching flow D 8 The electronic boards has to be fixed and hedged against humidity and electromagnetic influences D 9 The hatch shall work opening time mechanism under operating conditions D 10 The heat produced by the electric shall be dissipated Page 18 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 2 4 Operational Requirements O 1 The experiment shall operate automatically O 2 The experiment shall be release the hatch for the sensor protection automatically O 2 The hatch shall be released automatically O 3 The experiment shall accept a request for radio silence at any time while on the launch pad O 4 The experiment shall store the measured data on a SD card O 5 The experiment shall send a part of the measured data down to the ground station O 6 The experiment shall be able to turn off all electrical parts for landing O 7 The experiment electrics shall control the sensors all the time O 8 The sensors must not be touched when they are hot O 9 The automatic events shall automatically triggered by Timeline after liftoff 0 10 The manual events shall be transmitted over
62. ial pressure R done shall be possible between 10 bar and 1bar The atomic oxygen measurement partial pressure R done shall be made with an accuracy of 1 between an attitude of 30 to 90km The atomic oxygen measurement partial pressure T R done shall be made with an rate of 100 measurements F 2 Page 77 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden The molecular oxygen measurement partial pressure shall be possible between 10 bar and 1bar The molecular oxygen measurement partial R done pressure shall be made with an accuracy of 196 between an attitude of 30 to 90km The molecular oxygen measurement partial T R done pressure shall be made with a rate of 100 measurements every second The pressure measurement shall be possible R done between 10 bar and 1 5 bar P 11 The pressure measurement from 20mbar to 3 bar R done shall be made with an accuracy of 1 596 The pressure measurement shall be made with an T R done rate of 100 measurement every second The temperature measurement shall be possible R between 100 C and 200 C The temperature measurement shall be made with o done an accuracy of 1 C The temperature measurement shall be made with T R done a rate of 100 measurement per second P 16 The pressure measurement from 0 001 to 20mbar R done shall be made with an accuracy of 1096 The Exper
63. igen frequencies which differ extremely from measurement to measurement Concerning these findings the graphs which plot the eigen frequency of the two measurements are of significance X Axis After the first test measurements of the shaker were conducted the scan for the eigen frequency of the x axis from 5 to 2000Hz with 0 25g was started Concerning the structural analysis the first three eigen frequencies are of interest Time Eigen frequency Eigen frequency before Random after Random 00 00 02 Start at 5 00 Hz Start at 5 00 Hz 00 03 26 514 30 Hz 512 79 Hz 00 03 29 538 95 Hz 545 30 Hz 00 03 47 840 94 Hz 840 94 Hz 00 03 51 926 22 Hz 00 04 02 1194 83 Hz 00 04 07 1312 15 Hz 00 04 09 1379 09 Hz 00 04 11 1428 39 Hz 00 04 13 1518 94 Hz 00 04 16 1643 85 Hz We assume a very stiff constriction of our module due to the fact that the eigen frequencies are found at 514 and 539 Hertz The eigen frequency plots before and after the Randomtest in direction of the x axis are within the range of errors identical The eigen frequencies show only small shifts and are position within the rage of errors of 5 Also the strain of the eigen frequencies are within the range of errors of 25 Vibration Test Report Team MOXA Seite 19 27 REXUS 15 16 Team MOXA 16 01 14 00 8r6T 8Uv E9 T t 96ST Te StvT ZE SOET 6E tSTT 6T Z 0T 9 046 69848 St S64 TL ozs 68 TS9 v1 065
64. iment shall save and process the data at T done a rate of 10 Hz The Experiment control loop shall process at 50 Hz The experiment shall be designed to operate in the T done vibration profile of the RX rocket The experiment shall be designed in such a way T done that it shall not disturb and harm the RX rocket and the other experiments P 7 P 10 P 12 P 13 P 14 P 15 P 17 P 18 The experiment batteries shall be qualified for the A done rocket flight The experiment batteries shall be rechargeable to T A done run the experiment during pre flight test flight Page 78 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden preparation and flight The experiment batteries interface shall be accessible for recharging The experiment sensors shall be reachable for a ped late exchange passia D 7 The experiment sensors shall be put on the outer T A shape of the rocket for a convenient approaching done flow The electronic boards have to be fixed and hedged T against humidity and electromagnetic influences The hatch shall work opening time mechanism D 10 The heat produced by the electric shall be led T P away nas The experiment shall operate automatically The experiment shall release the hatch for the T done sensor protection automatically The experiment shall accept a request for radio T H silence at any time while on the la
65. ipation Urgency ss Switching Regulator 40 mW normal DC DC 3 3V 750 mW high DC DC 5V 3000 mW very high DC DC 12V 750 mW high uController 95mW low Temperature of the elements will be lowered by a heat sink design for the DC DC Converters direct connect to the aluminium case by thermal vias and heat pads below the board for smaller thermal losses microcontroller switching regulators 4 8 Power System 4 8 1 Power dissipation The anticipated power dissipation is mostly caused by the sensors heating The sensors resistance and therefore the power dissipation varies widely depending on the temperature of the platinum resistance and energy dissipated by heat convection The power dissipation of the sensors varies widely between the maximum value at startup with about 5 Watts and the mean dissipation of about 0 95 Watts measured in high vacuum chamber During the flight power dissipation will vary between this two sizes in dependence of mass flow over the sensor surface and barometric pressure The heating element is made of platinum The dependence between resistor and temperature is listed below E lt o E 320 temperature C fig 42 Resistance Min Max calculation Page 70 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden To allow sensor calibration and removing of sensors contamination the sensors will be heated
66. ir These are just small drill holes with a diameter of 2 54mm Below the D Sub bracket at 180 will be a pass in the bulkhead for any cables between the modules The dimensions are shown in the picture below Page 41 EuROLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden fig 17 pass for cables 4 4 2 Board box fig 18 board box Page 42 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Fil h ilter mes Top plate spacer boards backside Rubber sheet D Sub plug Side plate bottom Side for D Subs fig 19 board box exploded view The board box is the centre of the module It includes two mainboards two sensorboards and the powerboard Array of the boards from top to bottom mainboard senorboard mainboard sensorboard powerboard The board box consists of one bottom plate one front plate one backside plate two identical side plates and one top plate The powerboard is directly mounted onto the bottom plate the following boards are mounted and fixed on each top of another with 17mm spacers The front plate has two cut outs for the two D sub interfaces In the middle of the two side plates are two cut outs for the wires to the sensorboards and the powerboard The front and backside plates are fixed on the bottom plate with self sealing 2x EN ISO 10642 M3x8 the two side pl
