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1. Student Experiment Documentation Page 77 Deployment CELL MOUNT _LOWER 4 Al T6 Sheet 2 Deployment SOLENOID_ BODY 2 B22 Farnell Deployment SOLENOID_BOLT 2 B22 Farnell Deployment HINGE_PIN 4 3mm stainless rod workshop Deployment Deployment LATCH 2 mechanism workshop Deployment Deployment LINK 2 mechanism workshop Deployment SOLENOID_PIN 2 workshop Hub HUB_CORNER_H 4 Al T6 Angle 2 Hub HUB_CORNER_L 4 Al T6 Angle 2 Hub HUB_CORNER_W 4 Al T6 Angle 2 Hub HUB_MOUNTPLATE 2 Al T6 Sheet 1 Hub HUB_SIDESTRAP 2 Al T6 Sheet 1 Hub HUB_FOAM_BACK 1 STYROFOAM Hub HUB_FOAM_LARGE 2 STYROFOAM Hub HUB_FOAM_SIDE 2 STYROFOAM Hub HUB_FOAM_TOP 1 STYROFOAM Inflatable CELL 20 MYLAR Inflatable CELL HANGER 4 MYLAR Roof Mount SUPPORT_MOUNTPLATE 4 Al T6 Sheet 1 Roof Mount TUBE_LONG 2 Al T6 Tube Roof Mount TUBE_SHORT 2 Al T6 Tube M3 stainless nyloc ZGeneral M3_NUT 108 nut Falcon W S Supplies ZGeneral M3STUBBOLT 104 M3 x 6mm stainless Falcon W S Supplies ZGeneral M4_BOLT 2 M4x10mm stainless Falcon W S Supplies ZGeneral M4_BOLT_MED 6 M4x14mm stainless Falcon W S Supplies ZGeneral M4_HUB 24 M4 x 10mm stainless Falcon W S Supplies ZGeneral M4_NUT 28 M4 stainles nyloc nut Falcon W S Supplies ZGeneral M8s_BOLT 8 M8 x 75mm stainless Falcon W S Supplies ZGeneral M DOUT MED 8 M8 x 55mm stainless Falcon W S Supplies ZGeneral M8_BOLT_SHOR
2. Student Experiment Documentation Page 148 Phase OP 0 Pump 1 Pump 1 OP 10 Pump 1 amp 2 Pump 1 amp 2 OP 20 Pump 1 2 3 Pump 1 2 3 OP 30 All pumps off All pumps off OP 40 Pump 1 Pump 2 OP 50 Pump 1 amp 2 Pump 2 amp 3 OP 59 Switch both Hack HD off and then on to save stored data OP 60 Full Cycle Complete Repeat until cut down when systems go on standby CUT 5 GES team notified by mission control that 5min until balloon cut o iSEDE team will command automated CUT sequence CUT 4 Automated CUT sequence o Both Hack HD recording off safe data o Both Hack HD start recording CUT Balloon Cut Off CUT 15 Automated CUT sequence timed 20min after CUT sequence start command o Hack HD in standby to safe data o Hack HD shut down o Raspberry Pi shut down Landing Landing 6 4 Post Flight Activities The main post flight activity was to recover the SD cards from the cameras and hub on board the gondola Following this analysis of experiment data was undertaken as described in Section 7 Data analysis allowed us to characterise how successful the mission has been for documentation and presentation at the results symposium After the experiment data is securely copied on at least two computers the experiment was getting dismounted and prepared for shipping The table below describes a list of procedures
3. Jonathan Adam Larissa Craig Darryl Andrew Frazer Tiago 1 5 3 2 Fair share of work 5 Completed His Her Fair Share of the Work October 2012 May 2013 Jonathan Adam Larissa Craig Darryl Andrew Frazer Tiago BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH Student Experiment Documentation Page 12 6 Completed His Her Fair Share of the Work June 2013 September 2013 Adam Larissa Craig Darryl Frazer Tiago Over the summer Tiago and Larissa worked on the project as part of their exchange program internship Frazer and Darryl were on a paid Strathclyde internship and Adam and Craig promised to work on the experiment over the summer Andrew and Jonathan already said early in the project that they would not be able to work on it over the summer From the evaluation it can be clearly seen that the bulk of work was undertaken by Tiago and Frazer spending also most of their free time on the experiment Larissa did all the required work and responded quickly with results on new tasks On the other hand the work of Craig and Adam was non existent during the summer Also Darryl s work ethics over the summer was poor even though he was on a paid internship BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH Student Experiment Documentation Page 13 7 Completed His Her Fair Share of the Work CAMPAIGN Frazer Tiago Tiago Frazer Andrew Darryl a
4. BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 134 Figure 5 2 Deployment in Vacuum Chamber Inflation tests have been repeated in vertical configuration and successfully completed Table 5 28 Test Results 0 3 Test number _ 0 3 Completedi 1510812013 Test type Functionality micro pumps Results Controller was able to actuate Bartels micro pumps in and outside the vacuum chamber When connected to the soft robotic actuator micro pump was able to inflate actuator Table 5 29 Test Results 0 4 Test number _ 0 4 Gompleted 2010812073 Test type Shape changing of structure Results 04 1 Deformation of structure without soft robotic actuator micropums and added electronics was proven with manual actuation Single cells in the 5x2 satellite were deflated and a deformation was observed 04 2 When connected to the soft robotic actuator micro pump was able to inflate actuator Table 5 30 Test Results 0 5 Test number 0 5 Completed Test type Feedback position control Results Readings of IMUs and cameras were taken in lab assembly but need to verified during launch campaign Table 5 31 Test Results 0 6 BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Page 135 Test number 0 6 Gompletedi 1010812013 Test type Folding and packaging Results Full
5. BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Page 131 5 2 At balloon campaign Test duration 3 weeks Date status 5 1 August 2013 amperde 5 2 October 2013 GOmpleted BX16_iSEDE_SEDv5 1 31JAN14 EuROLAUNCH Student Experiment Documentation Page 132 5 2 2 Test Matrix The test matrix gives the connection between each test and the experiment requirements that are covered by it The colours in the table indicate if the test is finished green in progress yellow or not started yet white Table 5 25 Test matrix Test Text Test Experiment Requirement Number BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH R and SSC cooperation Student Experiment Documentation Page 133 5 3 Test Results 5 3 1 Test Results Breakdown Table 5 26 Test Results 0 1 Testnumber 0 1 Gomplete 1510112072 Test type Residual air inflation Results Tests found residual air inflation to be a reliable method of inflation The inflatable elements had sufficient trapped air to inflate at the pressures they experienced at heights above 30km Table 5 27 Test Results 0 2 Test number 0 2 completed 07 08 2013 Test type Deployment of Satellites Tests of deployment of the inflatable structure have been Results l l carried out using the horizontal configuration of the vacuum chamber Deployment was successful
6. EVUROLAUNCH A DLR and SSC cooperation Student Experiment Documentation Document ID BX16_iSEDE_ SEDv5 1 31JAN14 Mission BEXUS 16 Team Name iSEDE Experiment Title Inflatable Satellite Encompassing Disaggregated Electronics Team Name Student Team Leader Thomas Sinn Team Members Tiago de Fran a Queiroz Frazer Brownlie Larissa Batista Leite Andrew Allan Jonathan Gillespie Adam Rowan Version Issue Date Document Type 5 1 31 January 2014 Spec Issued by Tiago de Fran a Queiroz Electronic Lead Approved by Thomas Sinn Project Manager amp Scientific Advisor BX16_iSEDE_SEDv5 1 31JAN14 University University of Strathclyde University of Strathclyde University of Strathclyde University of Strathclyde University of Strathclyde University of Strathclyde University of Strathclyde Valid from 31 January 2014 Change Record Version Date Changed chapters 2008 12 18 Blank Book 2010 2013 0118 AN PORE o a o 1 1 BX16_iSEDE_SEDv5 1 31JAN14 2013 01 25 pre PDR 2013 05 13 CDR 1 1 references 4 1 2 amp 5 4 3 3 1 3 3 2 5 1 Appendix C 1 2 1 3 1 5 2 2 1 2 2 2 3 amp 2 4 Background on inflatables Illumination Added requirements PE13 14 Table of Components Improved task allocation Included known costs Updated test matrix Battery Data Sheets Consolidated Added softrobotics to Exp Objt New team members Software Added DE_50 DE_51 DE_52 DE_53 amp
7. Craig and Jonathan Date 26 10 2013 The following evaluation was undertaken for all members of the team except for Thomas This was necessary to keep the anonymous nature of the team member evaluation which was compiled and analysed by Thomas The team members were also allowed to give additional comments which are summarized below some of the graphs and the conclusion chapter Each team member evaluated all the others with the following scale 0 Non existent never 1 Poor 2 Average 3 Good 4 Excellent The following graphs are the average of the sum of all the team member inputs 1 5 3 1 Team Behaviour Reliability 1 Attended Team Meetings and Responded Promptly to Team e mails Jonathan H Adam H Larissa i Craig 1 Darryl L Andrew Frazer Tiago BW Ln LA LA Ln N N Ln w w Ln BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation 2 Helped Move the Team s Decisions Along Jonathan Adam Larissa Craig Darryl Andrew Frazer Tiago 3 Skilled in Analyzing What to Do Jonathan Adam Larissa Craig Darryl Andrew Frazer Tiago BX16_iSEDE_SEDv5 1 31JAN14 nS Lf EurRoLAUNCH A DLR and SSC cooperation Page 10 e EurRoLAUNCH A D R and SSC cooperation Student Experiment Documentation Page 11 4 Calibre of Contribution to Team Decisions
8. ETATS UNIS 1999 vol 108 nod pp 49 51 BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 176 13 14 15 16 17 18 19 20 21 22 23 24 25 Bernasconi M C Flexible wall expandable structures for space applications forty years of trying 1st European Workshop on Inflatable Space Structures 21 22 May Noordwijk The Netherlands 2002 Jenkins C H M Gossamer Spacecraft Membrane and Inflatable Structures Technology for Space Applications Progress in Astronautics and Aeronautics Volume 191 AIAA Reston Viginia USA 2001 Freeland R Bilyeu G Veal G and Mikulas M Inflatable deployable space structures technology summary 49th International Astronautical Congress Melbourne Australia 1998 Bernasconi M C Flexible wall expandable structures for space applications forty years of trying 1st European Workshop on Inflatable Space Structures 21 22 May Noordwijk The Netherlands 2002 Bernasconi M C Chemically rigidized expandable structures CRES rigidization and materials 2nd European Workshop on Inflatable Space Structures 21 23 June Tivoli Italy 2004 Defoort B Polymerization of composite materials in free space environment 4th European Workshop on Inflatable Structures 16 18 June Noordwijk The Netherlands 2008 Thomson M Mechanical vs Inflatable Deployable Structures for Large A
9. Part time students drop out PE30 PhD students complete Pee their research University work PE50 compromises ability to work on BEXUS Shortage of team member for integration PE60 and testing of experiment after end of academic year Shortage of team member for integration PE61 and testing of experiment after end of academic year BX16_iSEDE_SEDv5 1 31JAN14 Medium EurRoLAUNCH ADLR and SSC cooperation Page 43 Find new team members keep track of progress and keep design simple while still achieving objectives Most of the electronics and software is implemented now extensive testing is required Hand over manufacturing to core team members Hand over work to additional team member New PhD students should replace them Majority of team contributing as part of group project Medium Recruit students and secure university internships to work on project over summer Four students working on iSEDE full time over the summer internship from home university and paid internship from Strathclyde Student Experiment Documentation EurRoLAUNCH ADLR and SSC cooperation Page 44 Provide support and Extracurricular students PE70 struggle with workload C 2 flexibility and revaluate while carrying on studies project goals Se Ensure additional Soft
10. Testing the full mechanism at 40 C verifies this expectation 4 6 2 Thermal Design for Inflatable Structure A bonded Mylar inflatable structure has been thermally tested down to 30 C for a period of approximately 30 minutes It was found that the material s properties did not change during the experiment and that the adhesive seal was not weakened by the low temperature Further testing is required to establish whether the structure can withstand the expected temperature of 40 C and for a longer period of time 2 3 hours It is not expected that the Mylar is affected by the lower temperature as it is used as space blankets which is why it is being used for the inflatable structure material The BEXUS16 flight confirmed the correctness of this assumption 4 6 3 Thermal Design for Mechanical Structure The deployment modules rails and mount plates are all made from T6 aluminium which is the same material used for the gondola Therefore thermal expansion is not expected to be a problem 4 6 4 Thermal Design for Hub As the hub is made from polystyrene then the inside of the hub should be properly insulated To ensure this a simple calculation was performed By BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 96 using a general Fourier s Law for conduction equation the heat transfer rate for the hub design could be calculated y 2 U Assuming that the temperature inside the gondo
11. The Raspberry Pi runs Raspbian wheezy and is programmed using C and Qt framework Arduino based devices are programmed using the high level Arduino programming language In March 2013 Larissa amp Tiago were recruited into the iSEDE project team to work on the software aspect of the systems Both students have a Computer Engineering background with Tiago having additional expertise in embedded systems Since joining the team the implementation of the software systems has rapidly increased in place with much prototyping and testing being done over the previous months So far the data flow experiment timing and control algorithms have been defined Code has been developed performing all roles to be undertaken by the Hub and Satellite systems BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 110 4 9 Ground Support Equipment Ground support equipment covers software required for communicating with the experiment during the BEXUS flight No specific testing hardware is required to perform all necessary health tests and trouble shoots 4 9 1 Ground Support Software The ground station software has been made using the programming language Java Although the development has been on Linux the software works fine on any operating system as long as the correct version of the JDK is installed Furthermore a connection to the internet is required in order to make the softwar
12. d CS La LE E g 4 EA Ff d KE d A Lory Lar Figure 4 38 Schematic of Hub data board 4 5 2 1 Controller The Hub is based around Raspberry Pi model B 29 running Raspbian wheezy which allows for seamless interfacing with the BEXUS E Link and ease of programming whilst still providing the required functionality The Raspberry Pi is powered by the 5V supply from the 28 5 V DC DC regulator on board the Hub BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuNcH Student Experiment Documentation Page 83 Figure 4 39 Raspberry Pi model B The board provides 8 GPIO general purpose input output pins plus access to I C SPI UART as well as 3 3 V 5 V and GND supply lines An SD card is used as a non volatile memory that stores the operational system The Figure 4 39 shows the raspberry pi GPIO layout BX16_iSEDE_SEDv5 1 31JAN14 P EuroLauncH Student Experiment Documentation Page 84 Figure 4 33 Raspberry Pi GPIO layout This controller stores an automated version of the experiment timeline so as to allow full operation of the experiment in the circumstance where the BEXUS E Link is lost The Raspberry Pi is situated within the Hub unit with connections to the communications DC DC regulator and camera boards being housed in the header pins 4 5 2 2 Data Acquisition amp Sensors As highlighted earlier in this section the Hub collects data in the form of temperature and housekeeping information as
13. disaggregated across its inflatable structure Cameras shall capture the deployment and R A T performance of the satellites during the mission Passive inflation shall be demonstrated by R S T each satellite Wireless communication shall be established R T between the satellites and hub Each satellite should measure the ambient R T temperature and pressure Each satellite shall demonstrate an alteration R A S of its shape T Control of any shape alteration shall be R T 0 5 demonstrated Resolution of images captured by the R camera s shall be at least 800x600 pixels Images captured shall have at least 16 bit R BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 115 Temperature measurements of critical R components shall take place at a frequency of at least 0 2Hz Ambient temperature measurements shall R take place at a frequency of 0 2 Hz All temperature measurements shall have a R minimum sensitivity of 5 C Differential pressure measurements shall be R taken at a frequency of 0 1 Hz during adaptive phase Differential pressure measurements shall R have a minimum sensitivity of 20 Pa Any shape alteration shall be within 5 cm of R A T desired position During shape alteration the bottom cell should R A T not be displaced by more than 20 cm The wireless link between the hub and each R satellite shall be able to communicate wi
14. level procedure can be read by the onboard computer Test duration 3 weeks Date status February August 2013 6 mpletedi o 0712010 Table 5 13 Test 0 12 Test number 0 12 Test type BEXUS Experiment Communication Test facility University of Strathclyde iSEDE lab Tested item Entire experiment Test Validation that the experiment can communicate to the level procedure BEXUS service module and that all the necessary comments can be sent and received Test duration 3 week 2 days at launch campaign Date status May amp October 2013 G6mpleted BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation and SSC cooperation Page 126 Table 5 14 Test 0 13 Test number 0 13 Test type Thermal test of critical components Test facility University of Glasgow Thermal Chamber Tested item 0 13 1 Microcontroller 0 3 2 Batteries 0 13 3 Charging circuit components 0 13 4 Sensors 0 13 5 Wireless components 0 13 5 Micropumps 0 13 6 Cells with adhesive 0 13 7 Soft robotic actuators fluid Test Test if components breaks at temperatures up to 70C level procedure define if components need to be heated Test duration Various days Date status March August 2013 Pompe DES Table 5 15 Test 0 14 Test number 0 14 Test type EMC test Test facility University of Strathclyde tba Tested item Electronics Test Test on
15. liquids gases and mixtures 0 70 C 5000 h IP33 IT TIET Materials in contact with media polyphenylene sulphone PPSU Suitable evaluation controller mp x mp6 EVA and mp6 OEM Typical values of flow and back pressure for selected media values defined with mp x 250 V SRS Gases Max flow Max back pressure 18 ml min 300 Hz 100 mbar 300 Hz Liquids Water Max flow 7 ml min 15 100 Hz Max back pressure 600 mbar 15 100 Hz Typical values Values can vary under application conditions Content is subject to changes without notice recommended tubing 1 3 mm inner diameter Conditions suction pressure lt 10 mbar DI water settings mp x 100 Hz 250 V SRS the max flow rate will be reached after a few minutes of operation time Conditions DI water room temperature settings mp x 100 Hz 250 V SRS Can be changed to IP44 The mp6 is not stable against concentrated alcoholic solutions as MeOH or EtOH Please find more information concerning the controller and the equipment in the corresponding data sheets BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH cooperation A DLR and SSC Student Experiment Documentation Page 201 Technical Information TIES 1425 0 December 1998 Supersedes edition of September 1996 Registered trademark of BASE Aktiongasalschalt Properties Miscibility Specialty Chemicals BX16_iSEDE_SEDv5 1 31JAN14 Glysantin G 30
16. 01 07 13 Comment 4 9 1 table 4 5 Launch and operations You should include a photo of the RBF attached following fabrication MOBE You should show how to reattach the RBF is the recovery crew find the system with the satellite undeployed this should be discussed with your IPR reviewer MOBE As discussed in 6 2 the detailed procedures should be ready for EAR TOIBE You should be aware of the bounce of the gondola at float phase you may want to wait until constant pressure before deployment If the flight continues in the dark the gondola will also descend up to 2km PMAOMAS Date 04 07 13 Comment Added it to the timeline It s not recommend to have anything running after cut experiment should be shut down before cut OR you risk been on during landing possible corruption of storage You may suffer detachment of the satellites at landing this probably isn t an issue but you may need to instruct the recovery crew to retain these if they open up the gondola for any reason O BEVADDEDTAFTERIPR You may still have a risk of material release during the deployment this doesn t seem to have been addressed BEES You should implement an are you sure check on the deployment command LARISSA THOMAS Date 04 07 13 Comment Added to ground support section BX16_iSEDE_SEDv5 1 31JAN14 Le Student Experiment Documentation Page 190 BEXUS Experiment Integration Progress Review Evrolauncu Page 1 1 R
17. 02 Jul 13 LED HI BRIGHT SMM Bulb Size T 1 3 4 10 Premier Farnell 02 Jul 13 Premier Farnell 75 90 SENSOR ABS PRESS 14 5PSI 344B 4 03 Jul 13 Press 1 Premier Farnell CONVERTER DC DC 2 11 P 1W 12V DC 03 Jul 13 1 Premier Farnell HEATSHRINK 4 8MM CLEAR 1 2M I D 03 Jul 13 Sup 1 Premier Farnell RESISTOR 3 3K 0 125W 1 Product 03 Jul 13 Rang 10 Premier Farnell RESISTOR 0 125W 1 8K2 Product 03 Jul 13 Range M 10 Premier Farnell RESISTOR 0 125W 1 150R Product 03 Jul 13 Range 30 Premier Farnell LED 3MM GREEN Bulb Size T 1 3mm 03 Jul 13 LE 10 Premier Farnell 03 Jul 13 LED T 1 YELLOW Bulb Size T 1 3mm LE 10 Premier Farnell RESISTOR 0 125W 1 20K Product 03 Jul 13 Range M 10 Premier Farnell RESISTOR 10K 0 125W 1 Product 03 Jul 13 Range 10 Premier Farnell BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 32 LED 3MM RED 100MCD 643NM Bulb 03 Jul 13 Size 10 Premier Farnell 03 Jul 13 Premier Farnell 35 06 White PVC Equipment Wire 16 0 2mm 04 Jul 13 100m 1 RS Components 04 Jul 13 Clear heatshrink tubing 3 2mm bore 2 RS Components 04 Jul 13 RS Components 12 95 TOTAL 2 718 90 Table 3 2 Itemised Budget 3 3 2 2 Travel Budget Most of the students in the iSEDE team are eligible for the ESA funding to attend the workshops reviews and l
18. 204 Quality control Storage Stability Safety data sheets Handling and protective measures Note BX16_iSEDE_SEDv5 1 31JAN14 The data given here are typical data at the time of preparation of this data sheet They do not represent a product specification Specified values are contained in a special Product Specification Glysantin G 30 is stable for at least 2 years if stored in airtight containers Because of corrosion galvanised containers should not be used A safety data sheet according to EC regulations 91 155 is available The usual precautions for handling chemicals must be observed In Particular the place of work must be well ventilated the skin protected and safety glasses worn at all times Avoid contact with the skin The information submitted in this publication is based on our current knowledge and experience In view of the many factors that may affect processing and application these data do not relieve processors of the responsibility of carrying out their own tests and experiments neither do they imply any legally binding assurance of certain properties or of suit ability for a specific purpose It is the responsibility of those to whom we supply our products to ensure that any proprietary rights and existing laws and legislation are observed BASF Aktiengeselischaft Marketing Spezialchemikalien II 67056 Ludwigshafen Germany Printed in Germany EvuroLAuUNcH ADLR and SSC coopera Student Exper
19. 2512 2W 6K8 1 Product 02 Jul 13 Ran 5 Premier Farnell RESISTOR 2512 2W 7K5 1 Product 02 Jul 13 Ran 5 Premier Farnell CAPACITOR 4 7UF 35V SMD Product 02 Jul 13 Rang 10 Premier Farnell BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 31 CAPACITOR CASE B 2 2UF 50V Product 02 Jul 13 R 10 Premier Farnell INDUCTOR 10UH 10 3A TH RADIAL 02 Jul 13 Prod 3 Premier Farnell INDUCTOR 3 3UH 20 1 5A TH RADIAL 02 Jul 13 Pro 2 Premier Farnell TRANSISTOR NPN TO 92 Transistor 02 Jul 13 Polar 10 Premier Farnell 02 Jul 13 MOSFET P 200V 11A TO 220 Transist 4 Premier Farnell IC 74HC CMOS LOGIC Logic Device 02 Jul 13 Type B 9 Premier Farnell WIRE WHT 18AWG 1 18AWG 30 5M 02 Jul 13 ReelL 1 Premier Farnell RIBBON CABLE 6WAY PER M No of 02 Jul 13 Condu 5 Premier Farnell RIBBON CABLE HIGH FLEX 6WAY PER M 02 Jul 13 No 1 Premier Farnell HEADER SHROUDED R A 6WAY 02 Jul 13 Connector T 10 Premier Farnell HOUSING CRIMP RECEPTACLE 2 54MM 02 Jul 13 6WAY 10 Premier Farnell CONTACT SOCKET 26 22AWG CRIMP 02 Jul 13 Series 40 Premier Farnell HEADER R A 0 1 12WAY Connector 02 Jul 13 Type 5 Premier Farnell HOUSING 24AWG 12WAY Connector 02 Jul 13 Type Wi 5 Premier Farnell
20. 33 e SAT 217 11 C SAT 2 To 14 C BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 161 SAT IT L 12 35 Activate solenoid Command sent Received No deployment visual from webcam 12 43 SAT 2 Pump 3 Command Sent Didn t arrive Command resent Arrived 12 43 SAT 2 Pump 3 Rev Command sent Arrived 13 05 21 34 webcam time All pumps off both satellites 13 08 Both Hack HDs turned off Command sent Arrived Appears to be off from webcam visual 13 10 Both Hack HDs turned on Command Sent Arrived 13 11 21 39 webcam time Solenoid activated Command Sent Arrived Nothing happened Visual from webcam 13 20 SAT 2 Pump 2 Command Sent Arrived LED out of view of webcam 13 20 SAT 2 Pump 2 Rev Command Sent Arrived LED out of view of webcam 13 20 SAT 2 Pump 3 Command Sent Arrived LED out of view of webcam 13 20 SAT 2 Pump 3 Rev Command Sent Arrived BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 162 e LED out of view of webcam 13 41 e All pumps off 22 10 e Command sent for all pumps webcam e Command arrived at all pumps time 13 43 e Both Hack HD s off to save data e Command Sent e Command Arrived e 10 Second wait 13 43 e Both Hack HD s turned on e Comma
21. 4 5 amp 4 7 o Pumps in previous experiments have had problems starting at low pressure this should be tested o If the soft robotics element is to be included then you should inform your contact person before CDR You should keep the short duration of the project in mind when considering additions in the project You have to be able to connect external power to your experiment You should thermal test your hack HD batteries and consider changing them Your electronic design is a little under developed it s not clear how many seeds you have one on each cell What type of wiring is used between the cells It should consider the rigidity Look at litze wire The charging concept through the lines is not clear consider from BEXUS power to your satellite power and clearly document this The battery charging should be a functional requirement You should be aware of the dangers of li po cells Your charging introduces extra risks Overcharge could be a problem you should have a clear safety strategy You should use safety goggles when working with charging the batteries It s possible that the charging of the batteries could be a step to far You should verify that the other experiments do not use the same module and mess up your signal Use fixed resistors instead of potentiometers As the cameras are crucial for the experiment success you may consider powering them from the main power source rather than on board batteries a Th
22. 66 Figure 4 18 Structure deployed from module during vacuum inflation test The unit in Figure 4 19 was manufactured from folded 1mm aluminium sheet as recommended by mechanical advisors at the university however the tolerances required were not achieved partially due to the scale of manufacture As such the flight model is manufactured from CNCed sheets 2mm aluminium and bolted together with nyloc fixings instead of folding thus retaining the strength of the material and achieving a more accurate product The following figures illustrate this design m b h 16mm t 1 6mm D Figure 4 19 Deployment Module Corner Angles The deployment method used contains a solenoid which is connected to a linkage arm which in turn is connected to a latch Once the solenoid is activated the solenoid pin retracts this pulls the linkage arm vertically upwards This vertical movement then causes the latch to pivot around the link between the linkage arm and the latch This motion then causes the hook of the latch to lose contact with the sprung hinged doors hence releasing the inflatable structure BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 67 UI H WE ie t bh dl Figure 4 21 Deployment Module CAD Exploded View BX16_iSEDE_SEDv5 1 31JAN14 e EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 68 Figure 4 2
23. OP_16 Changed DE op DE_08 DE_12 DE_21 A OP_08 Deleted FU_01 amp FU_02 Added softrobotics to WBS Updated Schedule Updated manpower Updated budget Updated Outreach Added risk for soft robotics Updated Update experiment description Including interfaces Softrobotic actuation Mechanical section inc Deployment amp camera mount Restructured Electronics Design section Updated Electronics block diagram Added Section 4 5 5 Restructured Added detail amp schematics Restructure New headings Changed the RF module choice and details New Power Budget Updated Power Components Updated Power system design New Power Distribution Updated T amp V updated and test 0 13 added low temp critical comp Test results Dimensions amp Mass 6 3 Updated Mission Timeline Appendix A Added PDR Report 2013 06 24 Added missing Eurolaunch logo pre IPR Added new OP requirements Updated Schedule Updated Budget Updated Outreach Updated Experiment Setup Updated Experiment Components Added Inflatable Displacement Updated Hub Material Added Folding Technique Added Thermal Design for Deployment Mechanism Added Thermal Design for Inflatable Structure Added Thermal Design for Mechanical Structure Updated software description and changed from Arduino Ethernet to Raspberry Pi Updated Hub controller Raspberry Pi as Hub Updated to PanStamp added Connectors Updated Ground Support Software T amp V chapter updated Added EMC
24. PDR amp Training Week Instalment 1 ARCHIVES March 2013 February 2013 December 2012 PDR amp Training Week Project Update Selection Workshop Share this E Twitter Bi Facebook D Tumor Like this Like Be the firstto like this Figure 3 7 iSEDE Blog e Any performed outreach actions e g press releases published journalists contacted logos or information brochures designed o Team Branding BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 35 Logo created Figure 3 8 iSEDE logo e Details of media coverage e g newspaper articles radio TV interviews internet news articles etc o August 2013 Post on ESA Education facebook page on outreach activity of iSEDE team at UK Space Conference 2013 Glasgow UK e ESA Education shared a link 2 hours ago 20 university students from University of Strathclyde brought their enthusiasm to the 2013 UK Space Conference 15 17 July Here they showed how exciting is to engage into ESA s education hands on activities and presented to other students and a large public the experiments they built for launch on board the Rexus and Bexus educational sounding rockets and atmospheric balloons annual campaigns One of the conference s special guests ESA British astronaut Timothy Peak visited their stand and wished the student good luck for the upcoming Bexus launch campaign 4 14 October 2013 U