67. ity of our module we build a simple 2d model fig 35 with the assistance of simulation software to work with it Problems in this experiment might be the turbulent flow around the sensors placed at the bottom of the cavity and the conditions of the air properties in the higher altitude e g low density On the basis of these facts we agree to a supplementary configuration for ozone measurement in lower altitude up to 30 km U free surface boundary outlet 100 module wall fig 35 2d Scheme of the 2d model of the MOXA module For first simulations of the fluid models we use simple dates for incompressible fluids to show the functionality of our experiment in a simple ambience We want to consider the flow dynamics with different settings in stationary vicinity at determined altitudes The series of tests will start with constant density and low speed In additional tests the speed approach up to the flight speed of the rocket the density is still constant After the test with increasing speed of the incident flow we want to realize additional tests with changing density The velocity profile fig 36 is adopted by the experiments of Spalart Direct simulation of a turbulent boundary layer up to RO 1410 from 1998 Page 55 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden P R Spalart 0 0 2 0 4 0 6 0 8 I 1 2 y fig 36 Velocity profile at different
68. l DAC and ADC external DAC and ADC external DAC and ADC Chip Select DAC Chip Select ADC Powering the Hatch Sensing if Hatch does open Sensing if Hatch does open Programming Programming Programming A D Sensor 2 A D Sensor 2 Sensing if CAP is charged Programming Programming REXUS Interface Temperature Measure Temperature Measure RS232 RS422 RS232 RS422 A D sensor 2 A D sensor 2 A D sensor 3 A D sensor 3 A D sensor 3 A D sensor 3 Measure Range Sensor 1 Measure Range Sensor 1 Measure Range Sensor 2 Measure Range Sensor 2 Measure Range Sensor 3 Measure Range Sensor 3 Page 58 EuROLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden PC12 O Hatch_Charge PC13 O BAT_ON PC14 Quarz OSC PC15 Quarz OSC PD0 Quarz OSC PD1 Quarz OSC PD2 JTAG Interface We use a 20 Pin JTAG interface for programming Olimex standard layout for easy programming via an Olimex ARM JTAG RS 232 We use this interface is only used for testing Via jumper you can choose between RS 232 and RS 422 Different gage converter support both interfaces REXUS Interface RS 422 This interface for sending data up and down Via jumper you can choose between RS 232 and RS 422 Different gage converter support both interfaces D A Controller The D A Controller is for setting the right sensor temperature and sensor voltage Additional Information can be found in paragraph S
69. ment Concept Ozone atomic and molecular oxygen pressure and the temperature will be measured on the outer shape of our experiment module So the module has to be modified in a way that the sensors AO O2 O3 look outside but are not directly in the airstream because the high velocity and pressure variations would disturb the measurements of the sensitive sensors The sensor system is a balance between a good gas exchange in front of the sensors and the realization of an operation environment in which the sensors are able to work Two sensor boxes will be arranged in an angle of 180 degree and designed that the sensors are easy to exchange Each sensor box will be controlled by a single electronic circuit Each box is separated from the other to obtain two independent systems The sensor control provides a specific operating temperature for the sensors AO about 600 C O2 about 550 C O3 about 120 The data will be collected and saved on a SD card Some data will be send down to the ground station That we have live measurement data of the flight All electronic circuits the SD card and rechargeable batteries will be stored and stabilized in boxes which will be mounted on the bulkhead Page 14 EuROLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 1 5 Team Details 1 5 1 Contact Point Email contact rexus moxa de Tel Team leader 015228981521 Website www rex
70. mpared with the reference voltage The difference between those two signals sets the input of the Page 63 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden PI Controller The Pl Controller now adjusts the voltage The current at the anode correlates directly with the amount of oxygen witch impinges on the substrate You can find the PDF document for circuits and board layout as well as the part lists at Annex C 4 6 3 Power design Powerboard You can find the PDF document for circuits and board layout in Appendix C Page 64 EurRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 4 6 4 Temperature measurement We support the temperature standard sensor LM75 on all PCBs inside our electronic box via I2C We have little modules 11 mm x 11 mm that can be connected via a small connector JST SH connector You can find the pdf document for circuits and board layout in Annex C 4 6 5 Sensor boards A D finished A D Convert Calculate new Heating U measuring Reference Value Reference ru p i Value 126 N Reference Value analog D A Convert fig 41 Control amp Data Flow diagrams of sensors heating Heating and measuring is nearly similar for O O2 O3 the only difference is that there is no reference electrode needed for ozone and O2 measuring You can find the PDF document for circ
71. n Table 4 19 Description of 30 Byte Data Package Downstream SYNC SYNC MSGID MSGCNT DATAO 23 Table 4 20 Description of 22 Byte Data Package Upstream SYNC SYNC MSGID SGCN RC CRC A upstream command protocol will be used that allows setting of all elementary experiment parameters by remote most significantly the status and control parameters and allows remote triggering for the hatch and the sensors 4 9 7 Control Loop An digital PID controller has been implemented to control the heating The process parameters are flexible and can be adjusted before launch For good performance the control route parameters are determined experimentally and will then be used to establish the PID parameters using an analytic model with SIMULINK software 2 fr Delay 12 PID Controller fig 46 Analytic Simulink Model of the Heating with quasi continuous PID controller 4 9 8 Ground Station Software Design The ground station will be used to survey and save the received measurement data The ground station software is developed in Java language To access serial features the RXTX Library will be used For visualisation the open JFreeChart library is used All commands can be executed by sending an ASCII Code through a serial interface Start Stop Heating Start Stop Sensors Set Experiment Parameters Control Parameters Start Stop Bat
72. nboard B and Sensor board B They are identical Table 4 9 Measure BUS pin configuration Pin Signal Pin2 Signal2 Kind of signal 3 ADC1 1 4 ADC1 2 sensor1 13 DAC1 1 14 DAC2 2 sensor2 17 ADC3 3 18 ADC3S4 sensor3 19 DAC3S1 20 DAC3 2 sensor3 21 150 22 151 gain select sensor 1 23 PGA2SO 24 PGA2S1 gain select sensor 2 25 PGA3SO 26 PGA3S1 gain select sensor 3 27 GND 28 GND GND connected to GND 4 6 2 Sensor circuits Sensorboard Bun fig 38 Control amp Data Flow diagram of the different sensors Page 62 EuRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden A D finished Measuring U P um Value analog A D Convert Calculate new measuring Reference Value Reference Value I2C D A Convert fig 39 Control amp Data Flow Diagram of Sensors Measuring PI regulator V Cathode 0 0 0 0 fig 40 Control amp Data Flow Diagram of sensors measuring and feedback control The FIPEX sensor gets heated to a temperature about 650 C by a platinum filament heating This temperature has to be stable for at least one minute for atomic and O2 sensors and 15 minutes for O3 sensors before measurement to eliminate contaminations on the sensor surfaces Voltage regulation This is done by setting a voltage between cathode and anode Now the voltage between reference electrode and cathode is measured and co