25. Page 81 transmit it to the Hub actuate the micro pumps for shape alteration and implement closed loop control on the actuation process The control system on each satellite operates using readings from two accelerometers one static accelerometer situated at the top of the satellite and another moving accelerometer located at the bottom tip of the satellite It ensures that the deformation of the structure due to actuation remains within pre defined limits It is also worth noting that although there is a wireless link between Hub and both satellites there is also a hard wired connection in case of an issue with establishing wireless communication All the connections and the wiring between the cell satellites and hub is shown below Satellite 1 TS ote 4 37 Wiring schematic 4 5 2 Hub The satellites must be monitored and deployed by the ground station Ideally the communication would be directly from the ground to the satellite but in BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 82 order to simplify the experiment it was decided to use the BEXUS E Link for communication between the ground and the balloon A controller is needed to act as the interface between the E Link and the satellites As the E Link uses Ethernet the controller is capable of interfacing with both Ethernet and then wirelessly to the satellites
26. Self clinching nuts are very useful for applications where you don t have access to get to the nuts Don t over design the aluminium pieces for the hub were too thick Expect delays and problems when getting components manufactured Leave enough time to overcome problems Creating a perfect seal is very difficult with tubes and wires creating small holes through the seal Thin walled silicon actuators are difficult to manufacture without having small holes Silicon actuators are easily punctured Difficult to add tubing to the silicon actuators and ensure that they do not leak Anti freeze dissolves the adhesive layer of the Kapton tape BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 169 Anti friction tape can be used to help reduce the friction in the deployment mechanism system This allows the solenoid to be fired if the solenoid is not powerful enough to release the doors A window cleaning squeegee can be used to ensure that no air bubbles is trapped between the layer of Kapton tape and Mylar Double sided tape can be used to connect the two 5 cell arrays 7 5 3 Electrical Design component selection fabrication testing Electronics and software design have to be made together When choosing microprocessor microcontrollers always include in the requirements at least one communication interface exclusive for debug purpose Bottom up is the best approach to electronic design
27. Spinning webcam visual 11 15 Packages sending amp receiving GS visual 11 32 40 C T Sat 1 from GS 11 49 e HUB ambient temperature 30 6 C e SAT 1 36 C e SAT 2 35 C 12 04 e Float reached 27 3km 12 04 e SAT 1 17 C BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 160 e SAT 2 25 C 12 08 e First activation of solenoid Nothing happened webcam visual 12 09 e 2 attempt of solenoid activation Nothing happened webcam visual 12 12 e Power 5V e Command Sent e Command Received 12 13 e LED not on for Power 5V possibly broken due to thermal amp vacuum chamber 12 14 e 5V regulator Working e Pressure Reading Received GS confirmation e 1 6V pressure on both sides the same no inflation indication 12 18 e Beginning of IRN pump cycle no attached pumps 12 18 e Pump 2 SAT 1 e Command Sent e Received e LED on possible visual from webcam 12 20 e Pump 2 Rev Sat 1 20 49 e Command Sent webcam e Did not arrive time e Command Resent e Arrived e LED on visual from webcam 12 21 e SAT 1 pump 1 20 49 e Command Sent webcam e Arrived time e LED on webcam visual 12 24 e Beginning of BRU cycle Pre deployed with connected 20 52 pumps out of range of webcam view webcam time 12 24 e SAT 2 Pump 2 e Command Sent e Received 12 24 e SAT Pump 2 Rev e Command Sent e Received 12 24 e Timer started for 20 minutes 12
28. TRANSCEIVER Figure 4 3 Indicative Satellite Architecture ii The deployment modules include the interface between the payload and the support structure The satellite is mounted within the deployment module as shown in section 4 4 2 BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 51 The central controller the hub is the centre point for communications on the Gondola and connects directly to the BEXUS E Link and on board power supply for power and communications The hub and deployment modules is mounted directly to a support structure and suspended from the roof of the gondola The mounting is on top of the BEXUS rails In order to capture the full experiment visually there are two cameras mounted to monitor deployment The cameras view the actuation of the satellites going from left to right Fixed spots on each cell are used with post flight image processing to determine the displacement of the cells In order to capture accurate information that can be later analysed it is required to mount the cameras at a similar height to the centre cell and as far from the structure as can be facilitated within the gondola Through testing it has been verified that no external booms are required where two cameras are used to capture the deployment The cameras are hard wired for power and use an SD card to store all recorded data 4 2 Experiment Interfaces 4 2 1 Mechanical The following mechanical
29. Webcam on HackHD 2 on Satellite 2 d Component Status Altitude Light Intensity 00 59 30 01 00 Time Altitude Update intensity y 8 D S 8 RR ISIE areas Figure 4 53 Main screen of ground support software displaying all received data of the experiment BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 111 In order for the screen not to look over crowded the information related to the hub and of each satellite is displayed separately as illustrated above Also during the experiment an extra screen is used to display the pictures sent by the live camera webcam The satellite tables show the acceleration profile of the IMUs mounted on the top of the gondola and at the bottom tip of the iSEDE satellite If the acceleration of the gondola is low enough the actuation phase of the experiment can be started with the activation of the pumps 1 3 The ground station software is able to receive data from the Hub using a UDP communication protocol The software behaves as a server as it binds to a port of the operating system and waits on an infinite loop to receive packages Once the package is received the data is stored in a string This data contains information about temperature accelerometers pressure elapsed time since the beginning of the experiment and origin of the data The string is then processed by a method that checks if t
30. a better bonding with the other units with the cells o Cables that are connected with the units at the side of the cells are attached on them This type of design was not fully accepted by the reviewers due to the high probability of failure from the stiffness of the cables and the way they are attached Several advices and ideas were proposed to the team e Possible problems were identified regarding the inflation procedure and the boxes it might be the case that the inflation of the balloons will not allow them to come out of the box Folding strategy might solve the issue e The images quality of the cameras might be affected by the light coming from the opposite frame of the gondola Probably shading the frame might solve the issue e The thickness of the actuators are going to be changed thinner and smaller to improve the actuation e Mount the roof support structure on top of the E Link cradle support bars BX_IPR_Isede_V1 0_17Jui13 Doc BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation EuroLAUNCH cooperation ADLR and SSC Page 192 BEXUS Experiment Integration Progress Review Evrolauncu Ane egen Page 3 Electronics and data management SED chapter 4 2 2 4 2 3 4 5 amp 4 7 Homemade PCBs were manufactured But the result was not accepted Too many manufacturing errors It has been proposed to use a PCB manufacturer The transistors connected with the LEDs for the lighting should be replace
31. all unsuitable The analysis of the water should not exceed the following limits Water hardness Oto 25 Clark O 3 6 mmol l Chloride content max 100 ppm Sulphate content max 100 ppm Should the analysis of the water exceed the approved limits then it has to be suitably treated for example by mixing with pure distilled or deionised water Excessive chloride or sulphate levels can be corrected in this way EuroLAuncu Student Experiment Documentation Glysantin G 30 Chemical nature Monoethylene glycol with inhibitors Appearance Clear liquid without solid contaminants Properties Density at 20 C 1 122 1 125 g cm Viscosity at 20 C 22 26 mm2 s Refraction at 20 C 1 432 1 436 Boiling point gt 160 C Flash point gt 120 C pH value 8 2 9 0 Reserve alkalinity M 10 HCI 8 5 11 ml Ash content max 2 Water content max 3 Solubility Miscibility with water in all proportions Miscibility with hard water no precipitation Stability Inhibitor stability Technical data for Glysantin G 30 water mixtures Temperature C BX16_iSEDE_SEDv5 1 31JAN14 after 168 h Hard water stability after 10 days Frost Protection of Glysantin G 30 no separation no separation 25 30 35 40 45 Concentration volume A DLR and SSC Page 202 DIN 51757 procedure 4 DIN 51562 DIN 51423 ASTM D 1120 DIN ISO 2592 ASTM D 1287 ASTM D 1121 ASTM D 1119 DIN 51777 VW TL 774 D VW PV 1426 50 55 60 The values of
32. an RBF to prevent an accidental deployment You should make sure that you don t burn out your system if its actuated when the RBF is in You should include the data sheet for the new actuation fluid You should be aware of the disposal method Launch and operations SED chapter 6 o You should really check over the timeline Power On a Attachment on structure Ground deployment You should be clear about the testing at T 180 All pre flight activities should be expanded into verifiable checklists Your post flight activities should include mechanical dismounting packing disposal of any materials shipping During the FCT all electronics should be operated solenoid and wireless links You should consider the time between deployment and actuation maybe this should vary between timeline and command Maybe have a as you sure you want to do this on the deployment command PPE will be provided by Esrange British power adapter will not be provided by Esrange FT refers to a pressure sensor then a time sensor Organisation project planning amp outreach SED chapters 3 1 3 2 amp 3 3 O o O O Others o It wasn t clear in the budget about the amount for the non sponsored students travel Change ascl to space in the website URL Provide the URL for your Facebook in the main document You should be clear how many students you are Thomas is a student or an advisor You should coordinate with ARCADE R2 vi
33. be found in 30 BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 168 7 5 1 Experiment Design amp Requirements Keep numbers of deleted requirements to make documentation coherent Don t put anything outside of gondola Collaborate with other teams on board your gondola The gondola roof might not be covered The ideal is to have it decided and agreed with ESA at most at CDR as an open roof implies in design modifications 7 5 2 Mechanical Design amp Fabrication Talk about design concepts with the workshop who will be manufacturing the product find the best methods of manufacture and materials that are suitable to machine While the specification is required compromise and redesign to suit the manufacturing methods can improve the product produced and save time for everyone Manufacture always takes longer than expected Get designs in early The iSEDE concept requires complex and careful manufacturing if a project requires such consistent and perfect manufacture there should be a focus on finding funding to do it properly developing industry partnerships in heat sealing could have significantly improved the quality of iSEDE inflatable manufacture Folding aluminium sheet and welding produced a poor manufactured box Better to have sheets with screws Potential problem with using solenoid to deploy satellite due to low temp and pressure However more reliable than pyro cutters
34. communication shall be established between the satellites and hub ER_FU_07 Each satellite should measure the ambient temperature and pressure ER UO8 Decision June 13 charging during mission unnecessary ER_FU_09 Each satellite shall demonstrate an alteration of its shape ER_FU_10 Control of any shape alteration shall be demonstrated 2 2 Performance requirements a ER_PE_01 Resolution of images captured by the camera s shall be at least 800x600 pixels ER_PE 02 Images captured shall have at least 16 bit colour ER_PE_03 Temperature measurements of critical components shall take place at a frequency of at least 0 2Hz ER_PE 04 Ambient temperature measurements shall take place at a frequency of 0 2 Hz ER_PE_05 All temperature measurements shall have a minimum sensitivity BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 17 of 5 C ER_PE_06 Differential pressure measurements shall be taken at a frequency of 0 1 Hz during adaptive phase ER PE 07 Differential pressure measurements shall have a minimum sensitivity of 20 Pa ER_PE_08 Any shape alteration shall be within 5 cm of desired position ER PE 09 During shape alteration the bottom cell should not be displaced by more than 20 cm ER_PE_10 The wireless link between the hub and each satellite shall be able to communicate with
35. distributed control and autonomous operation The payload itself then has two primary design challenges There is firstly the design of the inflatable structure material shapes bonding methods and secondly the challenge of bonding electronics to the surface and facilitating power and communication bus paths The mass of the inflatable structure is negligible and the mass of electronic components contribute most significantly to the overall payload mass 4 4 1 1 Inflatable Structure The structure that is deployed is entirely made of inflatable cells It consists of two rows of 5 elongated ellipsoid cells deployed using the expansion of trapped air in the ellipsoids when subjected to vacuum conditions These cells have been manufactured from two sheets of mylar and kapton tape These films are lightweight strong and can withstand the temperatures that the experiment is subjected to It is important that these materials have a reflective surface to reduce the UV penetration into the cell The central cells include an actuation element which enables the structure to alter its shape This actuation element is not affected by the temperature but can degrade when subject to UV radiation Each cell has an un inflated length of 18cm and height of 13cm with a 1 5cm seam The deployable structure uses residual air inflation as a deployment mechanism The inflation of the cell is modelled using the relationships for the inflation of a sphere presen
36. frost protection are calculated according to the arithmetical means arising from freezing point and pour point EuRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 203 Viscosity DIN 51562 at orc 50 in water 8 10 mm s 33 in water 5 6 mm s at 20 C 50 in water 3 5 mm s 33 in water 2 3 mm s at 80 C 50 in water 0 9 1 1 mm s 33 in water 0 6 0 8 mm s Foaming tendency ASTM D 1881 max 50 mi 1 3 s Rubber swelling Corrosion tests Glassware test Simulated service corrosion test Cavitation erosion Corrosion test Heat transfer test Polarisation resistance BX16_iSEDE_SEDv5 1 31JAN14 with commonly used SBR and EPDM qualities 80 C 168 h 0 3 similar to pure water 50 in water ASTM D 1384 Metal typical weight loss in limit or alloy mg per coupon ASTM D 3306 copper 0 8 max 10 solder 1 2 max 30 brass 0 9 max 10 steel 0 1 max 10 cast iron DNK max 10 cast aluminium 4 0 max 30 ASTM D 2570 Metal typical weight loss in limit or alloy mg per coupon ASTM D 3306 copper 2 8 max 20 solder 1 7 max 60 brass 1 4 max 20 steel 0 3 max 20 cast iron 3 0 max 20 cast aluminium 3 3 max 60 ASTM D 2809 limit evaluation ASTM D 3306 Al water pump 9 min 8 ASTM D 4340 typical weight change limit in mg cm week ASTM D 3306 G Alsi6Cu 4 0 3 max 1 0 NF R 15 602 9 limit Aluminium 1 2 10 a cm gt 10 cm EurRoLAUNCH Student Experiment Documentation Page
37. interfaces exist between the experiment and the BEXUS gondola 1 Each There are two deployment modules and a hub mounted to a support structure suspended from the roof of the gondola There are two cameras mounted on an added cross beam at one side of the gondola interface withstands the forces specified in the BEXUS manual of 10g vertically 5g horizontally 4 2 1 1 Payload Deployment Modules amp hub This structure is suspended parallel to the BEXUS E Link The horizontal supports are clamped to the gondola roof crossbeams BX16_iSEDE_SEDv5 1 31JAN14 e EurRoLAUNCH A D R and SSC cooperation Student Experiment Documentation Page 52 Figure 4 4 Roof Support Structure Figure 4 5 Close View of Roof Mount Clamps BX16_iSEDE_SEDv5 1 31JAN14 es EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 53 4 2 1 2 Cameras The cameras require a clear view to the deployed payloads and therefore they are mounted directly opposite the deployment modules A sliding fit bracket with M4 screw and washer fixing around a square cross section tube is used which is in turn clamped directly to the gondola frame as shown below A plate is welded to each end of the aluminium tube cross beam and then fixed to the gondola with M8 bolts to the clamp counterpart CAMERA MOUNT _SUDEFIT PRT Figure 4 6 Camera interfaces 4 2 2 Electrical The hub and satellites interface with
38. most up to date data is shown on the correspondent tab of the main screen Furthermore some information where an indication of a long term change is important is displayed in graphics such as temperature and pressure BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 112 Creates UDP DatagramSocket Data received Yes Data is valid Yes No Ignore data received Creates TCP socket Connection established Sends Commands Response a received Ground Station TCP Client Flowchart Display information Ground Station UDP Server Flowchart Figure 4 54 Flow chart of ground station In order for the ground station to be able to communicate and send commands to the satellite the software relies on a TCP socket The software behaves like a client with its main function of sending data instead of receiving The client keeps trying to establish a connection with the server and once the connection is established the ground station is able to send commands to the hub such as described in Table 4 5 Also as the command is sent to the hub the software expects a response in order to verify if the command has been sent properly and the hub is still connected If for any reason this response does not reach the ground station the client goes back to the step where it tries to establish a connection to the server Table 4 5 Ground Supp
39. of float phase Close files etc before landing notice will be given before termination of flight BX_IPR_Isede_V1 0_17Jul13 Doc BX16_iSEDE_SEDv5 1 31JAN14 4 11 A Eurolauncn Student Experiment Documentation Page 193 BEXUS Experiment Integration Progress Review Evrolauncu Page 4 Launch crew will bring everything that they will find back RF frequency 868 915MHz SSC Esrange Team requests 1hour minimum on float phase better with 2h Revise timeline update SED Organisation project planning amp outreach SED chapters 3 1 3 2 amp 3 3 Detailed weekly planning from now open issues has to be assigned to members EAR week 36 37 start planning Ship the experiment latest 23 of September to Esrange End to end Test Yes breadboard electronics sw was demonstrated 5 FINAL REMARKS SL SA 5 3 5 4 Summary of main actions for the experiment team Finalize design manufacture and perform system level tests Summary of main actions for the organisers Put Campaign Requirement Plan CRP on Teamsite SSC Esrange has to decide frequency 868 915MHz Confirm campaign date IPR Result pass conditional pass fail Conditional pass new SED to be delivered Next SED version due SED Chap 6 to be updated Address the still open points from Alex K review Latest before EAR BX_IPR_Isede_V1 0_17Jul13 Doc BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student
40. of flow required to perform a particular change in shape The differential pressure sensor selected for this task is the LBAS250B 27 It can be seen in Figure 4 44 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 90 The sensor provides an analogue output within the range of 0 5 4 5V and has to be scaled down to interface with the microcontroller Accelerometers Two triple axis accelerometers are used in each satellite in order to provide an input parameter to the actuation control loop One accelerometer is placed in a static position on the deployment module box The second is placed on the bottom cell 5 and changes position with the alteration of satellite shape The accelerometers chosen are the ADXL345 accelerometers by Analogue Devices They have the capability of measuring 16 G at a resolution of 13 bits The accelerometers are both connected via the UC bus already containing the 4 TMP102 temperature sensors 4 5 3 3 Actuation Micropumps are required to pump between each pair of adjacent soft robotic actuators This changes the size of the cells in relation to each other and creates a shape change in the overall structure MP6 micro pumps from Bartels Mikrotechnik GmbH were selected 28 The micro pump is a piezoelectric driven micropump with dimensions of 30 x 15 x 3 8 mm anda flow rate of 18ml min BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Stude
41. other similar network tools can be used to store all network packets thus allowing to recover data if the ground station crashes before storing it Using a plaintext data also helps BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 173 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 1U AIT AP asap BO BR CDR COG CRP CUT DLR EAT EAR ECTS EIT EPM ESA Esrange ESTEC ESW FA FB FD FAR FST FRP FRR FT GSE HK H W ICD 1 unit cube dimensions of 10x10x10cm Assembly Integration and Test Adaptive Phase as soon as possible Bonn DLR German Space Agency Bremen DLR Institute of Space Systems Critical Design Review Centre of gravity Campaign Requirement Plan Cut off balloon Deutsches Zentrum f r Luft und Raumfahrt Experiment Acceptance Test Experiment Acceptance Review European Credit Transfer System Electrical Interface Test Esrange Project Manager European Space Agency Esrange Space Center European Space Research and Technology Centre ESA NL Experiment Selection Workshop Float Altitude Frazer Brownlie Flight Descent Flight Acceptance Review Flight Simulation Test Flight Requirement Plan Flight Readiness Review Float Ground Support Equipment House Keeping
42. risk I m not convinced your probability isn t B GAOMAS Date 03 07 13 Comment DONE most of the risks are mitigated and we are applying for travel grants for Tiago to attend the launch campaign SC10 and SC20 have all components been ordered now MAOMAS SC 10 Date 03 07 13 Comment DONE most of components already ordered FRAZER SC20 Date 01 07 13 Comment Added SC21 Experiment Concept Page 38 The hub will be mounted conventionally on the base of the gondola vs figure 4 1 where the hub is clearly mounted on the support structure near the roof of the gondola AND the statement immediately afterwards iv SES discussed at IPR You should confirm the use of the super bright LEDs or not PMAOMAS Date 07 07 13 Comment Yes LEDs are used Added array of 10 bright LEDs to experiment components and camera section mechanical and electronic Is the data from the Satellite to the Hub sent simultaneously over the wireless and hardwire If not what is the philosophy here MAGO Date 01 07 13 Comment 4 1 Do you transmit the camera images If not your storage becomes critical camera SD card is a SPF MAGO Date 01 07 13 Comment 4 1 and 3 5 table It s assumed the actuation of the satellites is back and forth i e toward and away from the camera Is there no way to use relative sizing distortion of a fixed sized spot on the final size to help verify the displacement How confident are you with the accelerometer m
43. state of the satellites e Receiving data When any data arrives the software goes to this state receives the data stores it and returns to the last state e Reading sensors reads all sensors processes the data and stores it e Sending data sends data to the Hub in case of failure of the main communication link the backup link is used eldle Waiting for commands The Hub has four communication links an Ethernet interface connected to BEXUS E Link two serial ports also known as UART or USART one connected to a wireless link and the other is used as a backup wired link with the satellites and an DC bus used to communicate with temperature sensors When activated the Hub preforms its boot sequence connects to BEXUS E Link and starts the Hub Control Software This software initializes and tests all peripherals and then it goes to an idle state performing housekeeping sending UDP packets with satellites readings and storing all data on its secondary memory To detect communication problems the Hub keeps a timer running to each satellite if the timer counts five seconds without any transmission from the satellite the wired link is activated If communication is not established it is notified to the ground station and the satellite is considered down Further attempts to reset the satellite and establish connection can be made The same process is used to detect communications failures with the ground station If there is no co
44. structure non reliant on the inflation gas after deployment 19 21 The industry is focusing on a variety of applications of inflatable structures to enable future space flight at present After 1996 inflatables were used as protection devices for planetary rovers The inflatable balloons were used to soften the landings of the Mars rovers Pathfinder in 1996 and Spirit and Opportunity in 2003 Figure 1 2 Deployment test of inflatable airbags of Mars Pathfinder mission in 1996 source NASA Various companies are working on the use of inflatable antennas reflectors booms and solar arrays as satellite components Just recently the company Space Ground Amalgam working on these inflatable satellite structures won a 100k prize in the Space Frontier Foundation s NewSpace business plan competition 22 Other research is carried out in inflatable boom experiments like the CFRP Booms from the German Aerospace Center DLR 23 Also NASA is working on a couple of inflation based structures which led to a successful test of the Inflatable Reentry Vehicle Experiment IRVE 3 in July 2012 The most ambitious plan comes from Bigelow Aerospace which has the target of building a Commercial Space Station consisting of inflatable modules In January 2013 Bigelow Aerospace was contracted by NASA to build an inflatable module called BEAM to be tested on the International Space Station during 2015 to 2017 24 BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuNcH St
45. structure was folded with and without flexible electronics tests proved that the whole deployable fits within the 1U cube satellite box Table 5 32 Test Results 0 7 Test number 0 7 COmpleted 20 07 2073 Test type Wireless communication Results Wireless communication between hub and both satellites over PanStamp is working also with back up hardwired link Table 5 33 Test Results 0 8 Test number 0 8 GOmpleted 15107 2013 Test type On board microcontroller test Results The microcontroller can read data from the IMUs pressure sensors can trigger the cameras control the pumps and communicate wirelessly and hardwired with the hub Table 5 34 Test Results 0 9 Test number 0 9 inprogress Test type Camera view angle test Results Both cameras are able to capture the whole deployment and the satellites in the gondola without the requirement of having the cameras mounted outside the gondola Cameras are now mounted on one of the sides of the gondola BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH R and SSC cooperation Student Experiment Documentation Page 136 Figure 5 3 Camera placement tests in the iSEDE lab Final calibration test needs to be undertaken at the launch campaign with the actual BEXUS gondola Table 5 35 Test Results 0 10 Test number 0 10 Gompletedi 310712073 Test type Performance v
46. successfully used for 3 complete experiment timeline cycles Table 5 41 Test 0 17 Test number 0 17 Gompletedi 100912073 Test type Roof Mounting test Results The deployment boxes hub and roof mounting plates were connected to the mounting tube using nyloc nuts Table 5 42 Test 0 18 Test number 0 18 Gompletedi 1009 2073 Test type HackHD Camera SD card storage test Results The HackHD camera was turned on and the SD card was able to store 6 hours worth of footage BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Page 138 Table 5 43 Test Results 1 0 Test number _ 1 0 Completedi 2710812013 Test type Integration test Results After fabrication of all mechanical and electronic components and systems a first integration tests showed that everything fits together as planned Table 5 44 Test Results 2 0 Test number _ 2 0 Completed 16109 2073 Test type Vacuum test Results A fully assembled experiment was tested and showed that that the full system worked in near vacuum conditions 15mbar Including Mobius camera Table 5 45 Test Results 3 0 Test number _ 3 0 GOmpleted 0510912013 Test type Thermal test Results A fully assembled experiment was tested and showed that the full system worked at low temperature 30 C similar to environmental c
47. that were planned to be carried out post flight Table 6 5 Post Flight Procedures N Procedure Tools Duration Responsibl BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 149 O mins Person 1 Make at least two copies Groundstation on different storage flash drive devices of all data received at the groundstation 30 TQ 2 Disconnect BEXUS power Camera from hub documentation 1 FB 3 Disconnect BEXUS E link Camera from hub documentation 1 FB 4 Scissors Remove camera camera harnessing cable ties documentation 10 FB 5 Remove Deployment Scissors boxes harnessing cable camera ties documentation 10 FB 6 Wrench amp M8 Allen key Dismount camera camera mounting tube documentation 5 FB 7 Wrench amp M8 Allen key Dismount Roof mounting camera tubes from gondola documentation 5 FB 8 Wrench amp M8 Dismount Deployment Allen Key boxes from roof mounting camera tubes documentation 5 FB 9 Wrench Dismount hub from roof camera mounting tubes documentation 5 FB 10 Place HackHd SD cards in SD card box silicate to dry for at least a silicate pad day in case of water camera damage documentation 1 day TQ 11 Carefully fold satellites back into deployment NA camera boxes documentation 10 FB 12 Put RBF pin back in to hol
48. the BEXUS link through a 4 pin male box mount receptacle MIL C 26482P series 1 connector with an 8 4 insert arrangement MS3112E8 4P shown below BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH Student Experiment Documentation Page 54 Figure 4 7 Power Interface The output from this interface is then stepped down and conditioned to suit the component requirements To facilitate Communication and control during the experiment the hub incorporates the Amphenol RJF21B connector which interfaces with the BEXUS E Link The component and drilling specification is detailed in the BEXUS user manual and shown below in Figure 4 8 BALEN 33311311 26 97 1 062 26 97 1 0621 o3s Lag 828 58 11 125 827 311 075 MAK O33 O nza dim in mm inch Figure 4 8 Amphenol RJF21B and drilling pattern The Hub and ground station are connected using an Ethernet connection TCP IP and UDP IP protocols The data sent from the Ground Station to the Hub uses a TCP socket and the following packet structure Satellite ID Command Payload size optional Payload 1 byte 1 byte 2 byte n bytes If the command does not require a payload the payload size and payload bytes are not sent Whenever the Hub receives a command it sends back an ACK BX16_iSEDE_
49. the IPR the team is focusing on getting all the subsystems ready and tested in the vacuum chamber before ordering PCBs In the first week of August the electronics and the mechanical structure was assembled and thoroughly tested timeline actuation vacuum thermal The week before the EAR week 37 was used to write up all the procedures for the launch campaign After the EAR the experiment was prepared for shipping on the 20 of September The launch campaign was from the 4 to 14 of October 3 3 Resources 3 3 1 Manpower A core team of seven students are completing most of the work on the project Thomas Sinn was work 10 hours per week on the project Every other team member has worked at least 15 hours per week on the project as per the academic requirements Two computer science students Tiago Quieroz and Larissa Leite have been recruited to work on the embedded programming and ground support software They shall also provide support with electronics as they have some experience in this area They were working on the project on a full time basis throughout the summer months as part of a Science Without Borders internship BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 28 Andrew Allan and Jonathan Gillespie stepped down from their roles after bringing their areas of the design up to CDR level This was managed by a controlled hand over of their work to other members of th
50. the Raspberry Pi securely in place The screws do not have access to the ambient outside air inside the gondola therefore no conduction can take place directly between the screw and the air This helps in the insulation of the Raspberry Pi 4 4 4 Camera Housing It is critical that the cameras are mounted in a location where there is a clear view to the deployed structures Figure 4 27 below indicates the optimal layout where there are two cameras each with a direct line of site indicated by the bold dashed line to one satellite and also an indirect angle to another This allows the inflation to be observed and understood most comprehensively The Hack HD cameras have a wide field of view almost like a fish eye lens Figure 4 27 Aerial View of the Gondola BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH SC Student Experiment Documentation Page 72 Figure 4 28 Side View of the Gondola GoPro provides a purpose built enclosure called the skeleton which houses the HackHD camera well This structure is designed for use in extreme sports and has been adapted easily for this application This is mounted using M3 bolts to the mounting plate and sliding fit as indicated in the camera mechanical interfaces section Between the two HackHD cameras a webcam with an array of 10 bright white LEDs is added to light up the inside of the closed gondola The webcam allows a live feed to the ground station during the flight Figure 4 29 Go
51. the behaviour of the experiment components in a level procedure EMC chamber To ensure that equipment items or systems dosen t interfere with or prevent each other s correct BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation and SSC cooperation Page 127 operation through spurious emission and absorption of EMI Test duration 1 2 days Date status August 2013 6Ompleteds 20108 2018 simplified test set up components were all working together when everything was switched on Table 5 16 Test 0 15 Test number 0 15 Test type Conductance test Test facility University of Strathclyde tba Tested item Electronics Test Conductance test of all components connections and level procedure cables validating grounding scheme Test duration Various days Date status August 2013 G6mpleted 2010812073 simplified test set up components were all working together when everything was switched on Table 5 17 Test 0 16 Test number 0 16 Test type Software Implementation test Test facility University of Strathclyde tba Tested item Electronics Software Test Full system was switched on and the software ran for 4 level procedure complete experiment timeline cycles BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Page 128 Test duration 1 day Date
52. the resources over summer to complete the fabrication and testing You should re read the guidelines about this section MAOMA Date 03 07 13 Comment sentence added that Darryl Frazer Tiago and Larissa working full time on project over summer 3 3 2 Budget e You should provide a breakdown of the total project cost i e include the travel costs and the sources of funding MAOMAS Date 07 07 13 Comment updated the budget added travel 3 4 Outreach e The URL is still broken for the project page you should replace space with ascl MOVAS Date 03 07 13 Comment Link got corrected somehow it was changed back and forward from space to ascl e You should keep on posting on the wordpress site aim for at least once a month BERING Date 07 07 13 Comment blog will be updated once a week from now on e You should reference appendix B in this section FAOMAS Date 03 07 13 Comment reference to Appendix B added 3 5 Risk Register e C120 does the mechanical design mitigate this risk yet FRAZER Date 01 07 13 Comment Added TC 121 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 187 MS80 have these simulations been performed yet FRAZER Date 01 07 13 Comment Added MS81 MS100 this should have been mitigated MAOMAS Date 03 07 13 Comment mitigated with extensive testing and impmentation of resistive heating PE10 and PE60 and PE80 This is a real
53. to satellites Shutdown Report to Ground station Read housekeeping sensors cooperation Student Experiment Documentation Page 108 4 8 5 Data Flow A preliminary data rate budget has been calculated for four temperature sensors two accelerometers two voltage measurements and 3 pressure sensors it is about 150 bytes to transmit all sensors readings including the protocol overhead It shows that the maximum throughput that could be observed at any single point throughout the duration of the experiment is lt 20 kbps per satellite This is very low providing a significant safety factor and allows for increased sampling rates if required As non volatile flash storage is required to be used it can be guaranteed the write speed of the SD card is more than sufficient The data throughput within the Hub is of course be twice the throughput per satellite The wireless communications modules chosen are capable of up to 250 kbps and this far exceeds the data rate required The on board webcam generates about 300kbps of data as the Ethernet device used has a 100Mbit connection so the communication bottleneck is PanStamp s processing speed rather than the communication links BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 109 4 8 6 Implementation As identified in Section 4 5 the Hub houses a Raspberry Pi and each satellite employs a controller design based upon the Arduino Pro Mini 3 3V architecture
54. using a powerful central controller Hub and simpler and less capable slaves satellites also proved to be very efficient The experiment also proved that to student experiments it is possible to use non space graded hardware thus making it easier for students to prove their concepts The graph below shows the logged temperature data on the Hub both satellites and Raspberry Pi SoC BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 167 7 4 Discussion and Conclusions All the disaggregated electronics worked with wireless communication control Even more all components were fully functional even at 50C well below their specification One satellite was deployed the other got stuck in the box Due to antifreeze leakage the deployed satellite did not inflate There were various reasons why the experiment was partially unsuccessful A significant example of this is that the team did not have a sufficient budget to cover all costs Therefore the team were forced to manufacture a lot of the components in house It can be seen that the most successful aspect of the experiment was the disaggregated electronics All of these components were bought in and the flexible circuit was professionally manufactured The complexity of the experiment was increased significantly when we had to incorporate a shape changing element to the structure The team ultimately ran out of time to manufacture successful
55. well as data gathered from each satellite throughout flight The data is stored using the SD card and transmitted through the E Link to the ground support software The Raspberry Pi is linked directly to the panStamp wireless module via UART pins This data is collected for processing and storage as described The temperature sensor is set to monitor the ambient temperature within the Hub unit The Raspberry Pi provides a single UC bus through pins GPIO2 SDA amp GPIO3 SCL these are used to interface with the temperature sensor used The temperature sensor is a TMP102 26 serial output sensor The device operates from the 3 3V regulated supply Housekeeping measurements within the Hub consist of sensing the voltage at the secondary end of each DC DC regulator and voltage at the unregulated BEXUS power supply This is done using the panStamp s analogue input that sends all data through UART BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 85 4 5 2 3 Camera Video cameras are used to record the deployment and actuation of the satellites This visual data is a significant part of the scientific return of the experiment As capturing video footage of deployment and actuation is so significant it is a requirement that the cameras must run as a standalone system As a result there is no video processing requirement for the Hub simplifying its hardware and software requirem
56. where possible Dr Brian Stimpson expert in mechatronic systems at the University of Strathclyde has also offered support in design considerations BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH Student Experiment Documentation Page 33 3 4 Outreach Approach Each member of the iSEDE team is using their skills and their network of contacts to arrange outreach activities and raise the profile of the project and the BEXUS programme This section details what has been done so far and how we plan to implement an outreach strategy The following list should provide a comprehensive overview over the planned and undertaken outreach activities of the iSEDE team more detailed press releases and articles can be found in Appendix B e Internet Facebook page https www facebook com iSEDE BEXUS Regular photo updates and updates on experiment progress I sede is on Facebook ede sign up for Facebook toda o connect with I sede P ISEDE gets accepted for the BEXUS 16 17 campaign Figure 3 6 iSEDE Facebook Page o Project page on the webpage of the Advanced Space Concepts Laboratory University of Strathclyde http www strath ac uk ascl research missionsystems isedebexus1 617 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH Student Experiment Documentation Page 34 Strathclyde ISEDE BEXUS16 17 o SEDE Blog http isede2013 wordpress com Blog About iSEDE PDR amp Training Week Installment 2
57. 0 14 and Conductance test 0 15 Added RBF Updated necessary preparations and countdown Added CDR report Appendix A Newsletters posters and press Appendix B releases Added datasheet actuation fluid Appendix D Glysantin G30 Added Technical Drawings 2013 07 07 Deleted in flight charging req IPR added clearance req 3 1 Updated task allocation tab3 1 3 2 Revised schedule 3 3 2 Revised budget 3 3 1 Added summer internship 3 4 Updated outreach working link Updated risk register 3 5 Added fixed spots on BX16_iSEDE_SEDv5 1 31JAN14 6 3 Appendix A 2013 07 11 post IPR 2013 08 12 2013 08 28 EAR 4 2013 09 16 2 3 Pre 2 4 Campaign 4 4 4 5 4 4 7 5 5 1 1 5 1 2 5 2 1 deployables Experiment component status table added Clearance requirement PCB Inflatable Mounting Updated Solenoid Description Updated Hub Design Updated Camera Housing Wiring schematic added Bright white LED lights added Added Thermal Design for Hub Deleted the charging section as well as other references to this Added Are you sure pop up to ground support software Added clearance req Updated timeline Added SEDv3 0 review New Contact Point ER_OP_18 altitude req Schedule IPR to Campaign Mounting Top of BEXUS rails ER_OP_18 altitude req Updated timeline Deleted battery requirements Updated risks Updated outreach Deleted battery references Changed schematic Updated Power Budget Updated T am
58. 10 TQ Hack HD s SD card SD card adapter and delete all tests logs from Pi s SD card 25 Secure SD card with Camera Kapton 5 TQ kapton tape Pictures tape Documentation 26 Connect deployment Cable Ties NA 20 FB boxes harnessing to Camera hub and connect to pictures gondola documentation 27 Connect cameras Cable Ties NA 30 FB harnessing to hub to Camera connect gondola Pictures Documentation 28 Connect Mobius Cable Ties NA 5 FB camera to gondola Camera pictures documentation 29 Connect BEXUS Camera NA 1 FB Power to hub pictures documentation BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation Page 145 30 Connect BEXUS E Camera NA 1 FB link to hub pictures documentation 31 Interference test NA NA 60 FB 32 Fold float altitude Camera NA 10 FB deploying satellite pictures documentation RBF pin 33 Flight Compatibility NA NA 60 FB Test 34 Sweet spot test NA NA 30 FB 35 Switch off experiment NA NA 60 FB turn off HackHD properly 36 Deploy pre deployed Camera NA 1 FB satellite pictures documentation 37 Physically switch on Camera NA 1 FB experiment via switch pictures on hub documentation 38 Remove RBF Pin for Camera NA 1 FB the deployable pictures deployment box documentation 39 Switch on Mobius Camera NA 1 FB Camera Pictures Documentation 6 2 1 Remove Before Flight RB
59. 1JAN14 e EuroLAUNcH Student Experiment Documentation Page 47 4 EXPERIMENT DESCRIPTION 4 1 Experiment Setup iSEDE comprises of one experiment with five primary subsystems The payload the deployment modules the central controller the hub the roof mounted support structure and distributed measurement devices There is direct communication with the experiment through the E Link during the flight i The payload of the iSEDE experiment is two inflatable structures with disaggregated electronics These inflatable structures are suspended from the roof of the gondola and hang internally as shown in Figure 4 1 lt J Figure 4 1 Gondola Layout BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH cooperation Student Experiment Documentation Page 48 ae L d Ce geg hie e T p 323 ele ih 2 Ri RB oi e Figure 4 2 Gondola Plan amp Elevation Views Two inflatable structures are being deployed on the BEXUS campaign Each inflatable structure is referred to as a satellite as it is a representative portion of a much larger inflatable structure Each satellite is made up of 10 cells 2 columns of 5 cells One satellite is deployed prior to launch in order to observe the steady inflation on ascent and correlate this with recorded ambient pressure data This also avoids the harsh deployment that was experienced when float altitude is reached ensuring that if components
60. 2 Test number 0 2 Test type Deployment of Satellites Test facility University of Strathclyde Vacuum Chamber Department of Physics Tested item Satellites with inflatable cells with and without disaggregated electronics Test Residual air inflation test of various prototypes in vacuum level procedure chamber Test duration Various days during time span BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation and SSC cooperation Page 122 Date status March August 2013 GOmipleteai O710812073 Table 5 5 Test 0 3 Test number 0 3 Test type Functionality test pumps Test facility University of Strathclyde Vacuum Chamber Department of Physics Tested item Micro pumps Test Testing functionality of micro pumps at ambient pressure level procedure and vacuum Test duration Various days during time span Date status May August 2013 66mpleted 15 0s2013 Table 5 6 Test 0 4 Test number 0 4 Test type Shape change of structure Test facility University of Strathclyde iSEDE lab Tested item Deployed satellite Test Satellite with inflated cells was attached to test stand at level procedure ambient pressure to perform actuation tests with various actuators to validate shape change 0 4 1 Deformation of structure without soft robotic actuator added electronics manual actuation 0 4 2 Deformation of structure wit
61. 2 Deployment Module Opening CAD BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A D R and SSC cooperation Student Experiment Documentation Page 69 Figure 4 23 Deployment Module Cross Section Post Deployment 4 4 3 Hub The hub is a simple structure to house the central electronic intelligence and acts as the controller of the satellites It is connected wirelessly and hardwired to the payload and cameras The hub is manufactured from lightweight aluminium angles and polystyrene The hub houses the power board and Panstamp data PCB the Raspberry Pi and physical electrical interfaces to the BEXUS service module and the other iSEDE experiment components The hub is insulated using 3cm thick polystyrene in order to protect the central controller from the harsh environment The dimensions of the aluminium angles are shown in Figure 4 24 The polystyrene was glued and then fitted within the aluminium angle frame BX16_iSEDE_SEDv5 1 31JAN14 EuRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 70 l b h 25mm t 3mm JF Figure 4 24 Hub Angles Dimensions Figure 4 26 Manufactured Hub BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 71 To ensure that the Raspberry Pi inside the Hub cannot freely move around during the flight is mounted to the Hub A thin sheet of Aluminium has been placed between 2 sheets of polystyrene This allows screws to be used to hold
62. 2 Launch Campaign E 151 7 2 4 Day 1 4 e 151 7 2 2 Day 2 5 Eeer 151 7 2 3 Day 3 6 October test ceo e e 154 7 2 4 Day Ee 157 7 2 5 reeL 158 7 2 6 Day 6 9 Eesen 165 7 2 7 Day 7 10 October E 165 7 2 8 Day 8 11 October eeseeeeeieieeiesisirieriesrerrerierrerrsresresresrn 166 7 2 9 Day 9 12 October EE 166 7 2 10 Day 10 13 ee 166 Uae VE e coe aa ae a a aa iaaii 166 7 4 Discussion and Conclusions 167 PBs eet 167 7 5 1 Experiment Design amp Heourements 168 7 5 2 Mechanical Design amp Fabteaton 168 7 5 3 Electrical Design component selection fabrication testing 169 7 5 4 Software Design Implementation Testing 000 170 7 5 5 Testing amp Validation Suggested tests problems time Hee el E 170 7 5 6 Workshops A Launch Campaign Who should attend travel suggestions preparation ceeeeeeeeeeeeeeeeeeeeeeeeeeeenneeeeeeeees 171 7 5 7 Project Management software tools outreach and risk ASSESSIMEML ic ccnccteeennsdassonceeeeescesndeesnedasbcsatdeseesnesldecieeeetbeles 171 7 5 8 E ee E 171 8 ABBREVIATIONS AND REFERENCEG 2 cccccssecceesessceceeeeessceeeeeeees 173 8 1 GADDFE e EE 173 EEN 175 BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 1 ABSTRACT The goal of this project from students of the University of Strathclyde is to design and build an initial prototype of an aall inflatable satellite with disaggregated electronics for deplo
63. 50 A quality Reduction in battery Foe testing deleted no batteries required anymore TC70 Temperature testing damages components Component failure TC80 during testing and integration Tc90 Not enough PCB space on inflatable structures PCBs mounted on TC100 inflatable tear inflatable structure Experiment does not fit TC110 together at integration Difficulty in accessing TC120 microprocessors for reprogramming BX16_iSEDE_SEDv5 1 31JAN14 Medium EurRoLAUNCH ADLR and SSC cooperation Page 40 Alternative method of sealing and or seal larger area Refine design until reliable inflation in vacuum chamber tests Estimate difference between lab and mission conditions Purchase higher definition camera more than one camera Buy spare batteries and use fresh batteries for Have spare components Have spare components Carefully review integration of inflatable structure and electronics throughout design Design PCBs without sharp edges or use flex PCBs Coordination between electronics and mechanics during design and during reviews Create mechanical interface design and create access plan Programme correctly first time Student Experiment Documentation Difficulty in accessing TC121 microprocessors for reprogramming C130 Failure of camera s SD Card MS10 Damage of mechanical structures dur
64. 85 833 876 01 Total BEXUS E link Requirements Max Current Draw 1527 06 Max Power Draw 7346 831 Power Consumption mWh 7777 429 Power Consumption mAh 1012 555 BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH ADLR and SSC cooper Student Experiment Documentation Page 100 4 7 6 Power Distribution Diagram amp Schematics ct E CZ l 7 cr Gi al Ee Figure 4 50 Power Schematic BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 101 4 8 Software Design 4 8 1 Software Overview The software implemented across the experiment acts to serve two main purposes 1 On board data handling 2 Experiment control and operational timeline For the on board data handling each satellite monitors its own deployable structure during adaptive phases carry out various measurements store and send to the hub and perform standard housekeeping voltage current and critical component temperature monitoring Cameras capture the deployment and shape alteration throughout the flight however the cameras selected are COTS products capable of carrying out their own data processing and storage Data collected by each satellite is sent to the Hub and stored on SD cards there More information on the recording times of the cameras can be found in the timeline in Chapter 6 The software operates in one primary mode once the satellite is fully deployed an
65. BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 98 Figure 4 49 Isolated SIP Voltage Regulators The regulators selected were isolated SIP Packages fixed to regulate to 3 3V and 5V The Models are 3 3V Regulator TMR6 2410 5V Regulator TMR6 2411 These regulators are said to operate with excellent efficiencies down to 40 C There is also the added advantage in that since both regulators are from the same series the accompanying circuitry is the same The regulators also have an input for a Remote ON OFF function which allows the input of a Transistor Logic Level TLL to switch on and off the regulator This means that on top of the passive components required at the power input and output there is a circuit required to input a TLL into the regulator The full power schematic can be found in the appendix which details the circuitry surrounding each regulator and how they connect to the system 4 7 2 2 Power Circuitry for the Satellite The components on the satellite require regulated voltage levels of 3 3V and 5V As in the hub a voltage regulator is required and a switching regulator is used Ideally due to the design and the concept of mounting electronics to the surface of the inflatable cell surface mount components are desirable This posed a possible problem The surface mount regulators have a smaller current draw than the through hole devices and this leaves very lit
66. D1 and HD2 remove SD and backup watch videos if point 3 all clear power up and perform full functional test solenoid gt HD1 gt HD2 gt pumps disassemble from gondola cable routes camera connections roof structure camera structure BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 165 non invasive inspection of deployables further bench testing as required disassemble all structures s c tests broken tracks solenoid maloperation or mechanism failure return to Glasgow invasive inspection of deployable units 7 2 6 Day 6 ah October Conducted fault analysis What s different analysis pedigree analysis fault tree analysis In order to ensure that nothing was going to be disturbed or possibly made worse planning the testing procedures to be undertaken and by whom was essential A full list of actions was developed and records were taken for each Having agreed as a team what the best course of action was exploration of all the failure possibilities was undertaken It was concluded with strong photographic evidence that a broken cable connection was the result of the solenoid failing to fire during float Further details of this can be found in the Solenoid Failure Analysis Report SFAR Once the team were all fully satisfied that we had found the root cause we gathered all the supporting evidence and held another meeting was arranged with Payload Manager PM Si
67. DARD PITCH DIN985 NYLOC LOCK NUT TYPE T FWS Artikel 190762409167 Transaktion Falcon Workshop 25 Jun 13 838144937009 1 Supplies 3 70 3 70 A2 STAINLESS NYLOC INSERT NUTS STANDARD PITCH DIN985 NYLOC LOCK NUT TYPE T FWS Artikel 190762409167 Transaktion Falcon Workshop 25 Jun 13 838144938009 1 Supplies 1 55 1 55 A2 STAINLESS NYLOC INSERT NUTS STANDARD PITCH DIN985 NYLOC LOCK NUT TYPE T FWS Artikel 190762409167 Transaktion Falcon Workshop 25 Jun 13 838144941009 3 Supplies 1 45 4 35 M8 8mm A2 STAINLESS STEEL SOCKET CAP SCREWS ALLEN KEY BOLTS HEX HEAD FWS Artikel 200831471285 Transaktio Falcon Workshop 25 Jun 13 n 906760784010 1 Supplies 5 60 5 60 M8 8mm A2 STAINLESS STEEL SOCKET CAP SCREWS ALLEN KEY BOLTS HEX HEAD FWS Artikel 200831471285 Transaktio Falcon Workshop 25 Jun 13 n 906760785010 1 Supplies 5 22 5 22 M8 8mm A2 STAINLESS STEEL SOCKET CAP SCREWS ALLEN KEY BOLTS HEX HEAD FWS Artikel 200831471285 Transaktio Falcon Workshop 25 Jun 13 n 906760786010 1 Supplies 6 45 6 45 M3 3mm A2 Stainless Steel Socket Cap Screws Allen Key Bolts Hex Head FWS Falcon Workshop 25 Jun 13 200832008647 3 Supplies 2 25 6 75 RESISTOR 2512 2W 33K 1 Product 02 Jul 13 Ran 5 Premier Farnell RESISTOR 4 7K 0 25W 1 Product 02 Jul 13 Range 50 Premier Farnell RESISTOR 2512 2W 5K1 1 Product 02 Jul 13 Ran 5 Premier Farnell RESISTOR
68. EVIEW Flight BEXUS 16 17 Experiment iSEDE Review location University of Strathclyde Glasgow UK Date 10 July 2013 Review Board Members Nick Panagiotopoulos ESA Technical Directorate Mikael Inga SSC Science Services Alex Kinnaird ESA Education Office document review only Experiment Team Members Thomas Sinn Darryl Black Tiago de Franca Queiroz Frazer Brownlie 2 GENERAL COMMENTS 2 1 Presentation e No comments 2 2 SED e Reviewed by Alex Kinnard 2 3 Hardware e Design still not frozen mechanical electrical software e Lots of open design decisions Still working testing of subsystems instead of complete system TM of one row of inflatable cells Actuator elements can also be seen in photo BX_IPR_Isede_V1 0_17Jui13 Doc BX16_iSEDE_SEDv5 1 31JAN14 EuroLlauncn Student Experiment Documentation Page 191 BEXUS Experiment Integration Progress Review Evuroleur Page 2 Electronic system Hack HD Camera inside housing VIEW BOARD COMMENTS AND RECOMMENDATIO 4 1 Science e Focus on main objectives if necessary 4 2 Requirements and constraints SED chapter 2 e ER_OP_18 Altitude will be minimum 25km but EuroLaunch can not guarantee a pressure below 20mBar 4 3 Mechanics SED chapter 4 2 1 amp 4 4 e Changes of the inflatable cells were made Specifically O The material of the cells is going to be changed into a different material The reason for this action is that there is going to be
69. E_SEDv5 1 31JAN14 EuroLAuUNcH ADLR and SSC coopera Student Experiment Documentation Page 213 2 d 14 14 262 BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation 90 196 250 105 ay 30 150 30 BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuNncH ADLR and SSC coopera Page 214 Frazer Brownlie iSEDE Hub Foam Back Hub Foam Ice Large Student Experiment Documentation 150 210 BX16_iSEDE_SEDv5 1 31JAN14 EvuroLAUNcH ADLR and SSC coopera Page 215 Frazer Broanile iSEDE Hub Foam Iesecscz Side Hub Foam Iess Top EuroLAuNcH ADLR and SSC coopera Student Experiment Documentation Page 216 iSEDE Hub Mount a Plate 0 1 ISEDE Hub Side Measurementmm Strap BX16_iSEDE_SEDv5 1 31JAN14 EuroLauncnu A DLR and SSC coopera Student Experiment Documentation Page 217 BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH ADLR and SSC coopera Student Experiment Documentation Page 218 iSEDE Solenoid ES Pin 14 2246 iSEDE Mountplate BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuNcH ADLR and SSC coopera Student Experiment Documentation Page 219 19 05 Frazer Brownlie iSEDE w N o 830 ISEDE 19 05 BX16_iSEDE_SEDv5 1 31JAN14
70. Experiment Documentation Page 194 BEXUS Experiment Integration Progress Review Evrolauncu Page 5 6 INTEGRATION PROGRESS REVIEW IPR Experiment documentation must be submitted at least five working days the exact date will be announced before the review SED version 3 The input for the Campaign Flight Requirement Plans should be updated if applicable The IPR will generally take place at the location of the students university normally with the visit of one expert The experiment should have reached a certain status before performing the IPR The experiment design should be completely frozen The majority of the hardware should have been fabricated Flight models of any PCB should have been produced or should be in production The majority of the software should be functional The majority of the verification and testing phase should have been completed The experiment should be ready for service system simulator testing requiring experiment hardware electronics software and ground segment to be at development level as minimum Content of IPR General assessment of experiment status Photographic documentation of experiment integration status with comments were necessary Discussion of any open design decisions if applicable Discussion of review items still to be closed Discussion of potential or newly identified review item discrepancies Discussion of components or material still to be ordered or received by
71. F pin To prevent premature deployment of the deployables from the two cube satellite boxes a simple retractable pin is used Each deployment box has one pin with a RBF flag attached to it The pin runs through a hole in the moving part of the latch mechanism and an aligning hole in the rigid deployment box and therefore preventing the doors of the deployment box to open BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuNcH ADLR and SSC cooperation Student Experiment Documentation Page 146 Figure 6 1 RBF pin to prevent premature deployment on storage boxes 6 3 Timeline for countdown and flight Table 6 4 Experiment Timeline Time mins Action T 1d Interference Test Just experiments with the gondola E link e all systems switched on physical switch o start all daemons using screen e communication test e fire solenoid test deploy satellite e Switch off experiment o Hack HD in standby o Raspberry Pi shut down o Physical switch to OFF T 1d Flight Compatible Test FCT all systems switched on both satellites deployed full communication test fire solenoid both satellites deployed Switch off experiment o Hack HD in standby BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 147 o Raspberry Pi shut down o Physical switch to OFF T 1d e Fold both satellites TO BE CONFIRMED WITH BEXUS T 250 Roll out of gondola T 200 e Sweet Spot Test Sweet S