73. nents sensors electronic material 3 Final Report 6 4 6 4 6 4 6 4 Page 88 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 7 DATA ANALYSIS PLAN 7 1 Data Analysis Plan We will start with a rough estimation in Kiruna if the sensors work or not After that we will analyse the gained data in cooperation with the Institute of Aerospace Engineering in Dresden The result of this investigation will be a partial pressure against time diagram for every measured gas Then we will compare these data with the GPS data of REXUS to get the partial pressure of each gas against flight altitude In comparison with the pressure we measured and the density against altitude we can calculate the density of each gas for every altitude Afterwards resulting distribution diagram will be compared with known data from various sources to value the functionality of the sensors and the electronic control 7 2 Launch Campaign After arriving in ESRANGE we shall inspect every part of the experiment First we disassemble every assembly group of the experiment which screws are not secured with Loctite already After that just the electronic boards and software will be tested by their own to check if there is a possible damage caused by transportation If these test run well the electronic boards will be connected to the sensors and tested as well In the end we shall simulate a fli
74. nner chamber with adhesive 10 All contact faces in the hatch between different parts or at places where cables will come through the structure will be secured with a paste that is temperature resistant 11 Installation of the new pyrocutter Assemble everything for flight secure screws with LOCTITE see APPENDIX F for detailed information Qo SOB womb Page 87 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 6 3 Timeline for countdown and flight The Sensors used for this experiment need a time for preheating and calibration This time is sensor dependant and should take up to 15 minutes before the measurements and therefore should be performed before Lift Off The protective hatch will be opened after the burnout of the motor Table 6 2 Timeline Time Event T 1000 Power on T 900 SOE Preheating of the sensors T 0 Lift Off T 28 Hatch opening Pyrocutter fired by service system T 600 Power Off 6 4 Post Flight Activities 6 4 1 After Recovery 6 4 1 Disassembly of the experiment and clean it documentation 6 42 Disassembly of the electronic box to get the SD Card 3 Examine all mechanical parts documentation 4 First analysis of data 6 45 Interpretation if the sensor worked or not 6 Celebrate the hopefully successful launch 6 42 After launch campaign 1 Deta analysis in detail 6 4 Functionality test of all compo
75. ns of atomic oxygen above 70 km and for Ozone between about 10 50 km we need to provide adequate measuring during the complete REXUS flight To provide best measurements during high and low atmospheric pressure two different kinds of measurement chambers will be used One set of sensors will be placed within an inner chamber The chamber is designed for high velocity and high pressures The outside chamber is protected by a hatch After the hatch opens the sensors will be directly exposed and will therefore perform measurements of low pressure slows down airspeed The hatch will be triggered by MORABA after the burnout of the rocket engine at around 30 km 28 seconds and expose the outside sensors during the apogee of the flight Additional pressure and temperature sensors are included to each module Table 4 1 Experiment Timeline 1000 900 100 O 28 50 100 150 200 250 300 350 Height km 0 30 40 70 90 70 30 Heating Measurement Valid Range A0 Valid Range 02 Valid Range 03 Hatch Shutdown The sensors will be exchanged at the beginning of the campaign in Kiruna to ensure their functionality At launchpad the Sensors will be preheated to their operating temperature Measurements will be performed after liftoff and the hatch will be opened at about 30 km height by timeline At shutdown all the sensors will be disabled and the experiment will be switched off 4 1 Experiment Setup The system design will
76. o achieve a constant operating temperature Vibration Test Report Team MOXA Seite 5 27 REXUS 15 16 Team MOXA 16 01 14 Test object The complete module was tested in the experiment organization which is complete for the flight In order to the test it should be simulate a realistic behavior as possible Except the boards the oxide sensors and the skirt battery weren t used in this test Boards and skirt batteries were replaced by dummies with an approximate similar mass and were built in like in the flight configuration The oxide sensors could be neglected because of the low mass and the retain assembly Vibration Test Report Team MOXA Seite 6 27 REXUS 15 16 Team MOXA 16 01 14 Picture 2 Experiment organisation X Axis Vibration Test Report Team MOXA Seite 7 27 REXUS 15 16 Team MOXA 16 01 14 box for the box for the PC bords magnet capacity electronics battery amp fixation hatch inner chamber ramp absolute pressure sensors box for the fixation for fly your message to space the sensor campaign Picture 3 Experiment organisation with components description X Axis Vibration Test Report Team MOXA Seite 8 27 REXUS 15 16 Team MOXA 16 01 14 Test configuration Test equipment Nr Equipment Manufacturer 1 56kN Shaker System V8 440 LDS Dactron 2 Power amplifier SPA56K LDS Dactron 3 Vibration adapter Deutsches Zentrum f r Luft und Raumfahrt 4 Accele
77. oOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden important fact and the reason why our sensors have been cooled down so far is that the current to a sensor has had to be regulated down to 500mA because of a bonding wire that is 0 025mm thick which is rated for at maximum that current This would not have been a problem at all but the sensors we got from the institute have had very low inner resistances Lower resistance means lower voltages at same current lower voltage at the same current means less power and therefore less heat More bonding wires parallel would be able to capture a much higher current but are very different to mount So finally only the data between 80s and 220s are useable for upcoming data consideration 7 4 First Data Results The figure 52 shows the pressure of the inner chamber and the hatch time resolved The pressure of the hatch is marked blue and shows an inverted parabolic curve like our rocket flight this is as expected The black curve shows the same results at the beginning what was very unexpected for us because we expected a much higher pressure maybe the hole at the ramp was to small so there could not get enough air inside the chamber As the sensor was not selected for that low values it is normal that it could not follow the blue line Pressure mbar Pressure VSP mbar 0 001 fig 52 The pressure of the inner chamber and the hatc
78. of Oxygen and Ozone in the Atmosphere Atomic Oxygen TU Keywords Dresden RX16 SEDv5 0 CONTENTS PREFACE Z escis di evite p Debts awashka do p UD eats OP RUD ayau CaaS 6 ABSTRACT a utr 7 1 INTRODUCTION ET 8 1 1 Scientific Technical Background 8 1 2 MISSION Statement sa u usu bate i i Aenea 12 1 3 Experiment Objectives zus 13 1 4 Experiment Gonception een 13 GUA E O os OI ee 14 151 CONA Ct PON S oro eS NEN EU 14 15 2 14 2 EXPERIMENT REQUIREMENTS AND CONSTRAINTS 16 2 1 Functional Requirements 16 2 2 Performance requirementis uuuuusssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 16 2 3 Design Reguirements a sn an nu 17 2 4 Operational Requirements 18 2 04 ROOMS AUS tapa caet oso en ifa ute ee a 18 d PROJECT PLANNING ar 19 3 1 Work Breakdown Structure WBS 19 3 2 Schedule u u ua non i dapi o a a B teu date ais dt elm 21 3 8 Resolifees siento sea E 22 3 31 oMarpbWOl naar et 22 3 32 JBUGGOL ASEE 27 3 3 3 External nenne 28 3 4 DUlrsach Approach anes tous a