72. Glysantin G 30 is a nitrite amine phosphate silicate borate free coolant based on ethylene glycol which must be diluted with water before use Glysantin G 30 gives outstanding protection against frost corrosion and overheating in all modern engines but especially highly loaded aluminium engines It effectively protects against corrosion and deposits in the cooling system with its vital parts the coolant channels in the block and cylinder head the radiator the water pump and the heater Glysantin G 30 is approved by Volkswagen for all engine coolant applica tions Glysantin G 30 remains effective for a long time so that the first coolant change can typically be done after not less than four years Follow the vehicle manufacturers recommendations Glysantin G 30 is miscible and compatible with previous silicate containing coolants meeting VW standard TL7 4B or C such as for example Glysantin G 48 Glysantin Protect plus or VW Coolant G 11 Since the special advantages of Glysantin G 30 such as improved protec tion for Aluminium and longer change intervals will only be achieved using pure Glysantin G 30 mixing with other coolants should be done only in exceptional circumstances Glysantin G 30 should be diluted 1 1 by volume with water before filling into the cooling system For preparation of the coolant use clean not overly hard water Waste water from mining sea water brackish water brine industrial waste water are
73. Hardware Interface Control Document BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation I F IPR LO LT LOS Mbps MEMS MFH MORABA OP PCB PDR PST SED SNSB SODS SOE SOC STW S W T TBC TBD TC TM TQ TS T amp V WBS E UROLAUNCH Page 174 Interface Interim Progress Review Lift Off Local Time Line of sight Mega Bits per second Microelectromechanical Systems Mission Flight Handbook Mobile Raketen Basis DLR EuroLaunch Oberpfaffenhofen DLR Center Printed Circuit Board electronic card Preliminary Design Review Payload System Test Student Experiment Documentation Swedish National Space Board Start Of Data Storage Start Of Experiment State of Charge Student Training Week Software Time before and after launch noted with or To be confirmed To be determined Telecommand Telemetry Tiago Queiroz Thomas Sinn Testing and Validation Work Breakdown Structure BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 175 8 2 References 1 2 3 4 5 6 7 8 9 10 11 12 Books Paper Proceedings 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 REA00 E60 23 June 2010 European Cooperation for Spa
74. However when trying to pee sway the glue the seal was broken rather easily with minimal force being applied Therefore the UHU Contact Power Glue would not be an appropriate give to be used to seal the inflatable structure at high altitude 1 2 Double Sided Tape Again the material was not cold when removed from the thermal chamber It was found that a lot of force was required to peel apart the cells Therefore this would be an acceptable glue to use for sealing the material 1 3 Stick it Roller The material again was found to be not cold when removed from the thermal chamber Not a lot of force was required to break the seal of the cell It was found to be not as strong as the double sided tape however it was a lot stronger than the UHU Contact Power Glue BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH cooperation ADLR and SSC Student Experiment Documentation Page 198 Thermal Testing of Inflatable Cell Bond Lines rage 1 4 Glue Dots Glue Strips The material was not cold once removed from the thermal chamber The seal was extremely strong and could not be broken when a high amount of force was applied Therefore this would be a very appropriate giue to seal the joints This glue was found to work the best when compared to the three other gives as the seal could not be broken at all 2 Double Cell 2 1 UHU Contact Power Glue From initial manufacturing testing it was found that UHU Contact Power glue worked well as it was the
75. It is suggested that you may still mount internally but as it cannot be guaranteed that your camera view will be un obscured you should consider mounting the camera s perhaps use one camera and a fish eye lens on an external boom looking in This will introduce an open side to the gondola and the organisers may insist on fixing the curtain between your experiment and rest of the gondola BX16_iSEDE_SEDv5 1 31JAN14 gt Le EuroLAuNncH A DUR and SSC cooperal Student Experiment Documentation Page 182 2 For the fixation to the gondola it is suggested you mount your CubeSats to a frame that can sit on top of the gondola s A suggested concept is included below this should be discussed in detail with your contact point and with SSC Olle Persson in parallel with the preliminary accommodation plan There is a scope for also fixing your hub to the mounting bars and reducing your lower footprint or flattening your hub and mounting directly below the deployables 3 Look at reducing your footprint by integrated the hub box o Finalise your battery charging concept and make this clear in your SED Paid k gond ole pron Perso wn Dpenrertrourtey bradst riiai PDR Result pass Next SED version due o 2 0 on 13 May 2013 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 183 BEXUS Experiment Critical Design Review Flight BEXUS 16 17 Payl
76. K Space Conference 2013 flickr com Like Comment Share Bs Figure 3 9 ESA Education facebook post on 9 of August 2013 BX16_iSEDE_SEDv5 1 31JAN14 a EurRoLAUNCH cooperation ADLR and SSC Student Experiment Documentation Page 36 o June 2013 Newsletter article on iSEDE s CDR from Mechanical amp Aerospace Engineering Department University of Strathclyde Article in appendix B o April 2013 News article on departmental homepage of Mechanical amp Aerospace Engineering University of Strathclyde http www strath ac uk mae moreaboutus news 3 C O wwwstrathacuk mae morea nes D Suggested Stes Web Sice Galley 5 imported FremIE 5 Imported from Firet Tropical Pizza Radi gt Gossamer ect o Article in edition of Strathclyde Telegraph university newspaper o Article in national newspaper The Scotland on Sunday BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 37 e Presentations given by team members e g at the university or a conference O September 2013 iSEDE presented at student team competition at International Astronautical Congress IAC in Beijing China August 2013 poster presentation on Smart Deployable Structures with iSEDE technology demonstrator at Alumni Conference of the International Space University Strasbourg France June 2013 iSEDE presented as part of research on Smart Space Structures Postgraduate Research Present
77. Pro Skeleton Camera Housing with HackHD BX16_iSEDE_SEDv5 1 31JAN14 ow S e 7 4 EuroLauncH Student Experiment Documentation Page 73 Figure 4 30 iSEDE webcam with LEDs 4 4 5 Mobius Camera The Mobius camera is used to capture footage outside of the gondola during flight The camera is going to be mounted to a part of the gondola rails by way of cable ties and duct tape Figure 4 31 Mobius camera 4 4 6 Support structures There are two primary support structures A cross beam at one side of the gondola for the cameras and from the roof of the gondola for the deployment modules and hub Both of these use 19 05mm square aluminium tube with wall thickness 3 25mm The Support mount plate is made from T6 aluminium sheet and M8 bolts are used to connect the deployment module with the mount support The cameras are mounted on one cross piece as shown in section 4 2 1 2 and BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 74 indeed weigh less than the mass of the beam itself and the deployment modules and hub are suspended from two beams The beam cross section dimensions are shown in Figure 4 32 PE b h 19 05mm t 3 25mm JF Moment of inertia about bending axis b b 2t 8 0 0194 00127 12 7 12 Figure 4 32 Beam Cross Section 8 9 x 10 m Section Modulus 2I 2x8 9x10 h 0 019 Two beams minimise the height of the support while max
78. SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 55 The data sent from the Hub to the Ground Station uses a UDP socket to send a string with the following pattern which consists in a descriptor and the data Su C u PC u A0 f 6 A1 66f 70 f 71 f P0 f P1 f P2 f n Where e u gt unsigned integer e f gt float e S gt Satellite e C gt Clock time that the satellite is on e PC gt Packet count e AO A1 gt Accelerometers e T0 T1 gt Temperature sensors e PO P1 P2 gt Pressure sensors e n gt new line character The data rate is about ten UDP packets per minute five from each satellite from the Hub to the Ground Station The data rate from the Ground Station to the Hub depends on how often the ground crew send commands 4 2 3 Radio Frequencies optional The satellites and hub communicate wirelessly with an 868 915 MHz panStamp RF module its main features are Data rate up to 600kbps depending on the modulation used Frequency Shift Keying FSK modulation 20 dBm output power at 868 MHz 27 dBm output power at 915 MHz The frequency used on the experiment is 868MHz BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 56 4 3 Experiment Components Each Satellite x2 Inflatable structure 6 micro pumps o 6micro pump controllers o 3 differential pressure sensors o 6 soft robotic actuators 1 panStamp transceiver 2 temperatur
79. Student Experiment Documentation Page 80 Wireless connection redundant hard wired not shown Figure 4 36 Block diagram of the full electrical system excluding power distribution The system functionality is described below with reference to Figure 4 36 The primary purpose of the electronics on board the Hub is to process collected data save it to the SD card and transmit it through the BEXUS downlink to the ground support software Additionally it dictates the operation of the satellites throughout flight and relays commands sent from the ground support software to the respective satellite The Hub electronics consist of a data acquisition system a microcontroller a power distribution system and wireless transmission system The microcontroller controls the data acquisition system communication with the satellites and ground station experiment timeline solenoid and operates the cameras All data received by the Hub over the wireless network is processed by the Hub for storage on the SD card and transmit through the BEXUS downlink to the ground support station Each satellite contains a microcontroller micro pump actuators with control system and a number of sensors for environmental readings and housekeeping The satellite s microcontroller is tasked to receive commands from the transceiver carry out actions accordingly read sensor data and BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation
80. T 12 M8 x 40mm stainless Falcon W S Supplies ZGeneral M8_NUT 28 M8 stainles nyloc nut Falcon W S Supplies 19 05x19 05x3 25mm Richard Austin ZGeneral Al T6 Tube 1 5m Alloys Richard Austin ZGeneral AI T6 Angle 1 1 16x16x1 6mm 5m Alloys Richard Austin ZGeneral AI T6 Angle 2 25x25x3mm 5m Alloys ZGeneral AI T6 Sheet 1 2mm 2x5m Richard Austin BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 78 Alloys ZGeneral Al T6 Sheet 2 1mm workshop ZGeneral STYROFOAM workshop 4 4 7 Folding Technique As the satellite is stowed inside a CubeSat box it is essential to establish an efficient folding technique Each individual cell is folded twice to fit inside the deployment box Each side of the cell is folded towards the middle The satellite is then folded 10 times in a z fold to obtain a rectangular packaging volume This technique along with the effect of gravity ensures that the satellite is successfully deployed Figure 4 34 Folding Simulation Where each fold is placed depends on the placement of the electronics onto the inflatable The same technique is carried out by the same team member to ensure consistency BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNcH Student Experiment Documentation Page 79 S RO Sa NN Figure 4 35 Folding lines on flight hardware 4 5 Electronics Design All components in this experimen
81. The experiment cannot operate any wireless communications on the 2 4 GHz 1000 MHz or 400 MHz frequency bands ii Power drawn from the BEXUS module cannot exceed 28 V ata peak current no greater than 1 A iii Power must be received through interfacing with a MIL C 26482P series 1 connector with an 8 4 insert arrangement MS3112E8 4P iv The electrical interface between the BEXUS E Link and the experiment must use the standard Ethernet 10 100 Base T protocol v Data transmission up and down the BEXUS E Link must be kept to a minimum vi The experiment must be able to withstand the accelerations stated within the BEXUS user manual throughout the flight vii The experiment must be able to withstand the harsh temperature profile experienced throughout the flight viii Experiment mass and volume must be kept to a minimum in order to allow for the other student experiments to be accommodated comfortably within the gondola 1 Schedule constraints can be seen in more detail within the Gantt chart BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 23 b Experimental i The design must incorporate a number of inter connected inflatable cells ii The electronics must demonstrate disaggregation across the full inflatable structure iii Each satellite must be capable of being folded into a lt 1U deployment box iv All data must be stored in the hub in addition to aboard each satellite in case any sa
82. This may have had a negative effect on the seals of the cells as antifreeze is a known solvent for the types of adhesives used in tape BX16_iSEDE_SEDv5 1 31JAN14 Le L a EuroLAuNcH Student Experiment Documentation Page 157 7 2 4 Day 4 7 October At the morning meeting each experiment team leader told the others teams where they were with preparation The FCP was pushed back to 1200 from 0900 which gave the team an extra three hours to repair the experiment Even with the full three hours the team was rushed to complete the modifications in time One satellite had the flexible electronics and pumps removed and all tubes entering and exiting cells sealed with Tear Aid and Kapton tape This was to give the maximum chance of a satellite deploying and inflating after the previous problems The final experimental configuration is shown below BX16_iSEDE_SEDv5 1 31JAN14 EuRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 158 Irn is stowed inside the box with its electronics removed and hung from the roof supports Bru is pre deployed and still had the semi functioning disaggregated electronics attached The FCP test was successful The ground station maintained communication with the satellite the pumps activated when instructed all telemetry data was being received successfully and the solenoid successfully deployed the satellite 7 2 5 Day 5 8 October Went to Dom at 0400 to start countd
83. US but also the thermal environment that would be typical of a satellite in low earth orbit LEO All components are rated for operation down to 40 C As such the only temperature challenges should occur during the ascent and at float where the temperature is significantly lower The materials used for the structure of the hub the interfaces and the inflatable satellite retain their properties across this wide temperature range BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 95 The inflation by residual air should also occur as expected modelled using gas law equations The electronic components that are chosen for the satellite are specified for operation at as low temperatures as possible but it is uncommon for electronics to be rated below 50 C Insulation has been used in the hub and camera housings to ensure these devices are kept within a standard operating temperature range The iSEDE team are continuing to research options that might be available to reduce heat loss from the printed circuits mounted on the inflatable structures minimising volume and mass for these structures is paramount to a successful design solution 4 6 1 Thermal Design for Deployment Mechanism At the moment the solenoid has only been tested in a vacuum chamber where it was successful As the solenoid link arm and latch is made from the same material thus thermal expansion is not expected to be a problem
84. a bandwidth of at least 75 kbps ER PE 11 All shape alterations should be completed in under 20 minutes ER DE 42 increase in SOC during Batteries should display a measurable the 30 minutes charging_phase Decision June 13 charging during mission unnecessary ER_PE_13 Differential pressure sensors must be capable of measuring between 250 250 Pa ER PE 14 Component temperature measurement must between 30 40 C be capable 2 3 Design Requirements ET Der ER DE OI The experiment shall be designed to work within the temperature profile of the BEXUS balloon ER DE 02 The experiment shall be designed to operate in the vibration profile of the BEXUS balloon with special consideration given to the launch and landing stages ER_DE_03 The experiment shall be designed in such a way that it shall not disturb or harm the gondola or any other experiment balloon Decision July 13 batteries unnecessary have sufficient capacity to run the experiment during pre flight tests fight preparation andfiight Decision July 13 batteries unnecessary o EE al BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 18 Decision July 13 batteries unnecessary ER DE Pre The deployment box for each satellite shall be no larger than 1U 10x10x10cm ER_DE_08 Each satellite shall consist
85. a the CRP FRP to be sure that you dont both try actuate at the same time 5 Internal Panel Discussion Summary of main actions for the experiment team o o o Address of all the above minor points Complete the thermal design Consider implementation of an RBF CDR Result pass Next SED version due 2 weeks prior to the IPR provisionally the 24 of June BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC coope Student Experiment Documentation Page 186 Review of BX17_iSEDE_SEDv3 0_24June13 with iSEDE team member task allocation General e Document ID date is DDMMMVY i e 24Jun13 HAOWAS Date 01 07 13 Comment corrected e The old Eurolaunch logo STILL appears from page 129 onwards THOMAS Date 01 07 13 Comment corrected e Spl Charing page 49 ROSS Date 01 07 13 Comment corrected e Blank page 127 HAOMAS Date 01 07 13 Comment corrected e Grey highlighting on page 131 MAOMAS Date 01 07 13 Comment corrected 2 4 Operational Requirements e ER_OP 18 Is 25km really sufficient You should have margin on the pressure required in the 1976 20mbar isn t achieved until slightly above 25km Some models may place the pressure at 25km up to 30mbar EES 3 2 Schedule e You should update your Gannt Chart at least your progress line BEME TOBE e In general it seems you re a little behind the preferred schedule BEME TOBE 3 3 1 Manpower e It s not clear from your manpower section that you have
86. able satellites ER_DE_51 A light source shall be mounted inside the gondola to illuminate the experiment ER DE 52 The soft robotic actuator element shall not leak fluid into the environment ER_DE_53 The fluid in the soft robotic actuator element shall not freeze at the temperatures to be expected during the balloon flight ER DE 54 A switch shall be mounted on the outside of the experiment to switch in between flight and test mode ER_DE_55 A clearance nothing mounted on the bottom of 25cm in actuation direction on the bottom of each satellite is required 2 4 Operational Requirements e o O ER_OP_01 One satellite shall be pre deployed before launch ER_OP_02 The hub shall accept commands from the ground station at any time ER_OP_03 The Hub shall be active from launch command given through the E Link from the ground support station ER_OP_04 At float altitude all systems shall become active ER_OP_05 Data storage shall begin as systems are online ER_OP_06 Any adverse behaviour identified through housekeeping should BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 21 be reported down the E Link to the ground station ER_OP_07 Status of critical components shall be reported to the ground station ER_OP_08 One satellite shall be deployed at float altitude ER_OP_09 Wireless communic
87. alidation of onboard sensors Results IMUs temperature sensors and pressure sensors are fully functional and can be read by the onboard microcontrollers and sent to the ground station Table 5 36 Test Results 0 12 Test number 0 12 inlprogress Test type BEXUS Experiment Communication Results communication over Ethernet port works validation during launch campaign still missing Table 5 37 Test Results 0 13 Test number 0 13 Gompletedi 0810812073 Test type Thermal test of critical components Results Most components are tested down to 30C due to limitations of the thermal chamber See test report TEST 001 in the appendix for more details on the cell bond line BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation and SSC cooperation Page 137 testing Table 5 38 Test Results 0 14 Test number _ 0 14 Gompleted 20108 2073 Test type EMC test Results Simplified test set up Components were all working together when everything was switched on Table 5 39 Test Results 0 15 Test number 0 15 Gompletedi 2010812073 Test type Conductance test Results Simplified test set up Components were all working together when everything was switched on Table 5 40 Test 0 16 Test number 0 16 Gompletedi 100912073 Test type Software Implementation test Results The software was
88. and a data rate using Frequency Shift Keying FSK modulation of 250kpbs is sufficient With its small compact design it has the following characteristics e Size 17 7 x 30 5 mm e Operates from 2 5 VDC to 3 6 VDC e 1 uA when in deep sleep mode 2 5 mA whilst transmitting 4 5 5 Cabling Pin Allocation The following chapter summarized the pin allocation of the cables in between the hub the satellites and the cameras For testing purposes a red and black striped cable has been created that fits in between all connectors which can be used for troubleshooting BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 94 Figure 4 48 DSUB numbering Table 4 4 Cable pin allocation Pin Hub Satellite Hub HackHD Hub iSEDE cam ED 6 wires 8 wires 6 wires 1 Solenoid Camera 2 Ground iSEDE cam black 2 5V Camera 2 5V iSEDE cam red 3 free free free 4 3 3V Camera 1 Ground free 5 Solenoid Camera 1 5V LED positive 6 GND Camera 2 Signal iSEDE cam green 7 RX Camera 2 LED iSEDE cam white 8 TX Camera 1 Signal free 9 RST Camera 1 LED LED negative 4 6 Thermal Design The iSEDE experiment aims to demonstrate synergy in design of inflatable structures with disaggregated electronics While not a requirement for the BEXUS programme the iSEDE project considers not only the thermal environment on BEX
89. and components mounted on each satellite shall withstand the strain exerted during folding All interfaces shall be secured tight to prevent loosening due to any vibrations during flight Solid state non volatile data storage shall be used Capacity of storage memory shall be sufficient to store all measurement and status data Cameras shall be positioned suitably to capture deployment of all satellites TT 11 Cameras shall carry out all image processing and store images locally A redundant power line shall be provided from the BEXUS module to the satellites The hub shall be powered by the BEXUS link BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 118 Status updates shall be generated and sent R T down the E Link to the ground station regularly for each critical component A control algorithm shall control the shape R T alterations of each satellite All data shall be communicated back to the R T hub for storage in its SD card Each satellite shall store all its data on an SD R card locally The ground station shall be capable of R T sending commands to each satellite and receiving data through the BEXUS E Link Feedback data shall be sent down the R T BEXUS E Link to the ground station The hub shall be insulated to provide thermal R S protection The hub shall have an Ethernet port fo
90. ar 13 Socket Solder Tail Single Row 1 Digi Key 1 23 1 23 26 Mar 13 Micropumps Controllers Tubing 1 Bartels 660 00 660 00 26 Mar 13 LBA Pressure sensors 1 LBA 478 64 478 64 26 Mar 13 Soft Robotics Material 1 Curetime 108 05 108 05 26 Mar 13 Linear movement actuator 5 6V 15deg 2 RS Components 21 78 43 56 26 Mar 13 Tool steel semi flush cutter 110mm 1 RS Components 6 87 6 87 26 Mar 13 Anti static band cordset 2 RS Components 17 59 35 18 26 Mar 13 DIGITAL MULTIMETER 5XP A 1 RS Components 36 00 36 00 26 Mar 13 0 5m black test lead 4mm plug 5 RS Components 2 04 10 20 26 Mar 13 0 5m red test lead 4mm plug 5 RS Components 2 04 10 20 26 Mar 13 HELPING HAND 1 RS Components 9 87 9 87 26 Mar 13 AVR Atmega328P Microcontroller 5 RS Components 1 90 9 50 26 Mar 13 PROTOTYPINGBOARD 36 2 RS Components 20 86 41 72 26 Mar 13 Kapton Film 304x200x 0 025mm 1 RS Components 30 00 30 00 26 Mar 13 High temp masking tape 1 RS Components 14 54 14 54 26 Mar 13 Capacitor for linear actuator 2 RS Components 8 00 16 00 26 Mar 13 Foil Blanket Pk 6 2 RS Components 10 58 21 16 26 Mar 13 Pull action latching solenoid 1 RS Components 6 27 6 27 26 Mar 13 Clear heatshrink tube 3 1mm i d 1 RS Components 6 95 6 95 26 Mar 13 Clear heatshrink tube 18 6mm i d 1 RS Components 7 26 7 26 26 Mar 13 LI ION CHARGER 2241 LI 2 CELLS 1 RS Compo
91. arth observation purposes This design will enhance the new concept of nano satellite further developing the University of Strathclyde s work on inflatable structures The project is focusing on disaggregating the electronics removing the need for a rigid structure containing the basic satellite subsystems The design will demonstrate feasibility for space applications and be deployed in a high altitude environment to prove this 1 3 Experiment Objectives 1 Deployment of Satellites e Observe deployment of the satellites e Verify existing LS DYNA simulations 2 Demonstrate Disaggregated Electronics e Wirelessly communicate between Satellite amp Hub e Take sensor readings transmit amp store data 3 Demonstrate Autonomous Behaviour e Generate reports depending on sensed values 4 Alternate shape of satellites e Deform cells via integrated soft robotic elements actuated via micro pumps 9 10 BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 6 e Measure displacement e Control displacement 1 4 Experiment Concept The concept of this experiment is to have a minimum of 2 satellites on board the BEXUS gondola and a central controller the hub One satellite should be deployed before launch and the other deployed when the balloon reaches float altitude When all satellites are deployed there is communication between the satellites and the hub The hub communicates with the ground station through th
92. ation Day University of Strathclyde Glasgow UK March 2013 SET fort Britain iSEDE mentioned on poster on Smart Space Structures House of Commons Parliament London UK December 2012 presentation of iSEDE concept to StrathSEDS Strathclyde division of UKSEDS student space society e Exhibitions of the experiment e g at a fair or university open day O July 2013 Booth at the UK Space Agency presenting REXUS BEXUS and the Strathclyde experiments Teaching Scouts and general public the advantages of inflatable space structures BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 38 Figure 3 10 Outreach booth at the UK Space Conference Glasgow UK o April 2013 Stand at Electrical and Mechanical Engineering Tradeshow Academic staff and representatives from industry viewed projects completed by students within the department Figure 3 11 Electrical Engineering University Tradeshow April 2013 BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 39 3 5 Risk Register Each risk is scored with a Total Risk Index TRI which is the result of multiplying its severity and likelihood of occurrence scores Severity is rated from 1 to 5 with 5 being most severe Probability is rated A to E with E being the highest probability The TRI is then classified in four groups Green Yellow Orange and Red Only Green risks are accepted by th
93. ation between the hub and satellites should be established after deployment ER_OP_10 Shape change shall begin upon receipt of command from ground station ER OP 11 Electronic systems shall operate autonomously ER OP 12 The satellites shall conduct measurements autonomously ER_OP_13 The experiment shall accept a request for radio silence at any time while on the launch pad ER OP 14 All data shall be relayed back to the hub SD card for storage ER OR 285 The charging phase shall be initialised only after shape change Decision June 13 charging during mission unnecessary ER_OP_16 The experiment light inside the gondola shall be able to be switched on ER OP 17 The float phase of the balloon shall be at least two hours to run through experiment cycle twice ER_OP_18 The flight altitude shall be at least 25km low pressure required for cell inflation ER_OP_19 During the actuation phase of iSEDE other experiments on the gondola shall not introduce any movement to the gondola ER_OP_20 The side walls of the gondola shall be attached during the flight ER OP 21 Remove Before Flight pins shall be attached to the satellite boxes to ensure safe handing 2 5 Constraints There are a number of constraints both technical and managerial that must be applied to the experiment in order to be compliant with BEXUS requirements academic needs and expe
94. aunch campaign Two of the team members are from Brazil which isn t an ESA member state therefore additional funding is required to be found for Tiago and or Larissa to attend the launch campaign The Aerospace and Mechanical engineering department might offer support but this needs to be negotiated by a case to case basis So far Tiago got sponsored by the department with 200 to attend the Soldering Course and the CDR at ESTEC in May Further funding to attend the launch campaign is currently sought for through various applications for travel grants IET home institution It is estimated that another 1000 person are required to send Tiago and or Larissa to the launch campaign flights and hotel 3 3 3 External Support The Advanced Space Concepts Laboratory at the University of Strathclyde provides the team with the most support The team s endorsing professor is Dr Massimiliano Vasile who is an Associate Director of the Advanced Space Concepts Laboratory As the majority of students study a joint Masters Degree in Electrical and Mechanical Engineering contacts within the EEE department are supporting on power electronics and communications The large percentage of work being related to students academic projects means that academic supervisors also provide support where required International magnetics manufacturer Coilcraft have offered their support to the iSEDE team in providing components and testing facilities
95. be altered in shape effectively from a command given from ground 2 3 g A large portion of this analysis was done through the videos captured by the cameras on board the gondola This allowed the team to study the deployment how the cells inflate and monitor the shape change of the inflatable structures This also partially proved the operation of the electrical subsystems disaggregated across the surface of the satellites by watching the structure change shape Through the reports sent back from the satellite during the flight we can prove the power and communications systems work in near space conditions We can also use temperature values and pressures measured to model what happened during the flight and use this data to build on for future experiments 7 2 Launch Campaign 7 2 1 Day 1 4 October Arrived at Esrange around 2330 Received security badges and room keys 7 2 2 Day 2 5 October Attended safety briefing at 0815 detailing the roles of SSC DLR ESA and ZARM personnel for the launch campaign Informed of areas off limits emergency procedures and fire procedures Proceeded to the Dom to unpack experiment Checked off each item against packing list and found that everything had arrived safely Checked satellites for damage during shipping The inspection of Irn revealed a hole in the flex BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNcH Student Experiment Documentation Page 152 PCB and possibly the sat
96. berry Pi to drive the MOSFET and activate the solenoid 4 5 3 Satellites Each satellite forms the basis of what would be a concentrated control hub as part of a larger smart space structure As such its electronics are designed to facilitate intelligence for performing various measurements to monitor and control the performance of the structure Each satellite gathers ambient and component temperature readings along with important voltage sensing for housekeeping Differential pressure measurements are also being taken to help characterise the inflation of the structure at deployment and throughout flight As described earlier the actuation is driven by Bartels MEMS micropumps which are connected electrically to the microcontroller through their own sub controller The control of the actuation is provided through two accelerometers positioned on the structure Data is not stored on each satellite it is instead only acquired and transmitted to the Hub via the wireless link The data is then processed stored and sent to the ground support station 4 5 3 1 Microcontroller The satellite controller circuit is a PanStamp based upon the Arduino Pro Mini It uses an Atmega328 chip and the open source schematics amp firmware made available by PanStamp This architecture allows for easy development of the embedded systems due to the availability of open source schematics and a wide user base Development boards have been purchased these al
97. ce Standardization ECSS Space Engineering Technical Requirements Specification ECSS E ST 10 06C 6 March 2009 European Cooperation for Space Standardization 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 Clark R et al StrathSat R Deploying Inflatable Cubesat Structures in Micro Gravity IAC 12 E2 3 7 63rd International Astronautical Congress IAC 2012 1 5 October 2012 Naples Italy Sinn T et al Bio inspired Programmable Matter for Space Applications IAC 12 C2 5 1 63rd International Astronautical Congress IAC 2012 1 5 October 2012 Naples Italy Sinn T et al Design and Development of Deployable Self inflating Adaptive Membrane AIAA 2012 1517 13th AIAA Gossamer Systems Forum as part of 53rd Structures Structural Dynamics and Materials and Co located Conferences 23 26 April 2012 Honolulu Hawaii USA Freeland R Bilyeu G Veal G and Mikulas M Inflatable deployable space structures technology summary 49th International Astronautical Congress Melbourne Australia 1998 Galen C Sun Stalkers How Flowers Follow The Sun American Museum of Natural History New York NY
98. check list for their area They should then combine the lists and discuss which procedures should get priority This helps to ensure that all required tasks are done during the launch campaign However if problems occur during the launch campaign then tasks need to be pushed back or done in parallel by other team members Specialised and commonly used tools in assembling the experiment should be taken by the team 7 5 7 Project Management software tools outreach and risk assessment Ideally it should be the same project manager throughout the project Conferences are very useful for outreach 7 5 8 Miscellaneous Ensure that when people are getting a part of the project handed over to them that they understand and know everything that is going on in their field so fewer surprises are likely to occur Ensure that all material and parts are constantly recorded and up to date Ensure that you have a clean and peaceful working environment M6 was dusty and had a lot of people coming in and out BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 172 e Ensure that all team members are willing to put in a lot of time and effort Especially the months leading up to the launch campaign e Ensure that there is sufficient budget e While connected to the E link network all software that use internet e g Dropbox Skype and etc should be deactivated closed to avoid unnecessary broadcasts e Wireshark and
99. clyde iSEDE lab Tested item Entire experiment Test Test of wireless communication between the satellites and between each satellite and the hub level procedure Test duration 2 weeks Date status April July 2013 G6mpleted 2010712013 Table 5 10 Test 0 8 Test number 0 8 Test type On board microcontroller test Test facility University of Strathclyde iSEDE lab Tested item Satellite and hub microcontroller Test Functionality and performance evaluation of microcontroller onboard satellites and hub validation of performing desired level procedure tasks Test duration 2 month Date status March July 2013 Elter Table 5 11 Test 0 9 Test number 0 9 Test type Camera view angle test Test facility University of Strathclyde iSEDE lab Tested item Cameras BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Page 125 Student Experiment Documentation Test Test of cameras in mock gondola ensuring that the level procedure cameras can capture displacement correctly Test duration 1 week 2 days at launch campaign Date status April amp October 2013 G6mpleted Table 5 12 Test 0 10 Test number 0 10 Test type Performance validation of onboard sensors Test facility University of Strathclyde iSEDE lab Tested item All sensors Test Validation of performance of all sensors proving that they
100. d as can as can be Some minor formatting errors cantered text in section 4 5 4 Some missing images insert image The Eurolaunch logo has dropped out check the template BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuncu A DLR and SSC Student Experiment Documentation Page 184 4 Panel Comments and Recommendations DEE and constraints SED chapter 2 There are no flight requirements altitude duration daylight Not as high as possible These should be derived from the other new requirements probably pressure Classic mistake don t commit to dates unless for a scientific reason in the mission statement Don t use may use should and shall remember Koen s presentations The frequency of the temperature measurements is very high GHz is this frequency is really needed a Mechanics SED chapter 4 2 1 amp 4 4 o Risk for shocks at launch has been included o Shock FEM analyses were also requested at PDR but not found o Overall experiment envelope is provided but if inflatable elements can deviate from vertical direction because of inflatable cells shape changes or wind or other and how much is not given The deployment mechanism to open the box lids is described spring driven and is tested in vacuum which is good The holding system is based on solenoid This is not sized min force provided by the solenoid vs required forces and would be nice to be tested or at least verified b
101. d NA camera the deployment boxes shut documentation 1 FB No Copy SD card data on SD cards 120 TQ BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation and SSC cooperation Page 150 computer via bit by bit copy after one day drying phase computer Make at least two copies on different storage devices of SD card data Computer external drive hard 120 TQ Wrap all components with bubble wrap for safe transport NA camera documentation 120 FB Take boxes back on flight to MAE department NA FB BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 151 7 DATA ANALYSIS PLAN 7 1 Data Analysis Plan This project is a technology demonstrator so the analysis isn t as big a task as for example a scientific experiment but there are criteria that shall be looked at The project was meant to demonstrate 1 That the residual air inflation gives us a viable means to create an inflatable space structure That it is possible to successfully deploy a large inflatable structure in space from a small volume That the electrical subsystems usually contained within a hub can survive and function when disaggregated across the inflatable surface of a satellite That it is possible to communicate wirelessly between the satellite and the Hub and then to ground in the conditions That the inflatable structure can
102. d systems are online the operational phase This mode is described here with reference to Section 6 3 The operational phase runs for 30 minutes and is where most major satellite functions are operated it is shown in the experiment timeline between FT 2 and FT 32 During this phase the adaptive phase AP of each satellite is demonstrated and the wireless communications between Hub and satellite are tested Once 1 cycle of operational is complete it simply repeats until the balloon reaches the end of its float and begins to descend 4 8 2 Hub The hub acts as the main experimental controller for the iSEDE experiment Its tasks primarily include controlling the experiment timeline storing data and allowing communication between the satellites and ground station through the BEXUS E Link The Hub co ordinates each satellite according to the experimental timeline and commands received from the ground station The Hub also ensures that the experiment does not deploy until deemed safe by the ground crew a go command is sent once the balloon has reached the float altitude of its flight Upon receiving this command the first cycle of the experimental timeline initiates The cameras automatically begin recording and storing data upon receiving command from the hub they are set to record through all operational phases carried out during the flight Across the full flight the Hub generates reports based upon critical data received from each satel
103. d with ones that have metallic case in order to avoid thermal problems Watchdog should be implemented in order to avoid deadlock and other issues Hardware watchdog was recommended Not fully prototyped not the full system on board this should have been done now The cables used for the harness should be exchanged with cables that suites the need better avoid the ribbon cables there is better cables Thermal SED chapter 4 2 4 amp 4 6 Raspberry Pi cooling issues in low pressure almost no convection has to be tested Software SED chapter 4 8 Finalize EGSE SW and test Finalize on board SW and test Finalize automatic timeline Implement TC verification at least TC Cmd counter in TM Full system use test should be done asap How to trigger the automatic sequence has to be finalized If shut down cmd is implemented check if cmd it is valid when received Verification and testing SED chapter 5 System level testing should be performed not only subsystem level testing Test harness issues asap thermal unfolding etc Safety and risk analysis SED chapter 3 4 RBF not necessary for safety There is no need for safety straps or RBF after landing for safety Launch and operations SED chapter 6 Maybe no RBF needed for operations but if keep it simple How to detect if in float phase also mentioned in 4 6 No risk of material release during deployment No bounce more like oscillations up to 100m in beginning
104. detached from the experiment at any point during the BEXUS flight The peak current draw from the BEXUS umbilical shall not exceed 1A at 28V Each satellite shall have a redundant hard wired data connection to the Hub Communication between the satellites and the hub shall be wireless The hub shall have a communications link with the BEXUS E Link Communication up down the BEXUS E Link shall not exceed 300 Kbps The wireless communication system shall have a bandwidth capable of transmitting all data defined within the data budget The deployment box of the satellite deploying at float altitude shall remain sealed until deployment command is given R I T TAAT TANT BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 117 The deployment boxes shall not cause any damage to the deployable structure The hatch on each deployment box shall remain attached after deployment of the inflatable structure Ae kl The inflatable cells shall not burst when subjected to vacuum pressure HAT Pressure shall be measured inside at least 2 adjacent cells in each satellite R T Critical components shall have the embedded capability of measuring their temperature All PCB s shall be resin coated to be prevent arcing in vacuum pressures All tracks and wires should withstand environmental conditions Tracks
105. e 3 4 shows a further breakdown of tasks for each software area of the project 3 1 HUB 3 2 Satellites 3 3 Ground mae Station Integration 3 1 1 Flow 3 2 1 Flow 3 3 1 Flow aech S x A Station amp Diagram Diagram Diagram HUB 3 1 2 Pseudocode 3 2 2 Pseudocode 3 3 2 Pseudocode 3 4 2 HUB amp Satellites 3 3 3 GUI Design 3 4 3 Full 3 1 3 Coding System 3 2 3 Coding 3 1 4 Testing amp Debugging 3 2 4 Testing amp Debugging 3 3 4 Coding 3 3 5 Testing amp Debugging Figure 3 4 Software WBS BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooper Student Experiment Documentation Page 26 Following from the WBS each team member was allocated tasks which reflected their specialisations and interests Table 3 1 Allocated Tasks Task Number Task Lead Engineer Additional Engineer 1 EE EHS Frazer Brownlie Thomas Sinn Andrew Allan Structure 2 1 Power Tiago Queiroz Jonathan Gillespie 2 2 Comms Tiago Queiroz Adam Rowan 2 3 Microcontroller Tiago Queiroz Adam Rowan 2 4 Sensors Tiago Queiroz Adam Rowan 2 5 Micropumps Tiago Queiroz Adam Rowan 2 6 Camera Tiago Queiroz Adam Rowan 3 Software Tiago Queiroz Larissa Leite 4 Verification Thomas Sinn Frazer Brownlie 5 Review All 6 Post Flight Thomas Sinn Vano eve DE Leite trazer Brownlie H Outreach All 8 Management Thomas Sinn 3 2 Schedule The GANTT chart below summarizes all the tasks that need to be performed from the IPR on
106. e BEXUS E Link The ground station is able to receive reports and give commands For example a command to cause the satellites to change their shape though the pumping of antifreeze between cells on the satellites BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 7 1 5 Team Details The team is made up of 7 members from different departments and at different stages in education The tasks have been distributed between the members 1 5 1 Contact Point Thomas Sinn PhD researcher at the Advanced Space Concepts Laboratory Thomas Sinn Team e mail isede2013 gmail com Personal e mail Thomas sinn strath ac uk Department Advanced Space Concepts Laboratory Department of Mechanical and Aerospace Engineering James Weir Building 75 Montrose Street Glasgow G1 1XJ UK 1 5 2 Team Members The team composition and organisation is given in the table below team member background project area academic interest credit Thomas Sinn Aerospace Project Manager Related to MSc PhD Cand engineering Payload Advisor PhD Thesis of Dept of Mechanical deployable Deployable Deployable amp Aerospace space structures Structure Smart Smart Space Engineering inflatable Structure Structures University of structures smart Outreach Strathclyde structures Tiago de Fran a Linux Servers Software Summer Queiroz BEng Embedded Embedded internship Computer Science Programming Systems Science Univer
107. e EAR and Yellow risks are justified Table 3 3 Risk Analysis Risk ID TC technical implementation MS mission operational performance SF safety VE vehicle PE personnel EN environmental Probability P A Minimum Almost impossible to occur B Low Small chance to occur C Medium Reasonable chance to occur D High Quite likely to occur E Maximum Certain to occur maybe more than once Severity S 1 Negligible Minimal or no impact 2 Significant Leads to reduced experiment performance 3 Major Leads to failure of subsystem or loss of flight data 4 Critical Leads to experiment failure or creates minor health hazards 5 Catastrophic Leads to termination of the project damage to the vehicle or injury to personnel The rankings for probability P and severity S are combined to assess the overall risk classification ranging from very low to very high ID Risk PIS PXS Action Change dimensions of Inflatable structure too TC10 B 3 deployment box or arge for GEDIOY MENEDOX inflatable structure BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation Seals of inflatable burst TC20 under inflation pressure Seals of inflatable leak TC30 e under inflation pressure Shape changing TC40 actuation cannot be fully tested in lab conditions Cameras give poor image TC
108. e findings show that the UHU Contact Power Glue is not an appropriate glue to use as the sealant for the cells 4 Results Thermal testing found that the material was not cold when removed from the thermal chamber and that the material was not any more or less rigid These would be advantageous to the overall experiment as the material would act as an insulator for the glue so the cold environment should not affect the give at ail it was also found that the glue which worked best was the Glue Dots Glue Lines This would be the best glue to use out of all that was tested as this was the most consistent and the seal could not be broken The worst performing glue was the UHU Contact Power Glue This was the less consistent of the glues which were tested and the seal was easily broken BX16_iSEDE_SEDv5 1 31JAN14 EuRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 200 APPENDIX D ADDITIONAL TECHNICAL INFORMATION 1 Bartel mp6 Micropump Datasheet microComponents Technical Data of the mp6 mp6 Pump type Number of actuators Dimensions without connectors Weight Fluidic connectors Electric connector Power consumption Self priming Pumping media Operating temperature Life time IP code Order code mp6 piezoelectric diaphragm pump Fd 30 x 15 x 3 8 mm 29 barbed tube clip outer diameter 1 9 mm length 3 5 mm flex connector Molex FCC 1 25 mm pitch lt 200 mW yes gt
109. e lab late and left early he also failed to deliver a report and poster at the end His work on the power system also had to be taken over and finished by Tiago Nevertheless the team decided to send Darryl to the launch campaign where he also did just work when he was told to do so he and Craig spent the rest of the time on their personal computer Jonathan Adam Larissa Craig Darryl Andrew Frazer Tiago Figure 4 Overall performance of team members Due to the poor performance of Craig and Darryl coupled with their unfulfilled promises during the summer and the campaign it was decided by the team and the supervisor to remove Craig and Darryl from BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 15 the team in October 2013 The delays and problems before and at the launch campaign were a result of the manpower lost during the summer BX16_iSEDE_SEDv5 1 31JAN14 and cooperation Student Experiment Documentation 2 EXPERIMENT REQUIREMENTS AND CONSTRAINTS 2 1 Functional Requirements a Design requirement ER_DE_50 Operational requirement ER_OP_01 ER_FU_03 The electronics of each satellite shall be disaggregated across its inflatable structure ER_FU_04 Cameras shall capture the deployment and performance of the satellites during the mission ER_FU_05 Passive inflation shall be demonstrated by each satellite ER_FU_06 Wireless
110. e of Mylar shiny side does not bond well Wetting table to stick Mylar to it allows you to remove any creases and kinks By adding straws for on ground inflation causes problems Small gaps are difficult to reseal Straw for each cell works better rather than having connecting straws through the entire structure Ensure that thermal chamber can go to desired temperature BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 171 Mylar s material properties does not change significantly down to 30 C Man made manufacture produces a lot of inconstancies Ideally the satellite would be produced by machine Heat sealing would be best alternative to adhesives to seal cells 7 5 6 Workshops amp Launch Campaign Who should attend travel suggestions preparation Carefully choose who attends design reviews considering their role in the overall project Where possible lead engineers should attend but they should understand fully all the subsections and other work that has been completed by colleagues Everyone who attends launch campaign should be briefed in fully so that they understand their role at the campaign Which means that they know what they are meant to be doing while at the launch campaign and can help out other colleagues Comparison website www p4d co uk is a useful website to find a cheap courier service for shipping the experiment The lead engineers should establish a procedure and
111. e organisers may also distribute your SED to current and future participants for specific examples e In case of a problem in your experiment that might affect its performance impact the schedule or have safety implications you must inform ESA and EuroLaunch immediately e The realisation of an outreach programme is mandatory Specific Conditions to be addressed at PDR 1 You shall expand the scope of your experiment to include either a structural interest or an electronics communications interest For structural interest you can consider the inclusion of an element of stiffness surface volume or strength for electronics you may consider a communication element across your electronics 2 You shall reconsider the configuration of the external appendages as presented in your oral presentation at the Selection workshop BX16_iSEDE_SEDv5 1 31JAN14 EuRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 179 REXUS BEXUS Experiment Preliminary Design Review BEXUS 16 17 Payload Manager Alexander Schmidt Experiment iSEDE Location DLR Oberpfaffenhofen Germany Date 04 Feb 2012 1 Review Board members Mikael Inga SSC Science Services Olle Persson Hans Henriksson Torbj6m Eld Klas Nehrman Natacha Callens SSC Science Services SSC Science Services SSC Science Services SSC Science Services ESA Education Office ESA Tech Structures and Mechanisms ESA Tech M
112. e power source The BEXUS link supplies a varying voltage around 28V providing up to 1A and so this is regulated down to a constant voltage for the hub components There is also a degree of filtering in an attempt to provide the components with an as close to perfect power input as possible In addition elements of isolation and protection are placed at points in the system to allow shut off if a fault occurs and prevent any damage to components or other experiments 4 7 2 1 Power Circuitry for the Hub The components in the hub require regulated 3 3V and 5V levels This can be seen in Section 4 7 3 Power Budget Breakdown This requires DC DC Convertors to step the voltage down There are two main kinds of regulators a linear voltage regulator and a switching voltage regulator There was an investigation and deliberation into whether the system should use linear or switching regulators Upon advice it was decided that from an efficiency point of view as well as a safety point of view isolated switching DC DC convertors are used These provide higher efficiencies than the linear counter parts and the added benefit of isolation of the input from the output should any faults occur These incurred a higher price than what was initially thought would be required for regulators but it was decided that the benefits of these would outweigh the negative of the higher cost The regulators chosen were from TRACO POWER shown below in the figure below
113. e s functionalities available although the GUI and the visualization of pre stored information do not need internet connection to work The software consists of a graphical interface to enable the controller to easily interact with the experiment The table below indicates which telemetry TM is sent by the experiment and the telecommands TC which are sent from the ground station to control the experiment Due to the fact that the firing of the solenoid can only be done once during the mission satellite deploys a pop up window has been implemented asking the user for a second confirmation An accidental triggering of the deployment is prevented The entire mission of the experiment consists of different phases ranging from preflight testing launch and ascent to float phase which is the main experimental phase to descent phase after cut off of the balloon To allow an easy operation and keep a clear interface all information is shown in a single screen using table to most of the data and graphs to more critical data Figure 4 53 shows the main screen From this screen it can be clearly seen if one of the systems is experiencing difficulties Experiment Comman ds iSED E TCP Disconnected Send Commands Timer 00 00 00 _ Send Start _Reset iSEDE Satellite tellite 1 Temperature Chart ass Temperature 2C 00 59 30 Time Temperature Altitude Chart WiFi Lor HackHD 1 Con
114. e sensors Accelerometer Flexible circuit Deployment Module x2 1U Deployment module structure o Hinged doors torsion springs 2mm aluminium T6 sheet amp angles Solenoid RBF pin Accelerometer Cable Tie Solenoid connector Satellite D sub Accelerometer connector Hub Hub structure o 2mm Aluminium T6 angles Insulation polystyrene Central controller Raspberry Pi 1 panStamp transceiver 1 temperature sensor Ambient pressure sensor E Link interface Power interface Power circuitry o Power board with regulators o Leds o Physical switch Cameras x2 Camera Housing o GoPro camera enclosure Camera Interface HackHD camera BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation Mounting Structures e Square tube Aluminium T6 3 4 inch 10swg e Array of 10 bright white LEDs with iSEDE webcam Cables e Hub Satellite cable x2 e Hub HackHD cable e Hub iSEDEcam LED cable cooperation Component Status Inflatable Structure Manufactured Micropumps Arrived Micropump Controllers Arrived Differential Pressure Sensors Arrived Soft Robotic Actuators Manufactured Regulators Arrived panSTAMP Arrived Temperature sensors Arrived Accelerometers Arrived Flexible power and data connections Arrived between circuit boards Deployment module structure Manufactured Solenoid Arrived Hub structure Manufactured 2mm Alu
115. e team They were still be available for consultation should the need arise Andrew handed over his design and responsibilities to Frazer Brownlie and Jonathan to Darryl Black Frazer Brownlie and Darryl Black are working on iSEDE full time over the summer as a paid internship of the Department of Mechanical and Aerospace Engineering University of Strathclyde Therefore during summer Frazer Darryl Tiago and Larissa are working full time with the support of Thomas over the summer on fabrication assembly and testing of iSEDE These five team members should be enough to finish the experiment in time for experiment submission in September 2013 3 3 2 Budget The budget of iSEDE is a sum of various dissertations projects and funding of the Aerospace and Mechanical Engineering Department University of Strathclyde 3 3 2 1 Component Budget The current funding for the project is 2950 Expenses so far come to a total of 2720 as of 07 07 2013 The spending on components materials and tools is itemised in Table 3 2 The funding is made up with 400 from the 5 year EME project 100 from A year EME project 50 from 4 year MAE project 400 department contribution and 2000 excess from a university project on inflatable structures Qu ant Unit Date Component ity Supplier Cost Cost 17 Dec 12 Arduino Nano 3 0 3 RS Components 29 00 87 00 17 Dec 12 Raspberry Pi
116. each satellite and draws a maximum of 200mA 4 5 3 2 Data Acquisition amp Sensors On each satellite there are a number of sensors used to gather ambient and component temperature data differential pressure between cells accelerometer data for actuation control and voltage at critical points in the system As stated earlier all data collected is sent directly through the wireless link or hard wired connection if the wireless is unavailable to the Hub for processing The analogue I O pins of the PanStamp microcontroller allow an input range of between 0 and 3 3 V This can be changed using the analogue reference pin but shall remain 0 3 3V as default All inputs out with this range shall be scaled with a voltage divider Temperature Measurement As in the Hub TMP102 temperature sensors are used within both satellites Four sensors are located throughout e 1 measuring ambient temperature in gondola e 1 measuring temperature of Atmega328 microcontroller e 2measuring on the cells All four sensors are located on the single I C bus connected to pins A4 and A5 of the PanStamp board Differential Pressure Measurement Differential pressure measurements are taken between the soft robotic elements in adjacent actuated cells That is they measure the differential pressure between two soft robotic actuation elements in each of the three closed systems The data collected here allows for characterisation of the system and the amount
117. eakdown Structure WD 24 e EE 26 Oi EE 27 3 3 1 SIAN DOW EE 27 313 ys UCC Cb cece te hed teehee he ee he ed ed et he eee 28 3 3 3 External SUDDOn ee 32 3 4 Outreach Approach E 33 3 5 Risk Register unn 39 4 EXPERIMENT DESCRIPTION anewaiecaikewanGuaineahen aiek te 47 4T eine D 47 4 2 Experiment Interfaces AEN 51 GEET EE 51 AZ gt EVO CIC E 53 4 2 3 Radio Frequencies optional 55 4 3 Experiment CGomponents AEN 56 WA Mechanical Eeer 58 4 4 1 Payload iSEDE satellte AAR 59 4 4 2 Deployment Modules unn 64 AS THUD DEE 69 AAA Camera HOUSING EE 71 BX16_iSEDE_SEDv5 1 31JAN14 Vii 4 4 5 Mobius Camera EE 73 4 4 6 Support structures 22 0 cceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaees 73 4 4 7 Folding Technique EE 78 4 5 Electronics DESIG EN 79 4 5 1 Electronics Overview EE 79 ele Po E IP te ERO DO ane Or CE E E 81 re e 87 4 5 4 Wireless Communication 93 4 5 5 Cabling Pin Allocation 93 4 6 Thermal Design 94 4 6 1 Thermal Design for Deployment Mechanisme 95 4 6 2 Thermal Design for Inflatable Structure nnnoooooooeooooneneeeeeen 95 4 6 3 Thermal Design for Mechanical Giruchure 95 4 6 4 Thermal Design for Hub 95 4 7 POwWer System e LINN Ne LIN ae ae ea ace ee ae Se eee ec 97 4 7 1 Power El 97 4 7 2 Power Circuitry E 97 Ee Chetone the Satele Bates mea ttt eege eg 98 4 7 4 Power REI EE 99 4 7 5 Power Budget Breakdown AE 99 4 7 6 Power Distribution Diagram amp Schematics snn
118. echanical Eng Dept ESA Education office DLR Institute of Space Systems Lucio Scolamiero Koen DeBeule Chair Alex Kinnaird minutes Martin Siegl 2 Experiment Team members Craig Hay Adam Rowan Darryl Black Andrew Allan Thomas Sinn available on skype 3 General Comments Presentation o Style is good this presentation answered some of the questions the board had from the pre discussion There is some evolution from the selection workshop The board suggests you are very stiff during your presentation try to be enthusiastic and look up In general the document is OK and is at a PDR standard Try not to send PDF with the comments inside 4 Panel Comments and Recommendations Requirements and constraints SED chapter 2 o You have some problems with the classifications the minimum number of satellites Le 2 is a design requirement You should look at the formulation of the requirements and consider the verification The satellite been deployed prior to launch is an operational requirement for the wording you re currently using Design requirement number 8 is difficult to verify Consistency between design requirement 12 and functional requirement 1 shall or BX16_iSEDE_SEDv5 1 31JAN14 en EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 180 should The team clarified this is due to the placement inside vs outside not the number of the satellites thi