79. of gravity CRP Campaign Requirement Plan DLR Deutsches Zentrum f r Luft und Raumfahrt EAT Experiment Acceptance Test EAR Experiment Acceptance Review ECTS European Credit Transfer System EIT Electrical Interface Test EPM Esrange Project Manager ESA European Space Agency Esrange Esrange Space Center ESTEC European Space Research and Technology Centre ESA NL ESW Experiment Selection Workshop FAR Flight Acceptance Review FST Flight Simulation Test FRP Flight Requirement Plan FRR Flight Readiness Review GSE Ground Support Equipment HK House Keeping H W Hardware ICD Interface Control Document I F Interface IPR Interim Progress Review LO Lift Off LT Local Time LOS Line of sight Mbps Mega Bits per second MFH Mission Flight Handbook MORABA Mobile Raketen Basis DLR EuroLaunch OP Oberpfaffenhofen DLR Center Page 96 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden PCB Printed Circuit Board electronic card PDR Preliminary Design Review PST Payload System Test SED Student Experiment Documentation SNSB Swedish National Space Board SODS Start Of Data Storage SOE Start Of Experiment STW Student Training Week S W Software T Time before and after launch noted with or TBC To be confirmed TBD To be determined WBS Work Breakdown Structure AO Atomic oxygen O2 Molecular oxygen 03 Ozone d n y Not clear at the state of development Pag
80. omic oxygen SOUS models provide results differing up to 40096 To predict climate it is important to know the distribution of oxygen in its forms molecular and atomic oxygen as well as ozone more accurately Also atomic oxygen has a major Experiment Design influence on space borne objects as it degradates exposed materials aggressively Electronic Therefore the MOXA experiment will measure ozone atomic Mechanics and molecular oxygen partial pressure temperature and Project News pressure during the flight The Institute for Aerospace m Engineering at TU Dresden has developed innovative sensors estin ng for oxygen and ozone with a very low response time and high Partner Teams measurement accuracy The atomic oxygen sensors of the FIPEX experiment already performed successful Impressum measurements onboard the International Space Station and Private Area will be integrated in our experiment in a new miniaturized form dann The currently developed ozone sensor will be tested by comparing data collected during flight with existing data In addition the data of the oxygen measurements can give a hint on the ozone values and will help to verify the Rexus 15 16 Launch Noch functionality of the ozone sensor The development of precise sensors for residual gases contributes to the more detailed investigation of the 46 Tage atmosphere It is crucial to correlate existing partially contradictive atmospheric models with new more ext
81. on ECSS Space Project Management Risk Management ECSS M ST 80C 31 July 2008 European Cooperation for Space Standardization ECSS Space Engineering Verification ECSS E ST 10 02C 6 March 2009 Project Management Institute Practice Standard for Work Breakdown Structures second Edition Project Management Institute Pennsylvania USA 2006 Page 98 EuroLruncH Students Experiment Document MOXA Experiment RX 16 TU Dresden APPENDIX A EXPERIMENT REVIEWS REXUS BEXUS Experiment Preliminary Design Review Flight REXUS 15 16 Payload Manager Mikael Inga Alexander Schmidt Experiment MOXA Location DLR Oberpfaffenhofen Germany Date 07 Feb 2013 1 Review Board members Andreas Stamminger chair DLR Mobile Rocket Base Martin Siegl minutes DLR Institute of Space Systems Hans Henricsson SSC Science Services Mikael Inga SSC Science Services Markus Pinzer DLR Mobile Rocket Base Maria Roth DLR Space Administration 2 Experiment Team members Alexander Mager Patrick Geigengack Alexander Schultze 3 General Comments Presentation o Very good presentation with lots of good information o Make sure to keep the time o Please explain the meanings of acronyms used in the presentation SED o Make sure your document looks good e g Fehler Verweisquelle Some sections are omitted fill all of them if required with N A o Please accept our apologies for
82. pend on different influences The most important one is the electromagnetic radiation of the sun which leads to photo dissociation temperature variations and many other effects Other Influences are atmospheric tide effects geomagnetism and up to now not cleared up variations Depending on wavelength 320 nm lt A lt 1180 nm ozone reacts to molecular and atomic Because of the temperature variation and the gravitational field atomic oxygen diffuse to a higher altitude and recombine again when the radiation relieving Then the oxygen fall down again Due to the reduction of molecular oxygen and the diffusion of the atomic oxygen in the altitude of 450 km atomic oxygen comes about 90 percent So the daily and annual variation of the sun radiation on a certain place on earth leads to significant changes of chemical composition in the atmosphere Atmospheric models were developed to predict densities temperature and pressure in different altitudes for different longitudes and latitudes These models differ on the theoretical assumption used data sources and needed input parameter Atmospheric models NRLMSISE 00 MSIS Mass Spectrometer and Incoherent Scatter is an empiric model that is based on mass spectrometer data and pressure measurements of rockets satellites and airplanes as well as on temperature measurements of incoherent scatter radars By addition of new data and combination with physical models the MSIS model has been de
83. q andi dace 28 341 Social Mediae ipn 28 342 NV ODS 29 3 4 3 Classic PHEWOIK zn een 30 3 4 4 Flyers Posters 30 3 4 5 Fly Your Message To Space 30 3 8 ISKCBediSIQE ate Cocca Bene sse oU gs se e DES ee 31 4 EXPERIMENT DESCRIPTION sa nale aaa ea 34 4 1 Experiment Selup seus oeil eps 34 4 1 1 System 35 Z2 MOOS ee a ET Uem e AE 36 4 2 Experiment Interfaces zu an 37 42 1 Mechanical 37 4 3 Experiment 39 4 3 1 Mechanical Patris ea 39 RX16 MOXA SEDv5 0 4 4 Mechanical Design 40 4 4 1 Outer structure nnne nnn 40 444 2 Board a DLP HN MEE MON HERR 41 44 3 Sensors box with Nate usi corre n Ce a de ecd 43 4 4 4 Inner 49 4 4 5 Pressure 52 4 4 6 Position and fixation of the Battery 53 4 4 7 fly your message to part 53 4 5 Fluid M echa ieu y IHE 54 4 6 Electronics
84. ration sensor PCB Br el amp Kjaer Adapter of vibration To realize a facsimile test behavior as possible the module which should be tested was screwed on a second empty REXUS module Thereby it was achieved an almost original fixing The lower empty module was screwed over his own bulkhead ground with the vibration desk Picture 4 Vibration adapter on the vibration desk Vibration Test Report Team MOXA Seite 9 27 REXUS 15 16 Team MOXA 16 01 14 Test process The test process for the X Y and Z Axis was in each time as follows Testorganisation and preparation Visual control Sinus Eigenfrequencies searching Random Qualification 3 Sinus Eigenfrequencies searching 3 Visual control Visual control During the visual control the components cable management and all boltings were checked before and after every test run for subsidence damage and bulking blasting phenomenon Vibration Test Report Team MOXA Seite 10 27 REXUS 15 16 Team MOXA 16 01 14 Test requirement The vibration test for the module is passed if following points are given e For each axis X Y and Z the test was executed according to the test run and the particular results logged e The defined test values which are fixed in the tables 6 4 1 and 6 4 2 were achieved in all axis directions e The eigen frequency progress before and after the particular random tests accord approximately and show o Relative to
85. s has to studied in further investigations Page 90 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Pirani pressure sensor One of the most sensitive component is the Pirani sensor This device sensor was designed for vacuum chambers in a laboratory and not for a rocket launch with high vibrations and a large temperature range To make the sensor suitable for our experiment we placed designed a damping bracket to avoid vibrations and placed it near the center of the bulkhead where a small temperature range was expected After the flight we recognized that the sensor is still operational This means that the damping bracket even could handle the payload touchdown Electronic Box The box wasn t damaged and cared for the storage of the electronic boards very well Gas Sensors The results of the inner resistance of the sensors show that the sensors did not heat up properly as shown in the following figure fig 51 Sensor resistance during the flight The figure 52 shows the inner resistance from liftoff till shutdown of the electronic 360s At the beginning the high velocity cooled down the sensors Our sensor control loop normally prevents that but two things went wrong On the one hand the PID values have not been that aggressive as they should be so the control loop was too slow for the fast changing in air speed and density The much more Page 91 EuR