119. ed at this section Some of the remaining glue holding the material together It was to be expected that the joint of the connecting cells would be more difficult to break as more give was applied to the 2cm gap than the 1cm gap For all of the double celled structures the material was not cold when removed from the thermal chamber 3 Multiple Cells 3 1 10 Cell Structure with UHU Contact Power Glue The final structure which was inside the thermal chamber was a full 10 cell structure with UHU Contact Power Glue as the glue which sealed the material However it was found that it did not retain the air very well so small strips of reinforced tape was used to seal the small holes which sir was escaping from It was found that the reinforced tape did not stick very well once removed from the thermal chamber It could be easily peeled sway The outer perimeter of the cells was also found to fail when a small force was applied to break the seal This was also found to be true for the joint which connected the cells together UHU Contact Power Glue was also used to connect the 2 arrays of 5 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 199 Thermal Testing of Inflatable Cell Bond Lines rage 4 Date 12 05 2013 cells with a small strip of the glue used at the centre of each cell to hold them in place However it was found that the cells could easily be unpeeled from one another Th
120. eeeeeeeeenae 100 4 8 Software Design 101 e Ee E RE 101 AiG Te Apia E ihn Se A os See tak as 101 4 8 3 AIGIING GS ict sche a ts ets ct tot a tee ht ttt 102 4 8 4 Software Implementation eneeeeseeeennnnenneeeeeeennennrnneseeeenee 102 4 8 5 Data EE 108 4 8 6 lei e EE 109 4 9 Ground Support Eoupment 110 4 9 1 Ground Support Software 110 5 EXPERIMENT VERIFICATION AND TESTING seeeeeeesseeerrenessrrrrrn 114 Deb Venticatiom Matii EE 114 5 2 Mest EE 120 5S2 eekleg 120 5 2 2 Test Mat E 132 D34 Test TEE 133 5 3 1 Test Results Breakdown 133 6 LAUNCH CAMPAIGN PREPARATION s sssssssssssssennnsssssssrrrnnnnessssrrrrrenn 139 6 1 Input for the Campaign Flight Requirement Plans 139 6 1 1 Dimensions E 139 6 1 2 Safety dE 139 BX16_iSEDE_SEDv5 1 31JAN14 viii 6 1 3 Electrical interfaces 2s 02 c aiaiaicavanavacauevanaucava 140 6 1 4 Launch Site Requirements ssosssnnneeneeeeeeennnnernreeserrrrrrenn 141 6 1 5 Balloon Mounting amp Mission Requirements eeasassenneee 141 6 2 Preparation and Test Activities at Esrange sssssssseeeeeeessesrrrrreenn 142 6 2 1 Remove Before Flight RBF pm 145 6 3 Timeline for countdown and obt 146 o Both Hack HD recording off Safe data 148 6 4 POSE Flight Activities 5s cs2ccc orechaseasnpdacscnege ed pnieed eeycesd be nenesd ee eeuess decree 148 7 DATAANALY SISA PLAN EE 151 Tet Data AMAalysiS Praise veces voce sed ea aE E Ee E A EAA 151 7
121. ellite cell itself due to the sharp pins of the Panstamp wireless board Luckily the hole had not damaged any flex PCB tracks Further scratches found were found on Irn and also on Bru All sharp edges should be eliminated from future designs File down pins or cover in Kapton tape or similar non conductive material The satellite was fixed with the materials available with the holes being patched with Tear Aid and Kapton tape The functionality of micropumps was then tested using the pumps and the pump test board It was found that the pumps were pumping antifreeze around the y connector possibly because the pressure is lower in the tubing than in the soft robotics No fluid entered the soft robotic element The fluid was taking the path of least resistance It was not possible to pump both ways because of this problem The pumps were reconfigured so that they were both pumping the same direction This problem occurred because the concept was not thoroughly tested before the launch campaign This was due to difficulties in manufacturing suitable soft robotic elements The manufacturing technique perhaps needs further development as the area where soft robotics join pumps were also prone to leakage The amplifier to amplify the voltage output of the atmospheric pressure sensor was not working correctly It amplified the input by double the value stated on the data sheet Changing the resistor that sets the gain of the amplifier had no ef
122. ents HackHD cameras are used as they fit these requirements The dimensions of the cameras can be seen in Figure 4 40 bet 9 5 SCALE 1 000 t 31 05 Figure 4 40 HackHD Camera Dimensions The HackHD uses a simple one button operation Referring to Figure 4 41 below if pin 3 is grounded the camera is operated and begins recording providing storage is available on the SD card and power is supplied mee i CR er Ground PIN1 ga A 3 7v In PIN2 Switch Button PIN3 3 7v Output PIN4 Ground PIN5 Video Out PIN6 L E D Out PIN7 Audio In PINS Ground PIN9 Figure 4 41 HackHD PinOut BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 86 Pin 3 is connected to a digital output pin on the Hub Controller If held low for a fraction of a second the camera automatically boots up and start to record in auto mode The camera continues to record until the terminal is grounded again in which case it stops recording and turn off By turning off and on when required power is saved Alternatively the camera can be put into standby mode by grounding pin 3 for 3 seconds It stays in standby mode until pin 3 is again grounded for a fraction of a second and it immediately starts recording until grounded again For simplicity both cameras are operated in auto mode Pins 1 and 2 are connected to the regulated 5 V power bus from the Hub Pin 7 provides a pulsed high signal w
123. ermal SED chapter 4 2 4 amp 4 6 Thermal will become an issue if you fly with the side open as suggested You should expand this section a little You should state in this section that the electronics and cells are able to withstand the temperatures BX16_iSEDE_SEDv5 1 31JAN14 ern EuroLAuncu ADLR and SSC Student Experiment Documentation Page 181 o You should consider faster discharge of camera batteries in the thermal environment Software SED chapter 4 8 o O You should definitely include more software engineers This section needs to be elaborated Verification and testing SED chapter 5 o You included some typical mistakes Batteries are to be qualified for use on the balloon uses ALL verification methods this is expensive and could be reduced Design requirement 49 referring to length this is done by test not inspection Overall the testing section is pretty complete The timings for the testing and location is good The test matrix is good ge and risk analysis SED chapter 3 4 Overall it s a good start but there is still some work to be done The personnel risks are good You should include the budgetary risks You may also include F party risks people on the ground TC120 difficulties in assessing microprocessors for programming should be before putting them on the cells not first time There is a risk that charging your batteries on board may damage o
124. ers 4 x UK European Plug Adapters provided by iSEDE team Monitor with DVI connector USB Mouse USB Keyboard 6 1 5 Balloon Mounting amp Mission Requirements The following requirements are taken from Chapter 2 and outline the requirements on the BEXUS balloon flight a a BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation cooperation Page 142 ER_DE_55 A clearance nothing mounted on the bottom of 25cm in actuation direction on the bottom of each satellite is required ER OP 17 The float phase of the balloon shall be at least two hours to run through experiment cycle twice ER_OP_18 The flight altitude shall be at least 25km low pressure required for cell inflation ER_OP_19 During the actuation phase of iSEDE other experiments on the gondola shall not introduce any movement to the gondola ER_OP_20 The side walls of the gondola shall be attached during the flight 6 2 Preparation and Test Activities at Esrange The following list outlines tasks that needs to be undertaken at Esrange in order to get the iSEDE experiment ready for launch Table 6 3 Pre Flight Procedures No Procedure Tools Compone Duratio Responsibl nts n e Person mins 1 Unpack all Camera NA 30 FB components pictures documentation 2 Ensure that all Packaging List NA 60 FB components have arrived Check off with packaging list 3 Set up equip
125. ethod MAOMAS Date 04 07 13 Comment DONE the actuation is from left to right and it is planned to use fixed points on the structure to obtain the displacement with image processing after the mission Electrical Interface You should detail the data rate and protocol of information sent over the e link GAGS Date 01 07 13 Comment revised Radio Frequencies You should confirm the details of the panStamp RF module such as bandwidth power level and modulation AGB Date 01 07 13 Comment DONE 4 2 3 You should confirm with your SSC IPR reviewer that the frequencies have been cleared with Esrange SEEESEEESESESERER Experiment Components You should at least outline the development status of each of these components ordered to be ordered manufactured etc You may add this information to the tables in each section and reference it in the experiment components section FRAZER amp DARRYL Date 01 07 13 Comment Added table with order status What is the CPU used for the hub The Pi is not mentioned here MAGO Date 01 07 13 Comment ADDED 4 3 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 188 Mechanical Design e Is the maximum displacement 30cm from the vertical for the bottom cell i e the clearance all around your bottom cell should be 30cm This should be clear in chapter 6 What margin is included here MAOMAS Date 04 07 13 Comment This is the margin at
126. f components MS110 Cable connectors come unplugged MS120 Component failures due to vacuum MS130 Component overheat in vacuum MS140 Damage of SD cards loss of data MS150 Damage from impact on gondola landing MS160 Soft robotic actuators leak during mission MS170 Shock on launch damages experiment BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Page 42 Structure is vertical gravity helps force the inflatable structure to come out of the box Test inflation period and attempt to limit unwanted structure vibrations Thermal analysis of components during design phase Components with wide temperature range were selected but thermal tests need to be performed gt possibly implement resistive heating Vibration testing Testing in vacuum chamber Extensive thermal tests of overheating components Add heat sink to problem component Specify high quality SD cards Transmit data down E Link where possible FEA and impact testing before launch Soft robotic element enclosed in inflatable cells tubing to pump shall be inspected thoroughly Finite element analysis and testing of mechanical structure Student Experiment Documentation Software electronics PE10 SE completion issues Software electronics PE11 ae completion issues Masters student project PE20 group cannot finish manufacturing in time
127. fastest st manufacturing cells anc created a strong seal Three different double celled structures were placed inside the thermal chamber Two of these structures had a 1cm gap one with a connecting straw and one with a separate straw for each cell The third structure had a 2cm gap with two separate straws it was decided before the experiment to inflate one of the cells of the structure with the 1cm gap and 2 separate straws When removed from the thermal chamber it was found that very little of the cell was deflated Therefore it retained the air within the cell while at a low temperature It was also found that very little force was required to be break the seal of the outer perimeter of the cell However st the joint which connects the two cells it was found that the seal was very difficult to break The structure with the 1cm gap with a connecting straw was found to be harder to break the outer perimeter of the cell and easier to break the joint which connects the two cells This was contrast to the other the structure with separate straws However this was to be expected as the connecting straw would create a weak point in the joint of the cells For the double celled structure with a 2cm gap with two separate straws it was found that it wes a lot more difficult to unpee the outer perimeter of the cells and at the joint of the two cells At certain points of the outer perimeter where the seal was attempted to be broken some of the material ripp
128. features of the satellites are e Housekeeping and self diagnostics e Read and process sensor s data e Control inflatable structures e Keep running when any non critical component fails e SE eee report sensors readings and experiment data to the Hub The main features of the Hub are e Housekeeping and self diagnostics e Communication with ground station e Activating deactivating the satellites e Activating deactivating the wireless communication e Control satellites deployment e Log all sensors readings and experiment status BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 103 e Keep running when any non critical component fails 4 8 4 1 Satellites The satellite software is developed based on the concept of a state machine State changes are driven either by commands sent by the Hub or when completing some tasks The states are e Initializing starts all arduino s peripherals and sensors e Self diagnostic checks all voltage levels tests communication channels sensors and actuators e Housekeeping checks all voltage levels and communication with the sensors e Receiving data When any data arrives the software goes to this state receives the data stores it and returns to the last state e Sending data sends data to the Hub in case of failure of the main communication link the backup link is used e Reading sensors reads all sensors process the data and s
129. fect It was either a problem with the reference voltage being supplied to the BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH R and SSC cooperation Student Experiment Documentation Page 153 amplifier or the component was broken This is not a major problem as it is a backup system that was only be used to deploy the satellite at float altitude if contact is lost with the balloon over E Link As it was not a major problem it was decided to focus on getting the experiment ready to flight without the pressure sensor Both satellites were then powered on using the Hub The flexible circuitry on Bru was found to be broken Although appearing undamaged on visual inspection earlier in the day the satellite would not power up correctly After removing the flexible circuitry we could clearly see that the sharp pins of through hole components have pierced the Kapton tape and mylar As well as damaging the inflatable cell this short circuited some of the flexible electronics on the board which required extensive troubleshooting Through hole components present many sharp edges any of which could pierce a cell Mylar is not an ideal material for constructing cells as it is conductive any contact with components can cause a short circuit Heat shrink tubing had come loose from some of the pressure sensors The problem seemed to be that the pump tubing was not physically connected to the pressure sensor and is only held in place by the heat shrink tub
130. first choose sensors actuators and any other peripheral and then the microcontrollers processors that are capable to communicate with them Make sure that the electronic and software team know how to use programme and integrate every component considered in the design before putting them in the final design and buying them DC devices are good to reduce the number of physical connections however if one device breaks down the whole bus can De compromised Avoid putting all critical components in the same bus When possible always use open source hardware and free software as they are easier to be modified to suit project needs as well as it usually is easier to get support At design phase make sure that all facilities needed to develop and test prototypes are available If electronics components boards are on the surface of inflatable flexible structures design all board with component on only one side the one that is not in contact with other structures and use only surface mount components Use professional manufacture and assembly to all PCBs and cables When connecting different boards use standard cables and connectors Ready to flight spare boards are highly recommended to be brought to the launch camping Software electronics designers and experts must be at launch campaign No one has a better understanding of flight software and hardware than the person group that developed it BX16_iSEDE_SEDv5 1 31JAN14 cooperat
131. ftrobotic elements which are made of highly flexible silicon rubber Softrobotic elements usually have a cavity inside them which can be inflated which causes a deformation of the element The advantage of softrobotic elements is that they can be casted in every thinkable shape and their actuation performance can therefore be tailored Figure 4 12 Actuation principle of actuators in the three middle cells By mimicking this principle with micropumps and soft robotic actuators the iSEDE inflatable obtains the capability of changing its global shape An actuator element consists of two softrobotic elements one in each cell that is connected via a micropump During fabrication a cavity inside the softrobotic actuator was created with a metal rod After curing with a nylon wire witha higher stiffness was attached to the bottom of the actuator If the softrobotic actuator gets inflated which would normally cause an elongation is now getting transformed in a bending of the actuator which means in plane shortening with a comparably high actuation force BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 62 i gt i H H Figure 4 13 Actuation principle of soft robotic element The soft robotic actuator element inside the iSEDE cells has the a width of 4mm and a height of 4mm with a 2mm diameter to form the cavity inside the soft robotic actuator for inflation through the micropumps The s
132. ght These satellites with a high area to mass ratio would be a great way to ensure that the satellite will reenter the Earths atmosphere in the recommended 25 years to mitigate space debris The iSEDE project follows up on the research of PhD student Thomas Sinn of the Advanced Space Concepts Laboratory on Smart Space Structures 9 BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 5 10 The undertaken research developed a bio inspired method to deploy and change the shape of structures in space facilitating residual air inflation and adapting nature s heliotropism concept 13 to a mechanical system consisting of inflated cells with interconnected micro pumps This led to the REXUS 13 experiment StrathSat R 8 with its ejected cube satellite SAM Self inflating Adaptive Membrane SAM will deploy an inflating membrane consisting of 36 cells with two actuator cells connected by micropumps in order to change its shape Due to some problems with the pyrocutters Strathsat R will be re launched upon REXUS15 16 1 2 Mission Statement The iSEDE team shall disaggregate the electronics of a nano satellite across an adaptable all inflatable structure to be deployed into a high altitude environment The iSEDE project will demonstrate the disaggregated electronics and autonomous behaviour required to successfully develop an adaptable lightweight inflatable space structure designed for short mission e
133. h added electronics micropump actuation BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Page 123 Test duration 2 months Date status 0 4 1 11 03 15 04 2013 SGmpleted 1510412073 0 4 2 10 08 02 09 2013 G6mpleted 2010812013 Table 5 7 Test 0 5 Test number 0 5 Test type Measure actuation displacement with onboard sensors Test facility University of Strathclyde iSEDE lab Tested item Deployed satellite Test Test to validate control algorithm to control shape of level procedure deployed satellite via micro pumps Set up similar to test 0 4 Test duration 2 weeks 2 days at launch campaign Date status 10 08 14 10 2013 GOmpl ted Table 5 8 Test 0 6 Test number 0 6 Test type Folding and packaging Test facility University of Strathclyde iSEDE lab Tested item Satellite structure with and without electronics Test Folding test to ensure that structure can be folded level procedure efficiently into deployment box and ensuring functionality of electronics afterwards Test duration 2 weeks Date status April August 2013 G6mpleted 10 0812016 BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Table 5 9 Test 0 7 Page 124 Test number 0 7 Test type Wireless communication Test facility University of Strath
134. he string is valid according to a pre established pattern The pattern consists of a string in which all the data is represented for example C 34040 A0 0 348 0 39494 0 45869 A1 0 945 0 444 0 7435 T0 20 495 T1 19 984 P0 0 987 The number after C represents the time since the beginning of the experiment AO and A1 and the subsequent numbers represent both accelerometers TO and T1 are the numbers for the temperatures and PO for the pressure In order to check the validity of the string the function String split is applied to the string to separate and insert it into an array with the data separated by commas Using the same example as above the array looks like the following C 34040 AO 0 39494 0 45869 Al 0 7435 TO 20 495 T ke 19 984 PO 0 987 0 348 0 945 0 444 After checking if the data is valid and the array is on this exact format the information is stored and then displayed to the user in forms of tables and graphics After the data is processed another method checks if any of the information received is critical by comparing such information to pre established values already defined as critical If the data is identified as critical an alert is displayed on the screen Data and information from both satellites and the hub is displayed separately for easier identification of the data s origin and its criticality For each of the components the
135. hen the camera is recording This is used to provide feedback to the Hub controller allowing for monitoring of the cameras status 4 5 2 3 1 Artificial Light In order to make the deployable visible in the closed gondola and array of 10 bright white LEDs is added between the cameras This LED array is powered and switched on over the Hub 4 5 2 4 Solenoid The solenoid used to actuate the deployment of the deployable satellite is triggered by the Hub It is crucial that the solenoid specified is capable of holding back the force exerted by the inflatable structure within the deployment box along with the additional shocks specified in the BEXUS user manual From calculation the static frictional force required to be overcome by the solenoid should not exceed 6N including a factor of safety of 5 The solenoid selected is the Ledex Box Frame Size B22 254 M 36 The component is operated at 25 duty at a stroke of approximately 5mm This provides an actuation force 20N with a DC voltage pulse of 24V Nom Due to the voltage required the unregulated 28V supply provided by BEXUS is used in conjunction with a MOSFET driven by the Hub controller to operate the solenoid The proposed circuit is shown below in Figure 4 42 BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 87 Voltage Source To Hub controller Figure 4 42 Solenoid actuation circuit A digital high signal 5V is provided from the Rasp
136. iaturized and distributed across the cells The required level of miniaturization is already available in smart phones Mobile phones are de facto complete satellites that could be potentially deployed in space The idea is to explode disaggregate a smart phone place its components on the cells and make all the components communicate The unique architecture of the inflatable structure opens the possibility of changing its shape to be adapted to various space mission stages or environmental conditions 9 Cells can then be individually controlled to change the overall shape of the satellite The experiment follows up on experiment to REXUS13 s StrathSat R 8 which has the purpose of deploying inflatable structures from cube satellites BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuNcH Student Experiment Documentation Page 2 1 INTRODUCTION 1 1 Scientific Technical Background Space vehicle size is nowadays mainly governed by launch vehicle dimensions The use of deployable structures became necessary due to their low stowage and high in orbit volume For the success of future space missions involving large space structure the development of new deployable structures and the improvement of current designs are of great importance Applications can be easily envisioned through truss structures masts crew quarters transport tunnels large solar arrays solar concentrators solar sails or antennas A valuable option for these large ultra light struct
137. iment Documentation Page 205 iSEDE Camera ee 12 55 Mount Tube Oo ka N Frazer Brownile iSEDE Camera a Mountplate BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuncn A DLR and SSC coopera Page 206 SEDE e ee Hi Frazer Brownlie iSEDE EuroLAuNcH ADLR and SSC coopera Student Experiment Documentation Page 207 Cell Mount Lower Measurementmm Tolerances 0 0 25 BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNcH A DLR and SSC coopera Page 208 iSEDE Deployment Box Measurement mm Side 1 Tolerances 0 0 25 EvuroLAUNCH A DLR and SSC coopera Student Experiment Documentation Page 209 e SE N yment Box Measurementmm 2 Tolerances 0 0 25 50 ny Depioyrmert Bos Massirenert zen oo aeren Dot 25 seg BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuNcH ADLR and SSC coopera Student Experiment Documentation Page 210 i iSEDE mm Tolerance 0 0 25 L BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNcH A DLR and SSC coopera Student Experiment Documentation Page 211 75 Depiopmert Sex Maem zeegt Lp okee 060 25 Le E e BX16_iSEDE_SEDv5 1 31JAN14 EuroLAuNncH A DLR and SSC coopera Student Experiment Documentation Page 212 5 r Depoynert Box Maem rere tre Up Lock EE 150 Oo BX16_iSED
138. imising the mass it can take 9 35 x 1077m In specifying the beam parameters a beam supported at both ends with a central point mass was considered as a worst case stress analysis F l l Fri Fro For this condition the maximum stress at an outer fibre and the maximum deflection are defined as BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 75 FL FL az mar een The young s modulus for Aluminium 6063 T6 is E 68 9GPa and it has a shear strength of around 150MPa and yield strength of around 200MPa The following calculations show that the beams chosen are significantly below these while not being over engineered and adding unnecessary mass o 4 4 6 1 Camera Supports For the cameras each having a mass of just 0 1kg and with the total beam mass of 0 5kg the maximum force to be considered is F 2 x 0 1 0 5 x 9 81 x 10 68 67N The beam length is the distance between the sides of the gondola which is less than 1 2m Therefore the maximum stress experienced by the beam would be 68 67 x 1 2 4x9 35x 10 7 68 67 x 1 2 Ang 7 4px Geox xBox Om 22MPa e Gei Figure 4 33 Cameras Mounted on Support BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperatio Student Experiment Documentation Page 76 4 4 6 2 Deployment Supports With each deployment module having a mass of around 0 9kg each payload of mass 0 6kg a hub of mass 2kg and beams of mas
139. ing BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation Page 154 a we The camera supports and the hub were then fitted to the gondola and the cameras were checked to make sure that they could capture images of the whole experiment 7 2 3 Day 3 6 October The damaged section of flexible circuitry on Bru had its components desoldered and removed and the power was rerouted around it with wires This restored the functionality of the remaining circuitry The hub electronics were then integrated into the hub The experiment was then tested with flight batteries with the BEXUS electronics expert present The experiment was powered on and off successfully during this test It was found during this test that the webcam providing the live feed did not have the field of view to see the satellites and the LEDs on the hub at the same time The webcam had to be repositioned at the top corner of the gondola This allowed a view of the LEDs on the Hub and a partial view of one satellite BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 155 The wired E Link test was then conducted with the BEXUS electronics expert still present The test failed initially The ground station successfully connected to the experiment then would sporadically disconnect Disabling the network manager on the ground station laptop solved this issue as network manager was overriding the manual setting of the IP addres
140. ing ascent MS20 Deployment box does not release satellite Movable parts damage MS30 experiment after deployment MS40 Battery charge too low MS41 Battery charge too low MS50 Camera fails to capture EurRoLAUNCH ADLR and SSC cooperation Page 41 Hub is easily accessible through side wall that is detachable Change the SD Card before mission FEA and testing before launch Testing of release mechanism More than one satellite for redundancy Ensure lid of deployment box opens in a controlled manner Monitor battery charge and have spares No more batteries on iSEDE experiment More than one camera Design cameras as standalone system Consider installing artificial lighting deployment MS60 Bad lighting conditions during mission MS70 Inflatable structure fails to inflate MS80 Inflatable structure gets trapped while inflating Design and test inflation for success in a one cell failure scenario Medium Simulate deployment and implement preventative measures where appropriate BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation 4 Medium MS81 Inflatable structure gets 3 trapped while inflating Inflatable structure does Ms90 not settle before shape 3 changing phase Temperature drops MS100 below operating range of components Temperature drops MS101 below operating range o
141. ion Student Experiment Documentation Page 170 7 5 4 Software Design Implementation Testing Keep a strict control version log and back up of every version of the software thus allowing a fast swap if needed at launch campaign Allocate more time than needed to software development it always takes longer than planned Develop and test the ground station software in the same laptop PC that is going to be used at launch campaign this avoids machine specific bugs issues Do not make any change in software after it been fully tested even an small change in graphical user interface data visualisation can introduce critical bugs 7 5 5 Testing amp Validation Suggested tests problems time allocation Ensure testing is booked well in advance to ensure it can occur at the correct times Mylar is useless to bond together Ideally kapton with printed circuits would be used Double sided tape produced most reliable seal during thermal and vacuum testing Mylar is so thin that it is very difficult to experimentally find its characteristics e g Young s modulus inertia of cell amp satellite change of cell area amp length Specialist equipment required Plastic template to create cells is better than cardboard ink soaks into cardboard and ruins template Double sided tape needs to be bonded directly onto Mylar cannot be touching the permanent marker ink Epoxy does not bond well to Mylar Need to bond tape to dull sid
142. ith a metal screw embedded in the Mylar Kapton inflatable can be seen in the Figure below Figure 4 15 Mounting schematic left and mounting prototype right To ensure a non conductive connection between the electronics and the cells M3 plastic screws and washers are used This assembly together with wire to board connectors enables a fast and reliable change of components on the cells 4 4 2 Deployment Modules The mechanical design of the deployment modules is concerned with the structure required to facilitate the deployment of the inflatable structure The deployment modules are simple 1U 10x10x10cm boxes made of lightweight but durable aluminium One inflatable structure is deployed prior to launch and the other deployed at float altitude BX16_iSEDE_SEDv5 1 31JAN14 L y EuroLAuNcH Student Experiment Documentation Page 65 A lid ejection method cannot be used as this would result in an uncontrollable swinging mass which could compromise the inflatable structure or other experiments While slightly more complicated hinged sprung doors are used to facilitate quick opening which doesn t compromise the structure The doors are released by mechanism actuated by a solenoid Figure 4 16 to Figure 4 18 show the prototype module including a vacuum deployment test Figure 4 17 Deployment module with insulation BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page
143. ity of Strathclyde Vacuum chamber Department of Physics Tested item Entire experiment Test Vacuum test of entire experiment according to BEXUS level procedure User Manual Test duration 1 day Date status September 2013 Gompleted 0610912073 Table 5 22 Test 3 0 Test number 3 0 Test type Thermal test Test facility University of Strathclyde Department of Mechanical amp Aerospace Engineering BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Page 130 Tested item Entire experiment Test Thermal test of entire experiment according to BEXUS level procedure User Manual Test duration 1 day Date status September 2013 Gmpleted O5109 2073 Table 5 23 Test 4 0 Test number 4 0 Test type Vibration test Test facility University of Strathclyde Department of Mechanical amp Aerospace Engineering Tested item Entire experiment Test Vibration test of entire experiment according to BEXUS level procedure User Manual Test duration 1 day Date status September 2013 Gmpleted O409I2073 Table 5 24 Test 5 0 Test number 5 0 Test type Inspection and functionality tests Test facility University of Strathclyde Tested item Entire experiment Test Complete functionality test of the entire experiment level procedure Simulation of several experiment cycles 5 1 After first assembly
144. l the structure of a satellite still represents a significant portion of its mass and a limitation on the achievable configuration and packing efficiency during launch The idea of this project is to replace classical rigid structures with lightweight inflatable ones The CDR consisted of a twenty minute presentation that was followed by a sixty minute discussion with a panel of experts from the ESA the German Aerospace Centre DLR Swedish Space Centre SSC and Swedish National Space Board SNSB During the discussion all topics of the mission were covered and the experts were quite pleased with the progress so far SEDE will be launched during the launch campaign in October 2013 at SSC s Esrange Space Centre in Northern Sweden onboard the BEXUS17 balloon With the positive feedback during the CDR the team will now finalise the fabrication of the experiment and begin subsystem system and environment testing In order to survive the stratospheric balloon flight the experiment needs to withstand temperatures down to 60C and pressures of just a few millibar over two to five hours The next review is the Interim Progress Review IPR in Mid July BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation EuroLAuUNcH A DLR and SSC cooperat APPENDIX C TEST REPORTS Thermal Testing of Inflatable Cell Bond Lines Prepared by Frazer Brownlie Date 10 05 2013 Checked by Thomas Sinn Date 12 05 2013 Summary Thermal tes
145. la is 40 C and that the inside of the hub box is at least 0 C which is the minimum operating temperature of the Raspberry Pi the thickness of the polystyrene box is 3cm and the thermal resistance of the polystyrene is 0 033W mk This results in a heat rate of 44W m The hub box totals an area of 0 14274m Then the total conductive heat rate for the hub is 6 3W Therefore it should not be necessary to heat the hub as when the Raspberry Pi is in use then it contributes to heating the hub by itself Therefore the hub is sufficiently insulated BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 97 4 7 Power System The Hub is constantly powered directly from the BEXUS link during operation There was a pre deployed satellite in the gondola and this requires power during the ascent phase to power sensors and the microcontroller and the cameras are also active In terms of how the power is distributed all power systems are hardwired The BEXUS power source is hardwired to the Hub in addition to the two satellites via the Hub 4 7 1 Power Sources The power source as previously stated is BEXUS 4 7 1 1 Hub Power Source BEXUS link The hub and all components housed within including the cameras are powered directly from the BEXUS link through some power conditioning 4 7 2 Power Circuitry The voltage and current levels for both the hub components and the satellite components are regulated from th
146. lite and transmits these through the BEXUS E Link to the ground station BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 102 4 8 3 Satellite s Each deployed satellite implements the same control and data handling techniques The main focus of each system is control of the inflatable structure however many other functions are present Each satellite performs its own housekeeping measuring voltage amp current at critical points and ambient amp component temperature 4 8 4 Software Implementation The software implemented across the experiment is a distributed system loosely coupled with a coordinator the Hub that runs across two different open source hardware platforms a RISC credit card sized single board computer Raspberry Pi and an Arduino based board PanStamp that uses an AVR RISC based 8 bits micrcontroller The Hub is responsible for handling all communication with the ground station and controls the experiment timeline sending commands to both satellites with instructions or requesting data The Hub is programmed using C and Qt framework the satellites are programmed using the Arduino programming language based on Wiring The integrated development environments IDEs used are QtCreator to write all code and the Arduino development environment based on Processing to compile and upload the code on Arduino based boards Both IDEs are integrated to work as a single system The main
147. lows the development of BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 88 software to proceed while the custom PCBs which are mounted to the surface of the inflatable cells are being designed and manufactured As can be seen from Figure 4 43 pins 4 through 12 provide analogue input output There are also 9 pins available for digital I O Arduino pin Atmega328p pin GND 1 GND Digital8 2 GND PWM Digital9 3 Digital 7 AnalogO 4 Digital 6 PWM Analog1 5 Digital 5 PWM Analog2 6 Digital 4 GND 7 Digital 3 PWM Analog3 8 Digital 1 TXD I2C SDA Analog4 9 Digital O RXD ZC SCL Analog5 10 GND Analog6 11 VCC Analog 7 12 Reset Figure 4 43 PanStamp PinOut Table 4 3 details the I O s available on the chosen microcontroller and their use in the electrical design Table 4 3 Satellite controller pinout functionality Pin Function DO TX Backup link D1 RX Backup link D3 Micro pump 1 D4 Micro pump 1 Reverse D5 Micro pump 2 D6 Micro pump 2 Reverse D7 Micro pump 3 D8 Micro pump 3 Reverse AO To diff pressure sensor AB 2 BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 89 A1 To diff pressure sensor AB 3 A2 To diff pressure sensor AB 4 A4 SDA to 12C SDA bus A5 SCL to 12C SCL bus The microcontroller is powered by the regulated 3 3 V supply on
148. loying at float altitude shall remain sealed until deployment command is given ER DE 22 The deployment boxes shall not cause any damage to the deployable structure BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 19 ER DE 23 The hatch on each deployment box shall remain attached after deployment of the inflatable structure ER DE 24 The inflatable cells shall not burst when subjected to vacuum pressure ER DE 25 Pressure shall be measured inside at least 2 adjacent cells in each satellite ER DE 26 Critical components shall have the embedded capability of measuring their temperature ER DE 27 All PCB s shall be resin coated to be prevent arcing in vacuum pressures ER DE 28 All tracks and wires should withstand environmental conditions ER DE 29 Tracks and components mounted on each satellite shall withstand the strain exerted during folding ER_DE_30 All interfaces shall be secured tight to prevent loosening due to any vibrations during flight ER_DE_31 Solid state non volatile data storage shall be used ER_DE_32 Capacity of storage memory shall be sufficient to store all measurement and status data ER DE 33 Cameras shall be positioned suitably to capture deployment of all satellites ER_DE_34 Cameras shall carry out all image processing and store images locally ER DE 35 A redundant power line
149. matics added on wiring and component placement Power Design e It s not obvious that the 15 minutes of charge is sufficient DARRYL Date 05 07 13 Comment No more charging required during flight all references deleted Thermal Design e This is immature a static thermal analysis for the float phase should done be done for the hub to determine the level of insulation required and whether any heating will be required FRAZER Date 01 07 13 Comment Thermal calculation of polystyrene hub e Heating for the battery power required for the battery may be significant an analysis is required here in order to sure up the power budget DARRYL Date 06 07 13 Comment Batteries will be placed in deployment box e Thermal design for deployment mechanism this is also critical and should be tested soon TO BE TESTED AFTER FABRICATION Software Design Section seems immature S BEDIGUSSEDIATIER BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 189 Does at least one camera record during ascent to capture the pre deployed satellite s inflation PAOMAS Date 04 07 13 Comment Added reference to timeline in Chapter 6 Figure 4 45 is unclear too many lines on top of one another MAGO Date 01 07 13 Comment 4 8 4 1 figure 4 45 You should be careful using LO as your start of experiment signal most people associated this as the lift off signal MAGO use SOE Date
150. ment in Camera NA 30 FB allocated workspace pictures documentation 4 Check all structures Camera NA 10 FB to ensure that they pictures have not been documentation damaged during transportation 5 Check all electrical Camera NA 20 TQ connections cables pictures within the Hub and documentation cables that connect Hub to satellites and cameras 6 Set Pi s IP address Power Source NA 10 TQ etc network interfac Monitor USB es and GS IP keyboard USB mouse 7 Check connectivity Power Supply NA 10 TQ between Hub and GS network cables x2 BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Page 143 8 Secure SD card with Camera Kapton 5 TQ kapton tape pictures tape documentation 9 Reassemble Hub and Power Supply NA 20 TQ check connectivity network cables with GS and satellites Camera pictures documentation 10 Check all inflatable Camera NA 5 FB cells for any pictures punctures or damage documentation 11 Test the deployment Power Supply NA 5 FB method to ensure that Camera it works on ground pictures documentation 12 Ensure that camera Camera Polystyren 5 FB lens is lined up Pictures e properly Documentation 13 Mount the cameras to M4 hex screw NA 10 FB the camera tube x3 washer x3 M4 Allen Key Camera pictures documentation 14 Connect valves to Scissors NA 30 FB tubing Valves Camera Pic
151. minium T6 angles Arrived Insulation polystyrene Arrived Ambient pressure sensor Arrived E Link interface Arrived Power interface Arrived Camera Housing Arrived GoPro camera enclosure Arrived HackHD camera Arrived Square tube Aluminium T6 3 4 Arrived inch 10swg BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation Table 4 1 Experiment summary table cooperation Experiment Mass Roof Mounted total hub 2xdeployment boxes 4 865kg Cameras total 1 215kg Experiment total mass 6 315kg Experiment dimensions in m when deployed Satellites 2x 0 2 x 0 15 x 0 74 m Hub 0 25 x 0 15 x 0 15m Mounted 0 83 x 0 3 x 0 74 Experiment footprint area in m Satellites 2x0 03m Hub 0 0375m Mounted 0 25m Experiment volume in m Satellites 2 x 0 022m Hub 0 006m Mounted 0 18m Figure 4 9 Gondola layout 4 4 Mechanical Design The mechanical design is concerned with the size shape strength and mass of the experiment the iSEDE satellite the deployment modules the hub the BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 59 camera housing and associated interfaces Some different constraints apply to each subsystem 4 4 1 Payload iSEDE satellite The iSEDE satellite concept is centred on the successful synergy of inflatable structures and disaggregated electronics enabling
152. mmunication for more than five seconds the E Link is considered down and a new attempt to reconnect is made If it does not work the Hub goes to an autonomous mode where it runs the experiment based on time and altitude measurements Even when in autonomous mode further reconnections attempts are made All data received from the Ground station or the satellites are stored with a timestamp allowing a detailed post experiment data analysis BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 106 The temperature sensors are used to housekeeping are connected to an DC bus and have their own communication protocol defined by their manufacture Each camera is connected to a digital output and receives a signal to start stop recording The flow diagram is shown in Figure 4 52 BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation Page 107 Relay coomand Initialize Arduino s Hardware Initialize Sensors Connect to Ground station Yes Initialize SDcard Start Watchdog Execute command Is command to satellte ommand arrive Wait for commands No command Read Housekeeping sensors Is connected Report to Ground station and log data SS Start satellites Request sensors readings Figure 4 52 Hub Flow Diagram BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Watchdog time out Reboot the system Send shutdown
153. mon Alex SSC and ESA members The team discussed their findings and the conclusion was agreed that there were a number of failings on both sides but a lot had been learnt as a result of the failure 7 2 7 Day 7 10 October Functional testing of experiment was undertaken for two reasons e to see what systems were still operational e totry and recreate failure states Functional testing was performed while the experiment remained mounted to the gondola to try and recreate fault circumstances and observe the results Photo and video records support the findings which can be found in the SFAR The Mobius Action Cam was successfully fitted on BEXUS 17 The BEXUS 17 balloon was launched BEXUS 17 lost contact with E link after reaching float phase and did not regain contact for the duration of the flight BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 166 7 2 8 Day 8 11 October Wrote reports Received recovery photos from BEXUS 16 recovery The gondola landed upside down which could explain how the IRN accelerometer ripped off and the bottom cell joint also ripped 7 2 9 Day 9 12 October Created campaign party video Attended campaign party 7 2 10 Day 10 13 October Packed experiment for travel with the team back to Glasgow 7 3 Results The experiment proved that the disaggregated electronics and wireless communication are feasible to inflatable and distributed satellites The architecture
154. ms shall become R T active Data storage shall begin as systems are R T online Any adverse behaviour identified through R T housekeeping should be reported down the E Link to the ground station Status of critical components shall be R T reported to the ground station One satellite shall be deployed at float H altitude Wireless communication between the hub R T and satellites should be established after deployment Shape change shall begin upon receipt of R T command from ground station Electronic systems shall operate R T autonomously The satellites shall conduct measurements R T autonomously a a msn mn mg BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation 5 2 Test Plan E UROLAUNCH Page 120 The experiment shall accept a request for radio silence at any time while on the launch pad R T All data shall be relayed back to the hub SD card for storage R T The experiment light inside the gondola shall be switched on before launch H The float phase of the balloon shall be at least two hours to run through experiment cycle twice A atmospheric pressure at flow altitude shall be lower then 20mbar altitude higher then 25km to ensure inflation of the satellite cells During the actuation phase of iSEDE other experiments on the gondola shall not introduce any movement to the gondola The side walls of the g
155. nd Craig where sent to the launch campaign in Kiruna Frazer and Andrew were responsible for the mechanical structure and the inflatables Tiago was responsible for electronics and software Craig was in charge of documentation which he failed to deliver and Darryl was responsible for support documentation and the external camera failed to deliver functional system for balloon flight duration Darryl was just doing work when he was told to do so 1 5 4 Conclusions In summary it can be said that Tiago and Frazer did the bulk of the work spending endless hours on the experiment throughout the entire project duration and at the launch campaign Tiago started off as the head of software but then also took over the electronic design over the summer Frazer worked first on testing and validation but then took over the mechanical lead in summer Without Tiago and Frazer s dedication especially over the summer there would have been no iSEDE at the launch campaign Also Andrew did great work for the experiment during his MEng project and the launch campaign He was the mechanical lead first and then supported Frazer on the mechanical side during the launch campaign Also during summer he responded to requests quickly and helped Frazer to understand the mechanical design Jonathan did great work during his MEng time on his area on power systems even though the design kept on changing frequently Larissa did a great job working on the ground support s
156. nd Sent e Command arrived e No visual from webcam for LEDs 13 44 e DV Sat turned off e Command Sent e Command Arrived e 5V Sat LED off visual confirmation from webcam 13 47 e Rapid Fire solenoid 13 50 e Fire solenoid for 5 seconds e Wait for 1 second e Rapid fire 0 2 seconds 15 times 13 56 e Long fire amp rapid fire did not work visual from webcam 13 58 e Hack HDs turned off 14 11 e Hack HD s turned on 14 18 e Code ready to fire solenoid during descending amp also switch off systems safely 14 21 e Fire solenoid for 1 second e Wait 5 seconds e 100 cycles 14 31 e 15 minute countdown 14 36 e Software stopped data saved 14 37 e Data copied on Raspberry pi SD card 14 44 e 150 cycle sequence to fire solenoid e 1 second on e 5 seconds off e Then turn off HD1 HD2 14 45 e CUT 14 58 e Stop at 130 cycles 14 58 e Enough time to start another 80 cycles so decision made to try another 80 cycles BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 163 15 07 e Everything shut down The packed satellite failed to deploy Solenoid was fired in a variety of ways short pulses long pulses rapid fire in attempts to deploy satellite Solenoid was rapid fired after cut away to see if satellite would deploy on descent Jamming could have been due to inflated cells pushing on the hatch therefore jamming the latch mechanism The team formulated a plan to find root cause of failure using fa
157. nd pattern and modulation This should be forwarded to Esrange for permission Esrange are currently investigating this You have very precise numbers for the power calculations Does this really account for all the DC DC converter losses Thermal SED chapter 4 2 4 amp 4 6 o The thermal design seems in progress o If you re not connecting the sensor to PCBs during the test then you should wait 1 or 2 hours to be sure the board has temperature has stabilised Software SED chapter 4 8 o The philosophy with regards to loss of wireless signal how long before it switches to BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 185 wired and re try etc should be documented There is a fault in the flow diagram if no connection is made to the ground station The procedure is not clear with regards to re set or crash for example At the moment you are dependent on the ground station for this restart You should be sure that you cannot overwrite the previous saved data Verification and testing SED chapter 5 There is no EMC test at least some conductance test should be included Two Satellites shall be deployed should be changed You should rephrase the house keeping requirement You cannot complete the camera view angle test until the exact distance is confirmed by Eurolaunch Safety and risk analysis SED chapter 3 4 o o You should consider
158. nents 35 00 35 00 26 Mar 13 DSUB SOCKET WIRE SOLDER 9 WAYS 10 RS Components 0 86 8 60 26 Mar 13 DSUB PLUG WIRE SOLDER 9 WAYS 10 RS Components 0 85 8 50 26 Mar 13 7 piece mini electronics tool kit 1 RS Components 20 24 20 24 26 Mar 13 5 piece general purpose cutter set 1 RS Components 26 37 26 37 26 Mar 13 50 ties and fixing assemT18R MB2A 1 RS Components 8 99 8 99 26 Mar 13 Sub 1GHz RF Transceiver CC1101 3 RS Components 3 84 11 52 26 Mar 13 A55KJ Soldering Iron Tips 1 Maplin 5 99 5 99 Richard Austin 20 Apr 13 5m 3 4inch 10swg Al T6 Tube 1 Alloys 36 00 36 00 Richard Austin 07 Jun 13 5m 16mm 10swg Al T6 Angle 1 Alloys 12 00 12 00 Richard Austin 07 Jun 13 5m 25mm 10swg Al T6 Angle 1 Alloys 10 00 10 00 Richard Austin 07 Jun 13 2 4m 2mm 10swg Al T6 Sheet 1 Alloys 47 00 47 00 M4 4mm A2 COUNTERSUNK CSK SOCKET CAP ALLEN BOLT SCREWS Falcon Workshop 25 Jun 13 STAINLESS STEEL 1 Supplies 2 40 2 40 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 30 FWS Artikel 190726817504 Transaktio n 838144932009 M4 4mm A2 COUNTERSUNK CSK SOCKET CAP ALLEN BOLT SCREWS STAINLESS STEEL FWS Artikel 190726817504 Transaktio Falcon Workshop 25 Jun 13 n 838144934009 1 Supplies 1 55 1 55 A2 STAINLESS NYLOC INSERT NUTS STAN
159. nflatable payloads a Remove Before Flight RBF pin is placed on both cube sats during transport and preparation This RBF is red and clearly visible see description below 6 1 3 Electrical interfaces Table 6 2 Electrical interfaces applicable to BEXUS measured at EAR 12 09 2013 BEXUS Electrical Interfaces E Link Interface E Link required Yes Number of E Link interfaces 1 Data rate downlink 300 Kbit s Data rate uplink 50 Kbit s Interface type RS 232 Ethernet Ethernet 1x BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 141 Power system Gondola power required Yes Peak power or current consumption 1 2A for few millisec measured solenoid firing Average power or current consumption 17W 0 6A measured Power system Experiment includes batteries No 6 1 4 Launch Site Requirements 6 1 4 1 General Requirements We require Power sockets Internet access Working Assembly Bench 2 pillars approximately 1 3m to assemble the roof mounting Any PPE Personal Protection Equipment required 6 1 4 2 Mechanical Requirements The mechanical team requires basic tools including Basic tool box items set of screwdrivers pliers Exotic tools will be provided by the iSEDE team 6 1 4 3 Electrical Requirements The electrical team requires Variable DC power source 2 x Multimet
160. nside hub The results of the What s Different Analysis were e Vacuum inflated cells e Temperature latch freezing solenoid freezing e All nuts changed to nyloc e Electrical disconnected and reconnected BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 164 Movement and vibration during flight Air flow open gondola roof not as per previous understanding Latch position taped spring in deployment box rushed job accelerometer resoldered on IRN VGA camera rerouted The team was first to the gondola after recovery at midnight that night Took photos of everything of interest Most attention was paid to Connection of solenoid electrical Position of latch mechanism Anti friction tape on hatch door Any signs of ice of freezing Indication of short circuits on solenoid wires All angles of deployment module Solenoid inside and out all angles solenoid wire solder broken photo shows good connection before flight maybe due harsh landing latch position incorrect can t prove or disprove from pre flight images anti friction tape on hatch door solenoid connection latch position The recovery plan consisted of Visual inspection and photos of all components and connections without any removal of gondola experiments visual solenoid hatch mechanism BRU other teams to dismount experiments carefully E link Hub visual invasive inspection for moisture H
161. nt 1 3 Satellites Housin Robotics Modules g 1 1 1 Initial Design 1 2 1 Initial Design 1 4 1 Initial Design 1 5 1 Initial Design 1 3 1 Initial Design 1 1 2 Design Review 1 2 2 Design Review 1 3 2 Design Review 1 4 2 Design Review 152 Prototyping 1 1 3 CAD Model 1 3 3 CAD Model 1 4 3 CAD Model 1 2 3 CAD Model 1 5 3 Testing 1 1 4 Manufacture 1 2 4 Manufacture 1 3 4 Manufacture 1 4 4 Manufacture 1 5 4 Manufacture Figure 3 2 Mechanical WBS BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 25 Figure 3 3 shows a further breakdown of tasks for each electrical area of the project 2 Electrical Systems 2 1 Power 2 2 Comms a 2 4 Sensors 2 5 Pumps 2 6 Camera j Microcontroller P g Zack 2 3 1 2 4 1 2 5 1 E Battery Component Component Component Component 2 6 1 Camera Selection i g g Selection Selection Selection Selection Selection 2 1 2 Circuit Design 2 5 2 Circuit Design 2 6 2 Camera Purchase 2 2 2 Circuit 2 3 2 Circuit 2 4 2 Circuit Design Design Design 2 2 3 3 A Ki row bed Breadboard Breadboard Breadboard Simulation i A i Testing Testing Testing Breadboard 2 2 4 Circuit 2 3 4 Circuit 2 4 4 Circuit F Integration Integration Integration Testing 2 1 5 Circuit Integration 2 5 3 Vacuum Testing 2 6 3 Camera Testing 2 5 4 Circuit Integration Figure 3 3 Electrical WBS Figur
162. nt Experiment Documentation Page 91 Figure 4 45 Bartels MP6 Micro pump The pumps require a specifically generated signal to be applied across each of the 4 input pins to produce the flow rate required This signal does range between 0 250 V at up to 100 Hz This has not been a problem as the previous StrathSat R REXUS experiment also successfully performed vacuum tests on these particular pumps In order to produce the signals required to operate the pump the Bartel mp6 OEM controller is used This is an additional control board purchased separately from the micropumps It generates the signal required to drive the micropumps from a 5V supply with maximum current draw of around 30mA Figure 4 46 shows how the OEM pump controller is connected together with the microcontroller and pump BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 92 GND CLOCK SHUTDOWN CLOCK_INT SLEWRATE AMPLITUDE SLEVV_INT GND2 GND3 P1 P2 P1 P2 MP6A OEM micropump mp6 connector Figure 4 46 mp6 OEm pump controller configuration Using the configuration shown the pump is set to a fixed flow rate with an output from the controller of 235 V at 100 Hz In this configuration the shutdown pin is connected to the relevant pin shown in Table 4 3 This allows control over when the pump is operated As two pumps are connected between each cell pair to allow flow in both directions an inverter is used to prevent
163. oad Manager Alexander Schmidt or Mikael Inga Experiment i SEDE Location ESA ESTEC The Netherlands Date 30 of May 2013 1 Review Board members Kristine Dannenberg Swedish National Space Board Mikael Inga chair SSC Science Services Alf Vaerneus SSC Science Services Martin Siegl DLR Institute of Space Systems Alexander Schmidt DLR MORABA Stefan Voelk DLR MORABA Alex Kinnaird mins ESA Policies Dept Education and Knowledge Management Office Natacha Callens ESA Policies Dept Education and Knowledge Management Office Syivain Vey ESA Technical Directorate Mechanical Engineering Dept Thermal Div Nick Panagiotopoulos ESA Technical Directorate Electrical Engineering Dept Data System Div By telecon Olle Persson SSC Science Services Document review only Lucio Scolamiero ESA Technical Directorate Mechanical Engineering Dept Structures and Mechanisms Div 2 Experiment Team members Craig Hay Adam Rowan Darryl Black Frazer Brownlie Tiago Queiroz Thomas Sinn 3 General Comments Presentation o The panel apologises for the chaotic start of your review The power architecture slide was a little difficult to read from the back of the room Try and engage the whole panel when giving your presentation not just one member Handing out hardware during the presentation is not the best idea Engineers distract easily SED Some minor grammar errors that would have been picked up in a proof rea
164. of ten interconnected inflatable cells ER_DE_09 One central control unit the Hub shall be located inside the gondola to control the experiment timeline and relay data up and down the BEXUS E Link ER_DE_10 Component circuitry shall be laid out in such a way to allow each satellite to be folded down into their deployment box before the experiment commences ER DE_11 COTS components shall be used where applicable and affordable ER DE 12 The experiment shall be mounted on the inside of the BEXUS gondola ER DE 13 No components or parts shall become detached from the experiment at any point during the BEXUS flight ER DE 14 The peak current draw from the BEXUS umbilical shall not exceed 1A at 28V ER DE 15 Power ball be distributed across each satellite Decision July 13 batteries unnecessary ER_DE_16 Each satellite shall have a redundant hard wired data connection to the Hub ER DE 17 Communication between the satellites and the hub shall be wireless ER_DE_18 The hub shall have a communications link with the BEXUS E Link ER_DE_19 Communication up down the BEXUS E Link shall not exceed 300 Kbps 13 09 2013 changed from 100kb to 300kbps after adding live webcam downlink ER DE 20 The wireless communication system shall have a bandwidth capable of transmitting all data defined within the data budget ER DE 21 The deployment box of the satellite dep
165. oft robotic element is manufactured out of Ecoflex 00 30 platinum catalyzed silicone which stays highly flexible also at very low temperatures of 60 C Ecoflex 00 30 is a two component mixture with a ratio of 1 1 anda curing time of 24 hours The maximum displacement of the cells during actuation was estimated to be 18cm However due to vibration or wind within the gondola the inflatable structure is expected to displace no more than 25cm at the bottom cell It is therefore required to have a clearance of 25cm in actuation direction nothing mounted on the bottom BX16_iSEDE_SEDv5 1 31JAN14 em Le EuroLAUNcH Student Experiment Documentation Page 63 Figure 4 14 Soft robotic element being made in vacuum chamber As a medium for inflation Glysantin Alu Protect G 30 from BASF see datasheet in appendix D is used Glysantin was used by the REXUS9 team EXPLORE and proved its capabilities at very low temperature and pressure conditions The actuation medium change from air to fluid was made due to the incompressibility of fluids which increase the controllability of the softrobotic actuation when subjected to vacuum The two softrobotic elements are already filled with a defined amount of actuation fluid which pretensions the structure At cell actuation the fluid is then pumped from one to the other softrobotic element which shortens one of them and elongate the other causing the structure to deform 4 4 1 3 Attachment of Elect