86. s ordered 0 10 battery FEYELECTRONIK ordered 0 14 box Fly your message to space CONRAD ordered 0 02 Total mass mechanic 4 04 Page 40 EurRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Table 4 5 Experiment summary table Attribute Dimension Experiment mass in kg 8 973kg including module and bulkhead Experiment dimensions in m 0 348 x 0 130 Experiment footprint area in m 0 0657 Experiment volume in m 0 012 Experiment expected CoG centre of x 137 y 106 z 0 191 gravity position 4 4 Mechanical Design 4 4 1 Outer structure We use a 170 mm module that is provided by the DLR together with the bottom mounted bulkhead The bulkhead will be modified with holes for screws to mount the board box and all parts that are located at the bottom of the module fig 16 Outer casing There are some modifications concerning the module To allow the sensors access to the environmental air 3 recesses will be made One is situated at 270 from the 0 line with the dimensions 95mm length and 30mm height This one gives the sensors in the hatch see 4 4 3 access to the ambient air As shown in the description of the hatch this hole will be closed at the launch and opened during flight The other two recesses are situated opposite of the one at circa 90 They will give the other sensors that are situated in an inner chamber access to the ambient a
87. s the area on hull The sensors will have a protective cap during tests fig 49 Warning sign at outer hull Page 84 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Hatch safety issues It has already been mentioned that the hatch will not be closed again So it will be open during reentry and landing To ensure that no hot gas will get access to the inner parts of the module we use some mechanism parts When an airflow with over estimated 200 C flows permanent over the sensors e g reentry the sensor could be damaged but this is set Our goal is to get as much data as possible which means we measure till the sensors are damaged A weak point is the photo sensor It is also made of plastic and could melt during reentry The hole that arises due to that is protected with an aluminum box shown in the picture below fig 50 aluminium box All contact faces between different parts or at places where cables will come through the structure will be secured with a paste that is temperature resistant Owing to the fact that the pyrocutter contains explosives there have to be some security constraints To prevent early ignition and damage to men or material the electric circuit have to be capsuled and seperated from other cords Page 85 EurRoLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 6 1 3 Electrical in
88. sensor will operate in our experiment in a miniaturized form They are solid electrolyte sensors based on amperometric combined with the potentiometric Nernst principle for polarization control cathode solid electr carrier substrate heater fig 4 Amperometric principle for the AO sensor Simplified cathode reaction O 2e 0j Page 12 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden In case of contact of the gaugeable species with the cathode the impressed voltage between cathode and anode leads to a current This is because the molecule or atom take electrons from the cathode and transport them to the anode The current can be measured and compared with diagrams which were created for different partial pressures of the gaugeable species and different static pressures of the gas composition Difference between the oxygen sensors The difference between the atomic and molecular oxygen sensor are the electrodes Atomic oxygen prefers reaction with gold electrodes however atomic and molecular oxygen prefers reaction with platinum electrodes So cermet electrodes on base of gold or platinum can allow a distinction between atomic and molecular oxygen The feedback control of the reduced potential with a reference electrode is very important because of the higher electrode polarisation in the gold electrode The Sensor for O2 and O3 does no
89. ss release and the article we gained a lot of attention Several media wanted to report about us and our project We were already interviewed by different media for example by the Campusradio Dresden and the MDR Mitteldeutscher Rundfunk 3 4 4 Flyers Posters Buttons So far we have already designed flyers posters and buttons which present our work in courses or on special events on university 3 4 5 Fly Your Message To Space FYMTS Our campaign Fly Your Message To Space FYMTS will give people the chance to send a small message to outer space These messages will be collected and printed out being included inside the MOXA experiment box each on a further sheet of paper We would like to use the campaign to get more attention for the rocket start about two months in advance We are quite sure that the press would love the idea to report about FYMTS and will also spread the call out for messages Page 31 EuroLruncH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX 16 TU Dresden 3 5 Risk Register Table 3 2 Risk Register ID Risk amp consequence if not Action obvious M X 01 Parts get unconnected due to Vibration test vibration M X 02 Hatch is not opening Function test M X 03 Hatch is closing uncontrolled Function test because of malfunction of the springs M X 04 Hatch is opening to early M X 05 Hatch tilts on the guide Test and good design of tolerances M X 06 P
90. t Temperature in C In house production AlMgSi1 melt at 585 Battery Operating from 20 up to 60 Battery rubber for fixation Up to 100 Battery Fixation steel Up to 1600 Piezo sensor 40 up to 85 Operating 5 to 50 Pirani irani sensor Storage 20 to 70 Pirani fix dampers operating from 20 to 80 Pirani fix Frame AIMgsSi1 melt at 585 cables Operating Up to 60 cable fixation Up to 100 Sealing compound Operating up to 300 Boxes for FYMTS Melti and board for hatch opening elting at 660 Interplay between the electronic boards and the electronic box The heat which the electronics will produce and emit is hard to calculate so it will be tested So we determine no temperature range but we show that the box can suffer the temperature and later after the tests show how much heat the electronic will produce to be sure everything will work or change the design Table 4 14 temperature profiles of components of the electronic box Part Temperature in C In house production AlMgSi1 melt at 585 Distance pieces steel Up to 1600 Foam for fiction Operating 20 up to 105 Cable outlet Operating at 20 up to 85 Screws All screws are made of steel and will handle the temperature profile Page 69 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Table 4 15 Heat Power Generation r Power diss
91. t need this reference Ozone sensor The ozone sensor works on another principle But we must not tell more about it because it is in a patent process Summary The development of these precise sensors is an important step for better understanding of the complex and dynamic character of our atmosphere By means of this you can make precise prediction of specific gas densities for example corrosive atomic oxygen That leads to a better assessment of necessary safeguards for long term missions in the low earth orbit In addition we can better understand climatie effects which will lead to a better prediction of climatic changes and the weather 1 2 Mission Statement We will test a new developed ozone sensor In a review we will compare the measured data in dependence on pressure will be measured with known data to estimate the sensors operation quality under conditions of the rocket flight Our secondary payloads are the sensors for atomic and molecular oxygen and a temperature sensor Page 13 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 1 3 Experiment Objectives Primary Obj 1 Test of the ozone sensor during the flight Obj 2 Measurement of atomic and molecular oxygen during the flight Obj 3 Measurement of pressure necessary for data analysis during the flight Secondary Obj 4 Measurement of temperature during the flight 1 4 Experi
92. terfaces REXUS Electrical Interfaces Service module interface required Yes No usually yes Data rate downlink 19 2 Kbit s Data rate uplink 0 Kbit s Power system Service module power required Yes Lr Peak power consumption K Average power consumption Total power consumption after lift off 7 Wh until T 600s Power OFF t 600s P Battery recharging through service module Yes Experiment signals Signals from service module required Yes No 6 1 4 Launch Site Requirements The Experiment must be kept above 7 C at all times to avoid freezing of the electrolyte within the sensors Heating and Isolation to keep the temperature above Page 86 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden this level is necessary for transportation and launch pad during times without experiment power At the launch site we require at Liftoff Local Temperature Local Pressure 6 2 Preparation and Test Activities at Esrange Installation and test of our ground station equipment Prove of integrity of all components after transport Change Installation of the battery Change Installation of all gas sensors Test of the functionality of the hatch pyrocutter Test of the functionality of electronics and the sensors Secure the reject mechanism of the SD Card with some glue Use test signals from the REXUS bus and test the right reaction Final fixation of the i
93. tery Read Save all Analog Values Currents Voltages Pressures Read Save all Temperature Values Page 75 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Groundstation Software Serial Port msan S LJ R5422 R5232 sss fig 47 UML Diagram of Groundstation software classes The software is accessible online via a revision software Git to allow collaboration and sharing of the software with fellow future teams Status jStation Moxa Experiment 00 00 00 22 36 26 9 ten vi Sensor 1 Sensor 1 Sensor 1 sewe Commands GL w r poe E Current x c Current x C Hatch Temes jLabe45 1065 jLabel46 Piranhi Sensor xx mBar Piezo Sensor Temp XS Temp XI Temp mBar m o Power xw Power xw Power xw Start Heating Temp Values 30s ADC Values 30s Value Value 0 _ 223557070 01 00 00 000 Time une ADC1 ADC2 ADCI ADC4 STM32 1 T2 T3 Temperatures Sensor Sensor2 Sensor3 7 0 P Measured fig 48 Preliminary GUI of the Ground Station 4 10 Ground Support Equipment Two laptops The ground support equipment will receive the data from the REXUS Interface and will analyse it for transmission error process and save the data We need
94. the module Therefore we don t expect any problems Even thought we can t determine the exact point in time when the hatch opens we can be sure that in any case no problems should occur Vibration Test Report Team MOXA Seite 26 27 REXUS 15 16 Team MOXA 16 01 14 Facit The results of the vibration test shows that the module and the experimental set up have a very rigid behavior and that only the interlocking system reacts sensitive of the vibration Searching for the eigen frequencies with different arrangement of damper on the fixture of the Pirani sensor results for the team intern interests information about the damper behavior at this component It should be realized that the interlocking system using a brad and an electromagnet doesn t demonstrate an optimal solution The reliability of the experiment could be warranted for the allowed vibration load Nathanael Warth Responsible person Alexander Mager Team leader www rexus moxa de Vibration Test Report Team MOXA Seite 27 27 Page 110 EuroLruncH Students Experiment Document MOXA Experiment RX16 TU Dresden APPENDIX F PREPARATION AND TEST ACTIVITIES AT ESRANGE
95. the REXUS Interface 2 5 Constraints C 1 The experiment shall fit in the module C 2 The experiment shall be able to handle the vibration spectrum 2 The electric produces heat C 4 The flow vector on the experiment sensors change during the flight Page 19 EuroLAuNcH Students Experiment Document MOXA Experiment RX16 TU Dresden 3 PROJECT PLANNING 3 1 Work Breakdown Structure WBS fig 5 WBS 1 MOXA Page 20 p EuroLrauncHh Students Experiment Document MOXA Experiment RX 16 TU Dresden Fig 6 WBS 2 MOXA Page 21 EuroLrunch LR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Schedule 3 2 bt _ pr xm naui naut ruis nn ung ona lox ONE SRSESEESESELESESS tarnar nuu mine t Rh tit Timetable of MOXA experiment fig 7 Page 22 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 3 3 Resources 3 3 1 Manpower Alexander Mager Aerospace engineer student Lectures of system engineering SOLID WORKS Bastian Klose Mechatronics engineering student Specialization power electronics Practical training in micro controller programming Alexander Schultze Mechatronics engineering student Specialization power el
96. the end Here is a list of the most important things e Very much about time management project phases manufacturing durations testing procedures and even response time for e mails e Define clear responsibilities in the team e Team work is challenging e Always review working packages in the team e Weekly meetings even when we didn t had so much to discuss are mandatory Page 94 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden e Important points have to be mentioned again and again to make sure everybody understood them e How to express the current project status in a presentation e Take deadlines seriously e Electronic engineers are rare but most important e Working independently on a project besides our studies e To elaborate the details is 90 of the work e Double check production orders e Learned a lot about Murphy s law Page 95 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 8 ABBREVIATIONS AND REFERENCES 8 1 Abbreviations This section contains a list of all abbreviations used in the document Add abbreviations to the list below as appropriate In version 5 of the SED final version delete unused abbreviations AIT Assembly Integration and Test asap as soon as possible BO Bonn DLR German Space Agency BR Bremen DLR Institute of Space Systems CDR Critical Design Review COG Centre
97. the resonance frequency discrepancies are less than 5 o Relative to the strain at resonance frequency displacement is less than 25 e The visual control after every test run doesn t show hardware damages or other damages Vibration Test Report Team MOXA Seite 11 27 REXUS 15 16 Team MOXA 16 01 14 Test structure and sensor configuration Test structure on the shaker The module was mounted on a test adapter with 30 M5x16 cheese head screws with hexagon socket The clamping torque betrug 5 4 Nm maximal allowed 6 5Nm The test adapter was screwed on the vibration desk with 9 M8 cheese head screws with hexagon socket and 24 Nm of clamping torque for the X and Y tests All screws were fixed with a dynamometric key Between the bulkhead of the adapter and the vibration desk is a distance of 8mm That s why around every 9 screws was laid a big M10 screw nut height 7 8mm to beware a bending and so a damage of the bulkhead and of the adapter module The 30 cheese head screws were released for the conversion from the X to the Y axis Then the test module was turned by 90 to the left and stabilized again The swing unit was disconnected with the vibration test for the Z axis test and was straighten up from the horizontal to the vertical The adapter with test module was screwed directly on the swing unit for the Z axis The reason for this procedure is that the swing unit uses the same mount as the vibration desk Picture 5 T
98. the risk of desoldered joints due to hot gas in the hatch compartment Perfect solution would be to open and close the hatch again Current hatch design requires an arm plug for testing Beware of thermal expansion with regard to manufacturing tolerances in the hatch Air inlets Should be discussed with EuroLaunch CDR panel not sufficient Steel wool poses risk of combustion in the module 000000000 Electronics and data management SED chapter 4 2 2 4 2 3 4 5 amp 4 7 o Deliver detailed electronics schematics Service module interface schematics not complete in the SED Capacitor Should be included in the schematic provide further details Consider sparking due to high voltage Perform tests accordingly Test the vacuum compatibility of the capacitor 0000 Thermal SED chapter 4 2 4 amp 4 6 o Thermal section severely lacking o Provide details regarding the expected thermal environment component ranges etc o Battery heating Not required Software SED chapier 4 8 Software risks are missing in the risk register Develop early try not to wait for flight hardware to arrive Provide details on signals and timeline Verification and testing SED chapter 5 o Design requirement 3 Cannot be done by analysis o Verify early and start with the easiest verification method Verification should not rely on a single test in the end o Most important tests vibration thermal are covered correctly but subsystem tests
99. the test equipment e Shaker Systemdescription Document ID 3000241D V8 V3 System pdf e Shaker Softwaredescription Document ID Dactron Software Beschreibung pdf e PCB acceleration sensor Document ID PCB 353B03 pdf e PCB acceleration sensor Document ID PCB M353B18 pdf e Br el amp Kjaer 3 Axis acceleration sensor Documet ID 4504A triaxial CCLD accelerometer pdf Vibration Test Report Team MOXA Seite 4 27 REXUS 15 16 Team MOXA 16 01 14 Test organisation The vibration test was executed at the institution of light construction and plastics engineering ILK in Dresden Johannstadt The necessary test equipment with software sensor acceleration and required tools was provided Furthermore the test adapter which is a second little REXUS module with a bulkhead for the test period was provided from ZARM Bremen The tests take 3 days and was executed on the 7th of January and 13 of January The interposition occurred by Dr Tino Schmiel and Paul Rossman from the institution of aerospace and space flight at the ILK Cooperators e Rainer Saalfeld test bed leader of the ILK e Alexander Mager Team leader e Nathanael Warth Responsible for the test and mechanics e Max Oswald Mechanics e Sebastian Weixler Mechanics Ambience conditions During the tests the temperature was around 20 C the relative humidity 55 10 at normal air pressure The shaker stood in a big dead room with aeration In each case a hydraulic pump was engaging t
100. the wrong EuroLaunch logo in the template Please replace it on our behalf 4 Panel Comments Recommendations Requirements and constraints SED chapter 2 o Very good functional requirements o 11 Check the required accuracy o Design requirement Status messages shall be sent to the ground station Mechanics SED chapter 4 2 1 amp 4 4 Use a 120mm or 150mm rocket module Consider rearranging the PCBs and electronics boxes Feed through cable hole in the bulkhead requested o O o Current hatch design is interesting it can be implemented if it is tested thoroughly and early on in the project breadboarding prototyping before the CDR vibration tests o Simplification of hatch design can be considered if it is not required to close Use of pyrocutters or melting wires in combination with springs is recommended in this case o of hatch could be controlled directly by the experiment not by EuroLaunch o Positioning of vibration sensor should not pose a problem as the rocket is spinning at 4Hz o Pirani sensor is critical in terms of handling consider a different ruggedized sensor Electronics and data management SED chapter 4 2 2 4 2 3 4 5 amp 4 7 o Use of uplink on ground is mandatory Use telecommands before LO not signals timeline before launch is not automated GPS data is only available after the flight More accurate definition o
101. threaded rods There is no modification concerning the mounting of the D Sub bracket or the attachment of the module with the experiments below and above All screws will be locked with Loctite at the final assembly Where we have enough space there will be serrated lock washers or rather screws with tooth head EuRoOLAUNCH ADLR and SSC cooperation Page 39 Students Experiment Document MOXA Experiment RX16 TU Dresden 4 3 Experiment Components Mechanical parts and connectors are listed in this section All electronic components that have to be soldered on one of the PCB Boards are listed in appendix C 4 3 1 Mechanical Parts Table 4 4 Mechanical Parts summary table component x supplier current status v weight in Kg Srews and little fixation parts several ordered 0 50 Hatch parts of in house production material AIMgSi1 TUD ordered 0 90 springs GUTEKUNST ordered 0 01 photosensor CONRAD ordered 0 03 slide bushes IGUS ordered 0 01 shafts MISUMI ordered 0 01 pyrocutter TRW ordered 0 02 Inner Chamber Ramp material X5CrNi18 10 TUD ordered 0 25 inside parts material AIMgSi1 TUD ordered 0 60 high temperature adhesive OMEGA ordered 0 01 Electronic box parts of in house production material AIMgSi1 TUD ordered 1 10 other several ordered 0 20 Module pirani sensor PCE ordered 0 12 pirani flexible tube LANDEFELD ordered 0 01 pirani vibration dumper Schwingungsdampfer DD ordered 0 01 piezo sensor sensor technic
102. uit and board layout in Annex C 4 6 6 Connectors For connecting the circuits we use mainly 2 different connectors manufactured by MOLEX and JST We use the Molex standard KK CME Connectors in 2 54mm width The Headers do have voided back walls and friction locks that provide additional polarisation feature and mate retention On the other hand we use JST SH connectors that can be mounted at TU Dresden for all signals etc Here is a table of all connectors we use inside our rocket module Page 65 EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Table 4 10 Connectors Connector Connector Connect Kind of Num Name Side A Connect to Side B to cable Weight g Sensor 1 Sens1 1 Molex Sensorboard 1 Molex AO Hatch 300mm 5AWG24 11 2 Sensor 2 Sens1 2 Molex Sensorboard 1 Molex O2 Hatch 300mm S5AWG24 11 2 Sensor B Sens1 3 Molex Sensorboard 1 Molex 03 Hatch 300mm 5AWG24 11 2 Sensor AO 4 Sens2 1 Molex Sensorboard2 Molex Cavity 300mm 5AWG24 11 2 Sensor 02 5 Sens2 2 Molex Sensorboard2 Molex Cavity 300mm 5AWG24 11 2 Sensor 03 6 Sens2 3 Molex Sensorboard2 Molex Cavity 300mm SAWG24 11 2 Sensor Pressure 7 Pressure1 JST SH 4 Mainboard 1 Plug Hatch 300mm 4AWG28 14 Sensor Pressure 8 Pressure 2 JST SH 5 Mainboard 1 Plug Cavity 300mm 4AWG28 14 Crimp Crimp 2 min 9 Battery H lse Powerboard H lse Battery 100mm AWG10 25 M
103. unch pad ve The experiment shall store the measured data ona T 4 SD card The experiment shall send a part of the measured T A d data down to the ground station The experiment shall be able to turn off all T 4 electrical parts for landing us O 7 The experiment electrics shall control the sensors T all the time The sensors must not be touched when they hot The automatic events shall automatically triggered T by Timeline after liftoff The manual events shall be transmitted over the T done REXUS Interface Page 79 EuroLaurcH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 5 2 Test Plan Table 5 1 Test description T1 Test facility TUD Test level procedure Qualification test and duration Test campaign duration Table 5 2 Test description T2 Test facility Not clear yet Test level procedure Qualification test and duration Test campaign duration Page 80 EUuROLAUNCH A DLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Table 5 3 Test description T3 Test facility TUD Test level procedure Acceptance test and duration Test campaign 21 day duration Table 5 4 Test description T4 Test facility TUD ZARM Test level procedure Qualification test and duration Test campaign 5 days duration Table 5 5 Test description T5 Test level proced
104. ure Acceptance test and duration Test campaign 15 day duration Page 81 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 5 3 Vibration Test To ensure the safety of our module and assembly we will do vibration tests with our complete module The tests will take part at the Dresden University of Technology previously it s necessary to prepare the tests in detail All parts will be mounted for the tests on a vibration table for inspection and functional checks we need relevant equipment Module The testing of the module will take part after the final assembly of our module to ensure safety and functionality of our project Inspection of structure fixation of wiring and functional tests are necessary after each axis of vibration The opening mechanism of the hatch has to be tested during every vibration test to ensure functionality after launch Additional accelerometers for each axis need to be mounted onto the board box the hatch and the pirani sensor Pirani Sensor In order to check the efficiency and capacitance of the Pirani sensor we will test the sensor within the whole module in functionality and simulate the conditions of the flight First we will check the qualification level of vibration therefore it s necessary to mount accelerometers for each axis X Y and Z and inspect the functionality of the sensor after the test for each axis Search for Ei
105. us moxa de 1 5 2 Team Members Alexander Mager Team leader Payload Aerospace engineer 6 Academic year Bastian Klose Electronic amp Software Design Mechatronics engineer 6 Academic year Patrick Geigengack Mechanics Aerospace engineer 4 Academic year Alexander Schultz Electronic amp Software Design Web Mechatronics engineer 6 Academic year Jonas Uhlman Mechanics Mechanical engineer 6 Academic year Daniel Becker Fluid mechanics Aerospace engineer 4 Academic year Fabienne Kinzelmann Outreach Philosophies and Catholic Theology 3 Academic year Susann Knapik Gas sensors Chemical engineer 4 Academic year Nathanael Warth Mechanics amp Tests Mechanical engineer 3 Academic year Page 15 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden Max Oswald Mechanics amp Tests Aerospace engineer 5 Academic year Sebastian Weixler Mechanics Mechanical engineer 3 Academic year Page 16 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 2 EXPERIMENT REQUIREMENTS AND CONSTRAINTS 2 1 Functional Requirements F 1 The experiment shall measure ozone on the outer shape of the RX rocket during the flight with two different electronic circuits F 2 The experiment shall measure atomic oxygen on the outer shape of the RX rocket during the flight with two different electronic circuits F 3
106. usion the prototype has to developed further but we learned very much about the handling of the sensor Page 93 EuRoOLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden 7 5 Discussion and Conclusions In conclusion MOXA mostly fulfilled its objectives There are two points that didn t worked as we expected One is the sensor heating in the beginning of the flight and other one are the flow conditions in the inner chamber as mentioned in chapter 7 3 4 Conclusions e In this configuration the gas sensor are more suitable for low airstream velocities This achieved partially in the inner chamber e Electronics and software operated very well and should be used for further operations of the gas sensors e The exact analysis of the measurements shall be done in a student research project MOXA was successful in the main intention of REXUS because we learned so much about procedures of projects from the very first beginning of a proposal to the final presentation of the results It was the first time for the most of us to get to know the difficulties and benefits of teamwork We would like to thank ZARM DLR ESA MORABA and SSC for this great experience We learned so much and we are glad that you make it possible to put our idea on your rocket Thank you 7 6 Lessons Learned We learned very much especially how an aerospace project has to be done from the very beginning to
107. veloped to the NRLMSISE 00 Naval Research Laboratory Mass Spectrometer and Incoherent Scatter model It predicts from sea level to the exosphere DTM The DTM model Drag Temperature model uses optical temperature measurements and data of atmospheric drag from satellites It works with the assumption that helium nitrogen and oxygen are the essential elements of the Page 9 EuroLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden atmosphere from 120 km to higher altitude and connect them with diffusion equations MET 2 0 The MET model Marshall Engineering Thermosphere Model has edge condition of temperature and gas composition of 90km and based on diffusion equations and temperature assumptions to the altitude where data from satellite retardation exist Prediction of atomic and molecular oxygen We calculated a prediction of atomic and molecular oxygen to an altitude of 340 km for longitude and latitude of O degree for the year 2012 based on these three models We used SPENVIS ESA European Space Agency Space Environment Information System for the calculation and the input parameters from the NOAA database 5 00E 10 4 50E 10 4 00E 10 3 50E 10 3 00E 10 2 50E 10 NRLMSISE 2 00E 10 1 50E 10 1 00E 10 5 00E 09 fig 1 Prediction of molecular oxygen In the prediction of molecular Oxygen the MET model shows a strong influence of the seasons The DT
108. x6 1x clamping plate page 5 Pyrocutter drawings 1x steel wire 0 8 Fa C G Ahrens 1x 002 stop page Seite 4 Materials for each component are shown in the attached drawings Page 45 I A aC jy EuROLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden box and sensor mounting b rt SS sensor board with plugs mounting plate BP box lower part fig 24 sensor mounting hatch The outer box is made of two parts that are assembled with screws 2 x EN ISO 4762 M5x15 and positioned with bolts 2 x EN ISO 8734 6x15 to realize an accurate mounting on the module wall The four sensors are positioned in four cuts in the upper part On the backside of the box there is a sensor board with four plugs mounted 8 x EN ISO 2010 2x6 The sensors are attached to these plugs To prevent an unplugging of the sensors we mounted them with a plate from the other side that pushes them with its 3 x EN ISO 2010 M3x6 screws against the box so that a form fit is realized the holes in the plate are smaller than the smallest sensors diameter Page 46 EuRoLAUNCH ADLR and SSC cooperation Students Experiment Document MOXA Experiment RX16 TU Dresden hatch mechanism guides m anti friction bushes clamping plate B fig 25 Hatch mechanism To move the hatch there are four antifriction bushes integrated in the aluminium plate They touc
109. yrocutter doesn t fire Calculation and test M X 07 Springs crack Test and consultation with manufacture for probability M X 08 Sensor breaks Sensors are intermountable M X 09 Hatch or inner chamber not Good design tight hot air gets in the module M X 10 Anything gets damages during A Plan of procedure late access M X 11 Air inlet or outlet gets Redundancy of unconnected during flight screws M X 12 Cables break get Design large bend unconnected radii M X 13 Flexible tubes breaks get Design large bend unconnected radii M X 13 Pyrocutter fires to early A 2 Controlled by MORABA E X 01 Mosfet gets overheated B 4 Vacuum chamber during the flight test E X 02 DC DC Converter gets B Thermal design and overheated during the flight Vacuum chamber test N EuroLAuNcH A DLR and SSC cooper Page 32 Students Experiment Document MOXA Experiment RX16 TU Dresden E X 03 E X 04 E X 05 L X 01 L X 02 L X 03 F X 01 F X 02 S X 01 S X 02 S X 03 Battery gets overheated Short circuit Connectors do not complete the circuit while flight Team member leaves the project Team member is temporary not available for personal reason Conflicts in the team slow the work flow Team member underestimates the amount of work Have not as much people as required working on the project Material on Order arrives too late Parts ordered too late Material on order are brok

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