166. oftware and responded quickly if a task needed completion Larissa delivered a working BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH Student Experiment Documentation Page 14 ground support software for the launch campaign Her not being physically in Glasgow over the summer might resulted in some minor difficulties Adam did a great amount of work during his MEng time until May but then disappeared for the summer even though he promised to work on the experiment Craig was the project manager first and did his fair share of work during his MEng time Craig disappeared completely over the summer even though he promised to work on the project as a result he lost the team leader role He resurfaced shortly before the launch campaign To be allowed to go to the launch campaign he promised to write and send a daily detailed report to Thomas project manager not at the launch campaign Craig failed to write the daily updates and final report The issue with the fragile solenoid connection could have been discovered before the flight with proper documentation and communication Darryl s performance during the whole project was well below average During his BEng time he was working on the wireless communication which had to be taken over by Tiago due to poor work ethics and bad research Over the summer Darryl was on a paid Strathclyde internship where he worked on the power systems for the experiment Half of the time he did not show up and came to th
167. onditions during flight Table 5 46 Test Results 4 0 Test number _ 4 0 Gompleted 04109 2013 Test type Vibration test Results Full experiment was tested in the boot of a car to replicate vibrations during flight Full system was still intact and no accidental firing of the release mechanism occurred Table 5 47 Test Results cm5 0 Test number _ 5 0 COmpleted Test type Inspection and functionality tests Results Final inspection and functionality test were undertaken at BEXUS launch campaign BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation and SSC cooperation Page 139 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 measured at EAR 12 09 2013 Experiment Mass Roof Mounted total hub 2x deployment boxes 4 865kg Cameras total 1 215kg Outside camera 0 235kg Experiment total mass 6 315kg Experiment dimensions in m when deployed Satellites 2x 0 2 x 0 15 x 0 74 m Hub 0 25 x 0 15 x 0 15m Mounted 0 83 x 0 3 x 0 74 Experiment footprint area in m Satellites 2x0 03m Hub 0 0375m Mounted 0 25m Experiment volume in m Satellites 2 x 0 022m Hub 0 006m Mounted 0 18m 6 1 2 Safety risks The table below is taken from the risk register previousl
168. ondola shall be attached during the flight H Remove Before Flight pins shall be attached to the satellite boxes to ensure safe handing H 5 2 1 Test Schedule The completed and future tests are summarised below Table 5 2 Mechanical tests schedule Time of Test Test November 2012 February 2013 Inflation tests of deployable March August 2013 of satellites Tests of shape changing capabilities electronics March August 2013 Test of functionality of entire August September 2013 of the entire experiment Thermal vacuum and vibration tests BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation and SSC cooperation Page 121 October 2013 Functionality of whole experiment at balloon campaign See below a more detailed list of the tests planned Test numbers starting with a 0 denote tests of subsystems at a pre integration stage All other numbers stand of tests of the integrated experiment Table 5 3 Test 0 1 Test number 0 1 Test type Residual air inflation Test facility University of Strathclyde Vacuum Chamber Department of Physics Tested item Inflatable structure Test Proof of concept of residual air inflation of prototype of level procedure inflatable structure Test duration 1 week Date status March 2013 6mpleted 51012013 Table 5 4 Test 0
169. one micropump flowing whilst the other is ON 4 5 3 4 Circuit Board Implementation The preferred PCB design for the satellite controller is components soldered to tracks printed on a flexible substrate This allows easier bonding of the circuit to the inflatable material reduces the likelihood of a PCB tearing the inflatable during packing or deployment and places fewer restrictions on the folding and packing of the satellite into the deployment module An example of the capabilities of this technology is shown in Figure 4 47 in the Arduino Seeed BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 93 Figure 4 47 Arduino Seeed The iSEDE flexible circuit board is manufactured by the company PCL and it runs over the entire inflatable satellite 4 5 4 Wireless Communication Wireless communication is used between the hub and each satellite The wireless module is integrated with the satellite controller and sensors on the same PCB to create a mote a small wireless sensor and processing unit The tranciever in use is the panStamp from PanStamp which is a 868 915MHz ISM band RF module and together with the Atmega328 provides a Miniature PCB mounting solution where a high performance is required from a small space It can be configured to operate at multiple frequencies none of which are restricted by the BEXUS User Manual The data rate is configurable up to 600kbps depending on the modulation used
170. or structure are adversely affected one payload should be in perfect condition There are two primary mechanical interfaces to consider the interface between the payload and the deployment module and the interface between the deployment module and the gondola The payloads are also hardwired for power and communications for redundancy There is sufficient space around the structure to enable the demonstration of structure shape adaptation BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 49 Figure 4 3 details the electrical architecture of one satellite Considering all the electronics mounted on one side of the structure there is a micropump controller pressure assembly on cell 1 2 and 4 counted from the top The central cell also has a transceiver to communicate with the other satellite and the hub An accelerometer is mounted on the bottom cell cell 5 The satellites have all components and circuitry hardwired for power and data with a backup hardwired data line from the hub in the event that wireless communications shall fail The inflatable structure also has imbedded actuation elements in the form of soft robotics These are present in the three cells as shown in section 4 4 1 2 BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 50 Pumps amp Pressure Pumps amp Pressure Actuation elements ZA top end sealed a bottom connected di VAY
171. ort Software Commands Command Process Start the communication BX16_iSEDE_SEDv5 1 31JAN14 EuROLAUNCH A DLR and SSC cooperatio Student Experiment Documentation Page 113 FS Fire Solenoid PUS Power Up Satellites PDS Power Down Satellites DP Deactivate Pumps AWe Activate Webcam DWe Deactivate Webcam AHD Activate Hack HD DHD Deactivate Hack HD ULI Update Light Intensity BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation EXPERIMENT VERIFICATION AND TESTING 5 1 Verification Matrix E UROLAUNCH Page 114 Five established verification methods for details see ECSS E ST 10 02C Verification by test T Verification by inspection I Verification by analysis A Verification by review of design R Verification by similarity S The following table lists all requirements and specifies their respective verification method s The number in the last column relates to the test that verifies the requirement Tests that still need to be performed are highlighted is without colour in progress are highlighted in yellow whilst tests already performed and passed are highlighted in green The abbreviation for the responsible test engineers are Thomas Sinn TS Tiago Queiroz TQ and Frazer Brownlie FB Table 5 1 Verification table ID Requirement text colour Verifi Status cation The electronics of each satellite shall be R
172. ospace Engineering Test release mechanism Premature deployment D Liaise with other SF10 may compromise other j aperimenis experiment teams RBF pin attachment as ate ER Collaborate with SSC DLR SF20 interfere with other and other teams experiments Premature wireless SE30 transmissions may Experiment on standby interfere with BEXUS or until float altitude other experiments Failure or leak of Ensure temperature range of batteries can handle EE May cause expected temperature SF40 damage during Low p J during all transport and integration transport or Ge mission phases Test flight ae batteries in vacuum Failure or leak of Pe EEN Ge No more batteries in iSEDE SF41 damage during experiment integration transport or flight Injury while Consider safety before SF50 manufacturing and Medium using tools or moving integration heavy objects Injury while Procedures documented SF51 manufacturing and and simulated by an integration assembly practise BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 46 SF60 Electrostatic Discharge Ground experiment and operator electrostatic wrist band As safety percussion and to ensure a safe handling of the inflatable payloads a Remove Before Flight RBF pin is placed in the closed deployment boxes during transport and preparation This RBF shall be red and clearly visible BX16_iSEDE_SEDv5 1 3
173. own for launch The launch log follows e Sweet spot everything working o Turned on o Both HDs turned on o Confirmed with webcam o IRN pumps turned on o Could see both HDs LED blinking e E link cable blocking camera 2 LEDs e Package count SAT 1 too high integer overflow e New version of GS software cannot deal with package the overflow and keeps crashing e Using old version of GS can handle package count overflow a few times BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 159 Lost logging data for a set time 09 07 lost 09 42 older version working Launch Sweet spot Time Stamped Launch Flight Time Stamped Time Stamped logged data Commands sent received actions readings from GS observations from webcam live stream Time Description Local 10 30 Launch 10 42 Ascent Everything working software GS 10 44 Power on 5V Hack 1 Command sent 2 Arrived 3 LED on visual confirmation from webcam 10 45 Both Hack HDs on 1 Command Sent 2 Arrived 3 Camera 1 No clear visual from webcam 4 Camera 2 View blocked from the Ethernet cable 10 46 Webcam visual of Hack HD 1 blinking 1 time 10 49 Webcam visual of Hack HD 1 blinking 2 time 10 56 25 C To Sat 2 from GS 10 57 27 C To Sat 2 from GS 11 03 40 C To Sat 2 from GS 11 06 10km information provided by SSC 11 06 47 C T Sat 1 11 08 Gondola
174. p V Updated timeline Removed Batteries RBF pin description Added IPR report Correction in wording Experiment components Cable pin allocation Updated T amp V Changed Requirement DE_19 Changed Requirement OP_16 Overhaul present tense Added Mobius Camera Added folding picture Updated Verification Matrix Updated Test Schedule Updated Test Matrix Updated Test Results BX16_iSEDE_SEDv5 1 31JAN14 iv Breakdown 6 1 1 Updated Dimensions amp Mass 6 1 3 Updated Electrical Interfaces 6 1 4 1 Updated General Requirements Updated Electrical 6 1 4 3 Requirements Updated Pre Flight Procedures 6 2 Table Updated timeline 6 3 Added Post Flight Procedures 6 4 Table 4 1 2013 09 23 4 3 Updated Experiment Revised Pre Description Table Campaign 4 45 Updated Mobius Camera 5 24 Updated Test Schedule 5 3 Updated Test Results 6 2 Updated Pre Flight Procedures Table 5 0 2014 01 13 1 5 3 Team Evaluation Final Report 7 2 Launch Campaign Description 7 3 Results 7 4 Discussion and Conclusions 7 5 Lessons Learned 5 1 2014 01 31 All Updated tense BX16_iSEDE_SEDv5 1 31JAN14 Abstract Keywords The goal of this project from students of the University of Strathclyde is to design and build an initial prototype of an all inflatable satellite with disaggregated electronics for deployment on board a BEXUS balloon as proof of concept The idea is to use cellular structures as support for all the sub
175. peratures or Still No Simple Answers Large Space Aperature Workshop 10 11 November Keck Institute for Space Sciences Pasadena CA USA 2008 Freeland B Deployable Antenna Structures Technologies Large Space Apertures Workshop 10 12 November Keck Institute for Space Sciences Pasadena CA USA 2008 Lake M A Vision for Reflector Technologies Large Space Apertures Workshop Keck Institute for Space Sciences Pasadena CA USA 2008 D Werner Space Ground Amalgam LLC Adjusted for Inflation Space News International p 16 27 August 2012 Straubel M On ground Rigidised Inflatable CFRP Booms for Various Deployable Space Structures 5th European Workshop on Inflatable Space Structures 10 12 May Noordwijk The Netherlands 2011 D Werner Bigelow Aerospace Inflatable Modules for ISS Space com http www space com 1931 1 bigelow aerospace html cited 24 January 2013 Arduino Arduino Ethernet http arduino cc en Main ArduinoBoardEthernet March 2013 BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 177 26 Texas Instruments Low Power Digital Temperature Sensor With SMBus Two Wire Serial Interface in SOT563 2012 27 SensorTechnics LBA series low differential pressure sensors http Awww sensortechnics com cms upload datasheets DS_Standard LBA_E_ 11691 pdf April 2013 28 Mikrotechnik mp6 Micropump http www bartels mikrotechnik de index
176. php mp6 html March 2013 29 Raspberry Pi FAQ http www raspberrypi org fags 30 Sinn T et al 2013 Lessons learned from the sounding rocket and stratospheric balloon experiments Suaineadh StrathSat R and iSEDE 64th International Astronautical Congress Beijing China 23 27 September BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 178 APPENDIX A EXPERIMENT REVIEWS Terms amp Conditions at Selection Workshop Stage Terms The offer comprises subject to passing PDR e A flight for your experiment on a stratospheric balloon during the BEXUS 16 amp 17 campaign e Two reviews of your experiment design by a panel of experts drawn from space agencies and industry e Technical support by ESA and EuroLaunch during the payload integration phase and during the launch campaign e Sponsorship by the ESA Education Office for the travel and accommodation expenses of students attending reviews and the campaign conditions apply General Conditions e You must ensure compliance with the requirements of the BEXUS User Manual e You must comply with the overall project schedule and any requests made of you by ESA SNSB DLR or EuroLaunch in relation to the execution of the project e You must update and submit the Student Experiment Document SED at the specified milestones including the final post flight report even if the experiment is not considered to have been successful Th
177. pot Test e All systems on physical switch o Start all daemons using screen e Final test of the functionality and communication e Switch on both HackHD cameras and webcam e Switch off experiment o Hack HD in standby o Raspberry Pi shut down o Physical switch to OFF T 199 e Un deploy one satellite BRU TO BE CONFIRMED WITH BEXUS e Remove RBF pins e switch on experiment physical switch T 80 Inflation of balloon T 60 Power from Hercules switched to BEXUS internal batteries T 0 Balloon Launch T 45 15km Activate the Hack HD Camera on the Pre deployed Satellite BRU FT Approx Float Phase account for oscillation of the gondola at T 90 float phase wait until constant pressure FT 3 Start second HackHD for IRN FT 4 Activate Solenoids to Start Deployment after gondola has movement within requirements Are you sure FT 5 Power up the other half of newly deployed satellite IRN FT 10 Start Operational Phase after gondola has movement within experiment requirements groundcrew Start the Actuation of the 2 Satellite structures Monitor the actuation through the accelerometers by sending readings to Ground Station via Hub Take continual pressure and temperature readings Take video with both HackHD cameras of actuation Transmit the data to the Ground Station via the Hub Operational SAT 1 IRN SAT 2 BRU BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH
178. r R connection to the BEXUS E Link Any change in shape shall not interfere with R A T electronics or external structures The wireless communications shall not use R any BEXUS prohibited frequency bands Each satellite shall be securely fastened to R the gondola The hub shall be securely fastened to the R gondola The experiment structure should be no longer R than 650 mm There shall be a minimum of two deployable R satellites A light source shall be mounted inside the R gondola to illuminate the experiment The soft robotic actuator element shall not R T leak fluid into the environment et lr hu Uff TATA NSS BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 119 The fluid in the soft robotic actuator element R T shall not freeze at the temperatures to be expected during the balloon flight A switch shall be mounted on the outside of R I the experiment to switch in between flight and test mode A clearance nothing mounted on the bottom of 25cm in actuation direction on the bottom of each satellite is required One satellite shall be pre deployed before R launch The hub shall accept commands from the R T ground station at any time The Hub shall be active from launch R T command given through the E Link from the ground support station At float altitude all syste
179. rimental requirements All constraints are listed below BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 22 1 Schedule a b The project team shall all receive academic credit for the work carried out with iSEDE Therefore a considerable amount of the work must be carried out within the academic year in order to show sufficient evidence that will warrant academic credit In addition the project must run alongside the BEXUS 16 timeline in order to meet design reviews integration launch and reporting deadlines 2 Cost a The project is running on a tight budget with set funds being allocated to each academic project involved in iSEDE by the engineering faculty The only additional support being received is through provision of passive components by sponsor Coilcraft and an undisclosed quantity of funds from the experiments academic sponsor Therefore it is important that the budget outlined in section 3 3 2 is strictly adhered to 3 Manpower a The iSEDE project team currently consists of 9 members It is endeavoured that this shall increase through our current recruitment drive however it is important that the scope of the project remains relatively constant throughout Any significant scope creep could lead to substantial increases in the already tight schedule and could put the project at risk of failing to meet deadlines 4 Technical a BEXUS Compliance i
180. ronics Electronics on printed circuits and the associated hardwired power and data connections must be connected to the surface of the inflatable structure This must be done without impairing the structures inflation and must not present any danger to the structure such as puncture during the deployment process Another requirement of the mounting is that the electronic components can be de attached easily and transferred to another inflatable therefore adhesive bonding is not ideal A flexible printed circuit is used to mount the electrical components to the inflatable structure This allows the structure to remain flexible enough to alter the shape of the entire structure The only component which this causes a BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 64 problem with is the IMU on the bottom cell As the centre of the inflated cell is flat compared to the area around the circumference then the proposed solution takes advantage of the conventional mounting of PCB with screws and through embedded holes in the PCB The mounting assembly consists of a M3 plastic screw with countersink head and a large washer The washer with the head are joined together to obtain a rigid connection this assembly is then glued between the Mylar inner layer of the cell and the adhesive Kapton outer layer obtaining a mounting point for the PCBs The sketch of the principle and a first prototype w
181. s 0 5kg the total mass supported is 6kg As there are two beams each experiences half of this mass 3kg The maximum force is therefore F 3 x 9 81 x 10 161 8N The length of the roof supports is 0 8m therefore the maximum stress is 161 8 x 0 8 4x 935 x 10 7 161 8 x 0 8 Amax 48 x 68 9 x 10 x 8 9 x 107 Table 4 2 Mechanical Components Breakdown 63MPa 0 005m Group Part Quantity Additional Info Supplier Cameras CAMERA_MOUNTPLATE 4 Al T6 Sheet 1 Cameras CAMERA_MOUNT_TUBE 1 Al T6 Tube GOPRO SKELETON Cameras HOUSING 2 GoPro CAMERA_MOUNT_SLIDE Cameras FIT 2 workshop Deployment DEPBOX_CORNER_1 8 Al T6 Angle 1 Deployment DEPBOX_CORNER_BASE Al T6 Angle 1 inside deployment Deployment CELL MOUNT 2 module Al T6 Sheet 1 Deployment DEP_LID 2 Al T6 Sheet 1 Deployment DER UD LOCK 2 lid with overlap Al T6 Sheet 1 Deployment DEPBOX_BASE 2 Al T6 Sheet 1 Deployment DEPBOX_BASE_FILL 2 Al T6 Sheet 1 Deployment DEPBOX_MOUNTPLATE 2 Al T6 Sheet 1 Sides with hinges Deployment DEPBOX_SIDE_1 4 attached Al T6 Sheet 1 Side opposite Deployment DEPBOX_SIDE_2 2 solenoid Al T6 Sheet 1 Side with solenoid Deployment DEPBOX_SIDE_2 5 mounted Al T6 Sheet 1 Deployment HINGE_BOX 4 Al T6 Sheet 1 Deployment HINGE_LID 4 Al T6 Sheet 1 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperatio
182. s is acceptable You have successfully covered the important design requirements from the safety point of view One of the operational requirements makes it confusing about when the satellites are deployed o In your next SED make the above point clear It is not immediately obvious for non native speakers to define the difference between deploy and inflate o You should test your SED on someone outside the team a Mechanics SED chapter 4 2 1 amp 4 4 H was unclear in the document about the overall envelope A good overall dimensioned drawing would be good There were questions about the release of material due to a possible explosion of the inflatable structure The team preferred internal mounting It is possible to mount to the roof on the gondola but this is bespoke and can be difficult There a possibility to fly with a panel open with the camera mounted externally Shocks is not included in risk FEA or numerical analysis is required for the shocks There should be a procedure for the folding and this should preferably be done by the same person each time The release of the hatch should be well documented in the SED and it should be clear that it is safe Try to reduce the footprint by integrating the hub There s a tendency for condensation on the go pro case you should check this in TVAC and modify the case take the seal off or drill through a Electronics and data management SED chapter 4 2 2 4 2 3
183. ses on the ground station laptop The wireless E Link test was then conducted This failed on the break test where the connection was deliberately disconnected and then connected again in order to simulate what would happen in the event that contact was temporarily lost with the balloon When running this test the ground station could not re establish contact with the experiment This issue was solved by changing way the network settings were done in the ground station and Raspberry Pi flight hardware Holes were cut in the polystyrene of the hub to increase the air flow into the electronics on ascent This was to aid the cooling of the Raspberry Pi when it was sitting on the ground and also during ascent BX16_iSEDE_SEDv5 1 31JAN14 74 EuroLAUNcH Student Experiment Documentation Page 156 SSC wanted to fit the gondola batteries in a position that got in the way of the cameras observing one of the satellites After a long discussion it was decided that one of the battery boxes could be fitted on the roof of the gondola allowing the cameras full view of the experiment As one of the final steps before full final testing the pumps were connected up to the soft robotics and primed with anti freeze It was found that all of the soft robotics elements of Irn were leaking anti freeze All of the antifreeze was slowly bleeding out of the system The experiment had to be hung up overnight to try and drain the leaked antifreeze
184. shall be provided from the BEXUS module to the satellites ER_DE_36 The hub shall be powered by the BEXUS link ER_DE_37 Status updates shall be generated and sent down the E Link to the ground station regularly for each critical component ER DE 38 A control algorithm shall control the shape alterations of each satellite ER_DE_39 All data shall be communicated back to the hub for storage in its SD card ER DE 40 Each satellite shall store all its data on an SD card locally ER DE 41 The ground station shall be capable of sending commands to each satellite and receiving data through the BEXUS E Link ER DE 42 Feedback data shall be sent down the BEXUS E Link to the BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 20 ground station ER_DE_43 The hub shall be insulated to provide thermal protection ER DE 44 The hub shall have an Ethernet port for connection to the BEXUS E Link ER DE 45 Any change in shape shall not interfere with electronics or external structures ER DE 46 The wireless communications shall prohibited frequency bands not use any BEXUS ER DE 47 Each satellite shall be securely fastened to the gondola ER DE 48 The hub shall be securely fastened to the gondola ER DE 49 The experiment structure should be no longer than 650 mm ER_DE_50 There shall be a minimum of two deploy
185. sity of Electronic Lead Without Strathclyde Borders Frazer Brownlie Mechanical Mechanical Summer BEng Mechanical systems Lead Testing amp internship Engineering Validation Strathclyde University of Honours thesis Strathclyde project BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 8 team member background project area academic interest credit Larissa Batista Java GUI Ground Support Summer Leite BEng Design Software internship Computer Science Science University of Without Strathclyde Borders Adam Rowan Power systems Software Master s thesis MEng Electrical and engineering Electronics project Mechanical Space Outreach Engineering technologies University of Mechatronics Strathclyde Jonathan Gillespie Control amp Power systems Master s thesis MEng Electrical and Automation Outreach project Mechanical Power systems Engineering University of Strathclyde Andrew Allan Autonomous Mechanical Master s thesis MEng Electrical and systems Design project Mechanical Adaptable space Outreach Engineering structures University of Strathclyde BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH Student Experiment Documentation Page 9 1 5 3 iSEDE Team Member Evaluation Evaluations from Tiago Frazer Andrew Larissa Craig Darryl and Jonathan Evaluation forms analysed and plotted by Thomas Text compiled with comments from Tiago Frazer Andrew Thomas Larissa
186. soft robotic actuators and to find a successful manufacturing technique incorporating them Ideally we would have found a company who could manufacture them to a high enough standard However the team did not have enough budget for this Ideally the inflatable structure would have been manufactured professionally also as it was vital it had to be completely sealed to ensure inflation However this was not the case and the manufacture of the inflatable structures were not at a high enough standard Another issue that faced the team was the departure and absence of team members As some team members left the team at the start of the summer it was anticipated that a lot of work had to be done right up until the launch campaign however it was thought that there would be enough manpower to cover the work However certain team members did not pull their weight over the summer which meant that the experiment was not fully tested If there was sufficient manpower the likelihood of the experiment being unsuccessful would have been reduced Although the team discovered many issues throughout the BEXUS process the possibility of inflatable structures working successfully in space applications is still high This has been proven in the testing that has been carried out by the team and the success of the electronic components used by the team 7 5 Lessons Learned The lessons learned are split into the following subchapters Further lessons learned can
187. status September 2013 mpera yona experiment switched on and software ran through 3 complete experiment timeline cycles Table 5 18 Test 0 17 Test number 0 17 Test type Roof Mounting test Test facility University of Strathclyde Tested item Entire experiment Test To see if all parts of the experiment can be mounted to the level procedure roof mounting tubes Test duration 1 day Date status September 2013 ampera 100912013 Table 5 19 Test 0 18 Test number 0 18 Test type HackHD SD card storage test Test facility University of Strathclyde Tested item Hack HD Test To see the maximum amount of footage that the SD card level procedure can hold Test duration 1 day Date status August October 2013 G6mpleted 2710812013 Table 5 20 Test 1 0 BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation and SSC cooperation Page 129 Test number 1 0 Test type Integration test Test facility University of Strathclyde Tested item Entire experiment Test To see if all parts of the experiment can be integrated as level procedure planned and measure the total mass after integration Test duration 1 week Date status August October 2013 S6mpleted 2710e812013 Table 5 21 Test 2 0 Test number 2 0 Test type Vacuum test Test facility Univers
188. systems composing a typical nano satellite Each subsystem and component is mounted on a different cell Cells are both individually inflated and individually controlled The aim is to design and build a prototype for this new type of satellite demonstrating the deployment and wireless communication among components Furthermore the inflatable satellites have the ability to change their shape to prove a smart structure concept from the bio inspired mechanism that plants are using to follow the sun Inflatable Disaggregated Electronics Satellite Gossamer Structure Residual Air Inflation Passive Deployment Shape Change Smart Structure BEXUS BX16_iSEDE_SEDv5 1 31JAN14 vi CONTENTS PREIS E 1 1 INTRODUCTON esse a ie aie A ce Se ae as eee et ee Gee 2 1 1 Scientific Technical Background 2 1 2 MISSION Gerten 5 1 3 Experiment Objectives sssseeesessenerrrrresserrrrrnrrrneetrrnrnnnnnnneerrrrne nnn 5 UE WR elen Ener EE 6 dee heat Detall Seinna nate aaa ole dete Rise crete seas 7 1 5 1 Contact POM a ected take te 7 1 5 2 Team Members EEN 7 1 5 3 iSEDE Team Member Evaluation cccccccceeeeeeeeeeeeeeeeeeeees 9 1 54 EREM ee 13 2 EXPERIMENT REQUIREMENTS AND CONSTRAINTS oaaae 16 2 1 Eelere TE 16 2 2 Performance Ee re E 16 2 3 estate Dette EEN EE 17 2 4 Operational Heourements Au 20 25 VE DEE eege 21 3 PROJECT PLANNING ccccecceeeeeeeeeeeneeeeeeeeeeeeeceecaaeeeeeeeeeeeeeesennneeeeeeees 24 3 1 Work Br
189. t are COTS and have been selected as they have low mass volume and footprint and they work within the harsh environmental operating conditions The system architecture is designed to be robust and fulfill its purpose with the minimum components and simplest implementation At this stage in the project the electronics design of each subsystem has been completed and is undergoing rigorous prototyping and testing Section 4 5 1 gives an overview of the electronics implementation 4 5 1 Electronics Overview The electrical system can be divided into two subsystems the Hub and the satellites Although the experiment launched two satellite units the electrical systems on each are identical and so are described singularly As described only one satellite is deployed at float altitude with the other being pre deployed before launch The deployable satellite is actuated following a command given manually from the ground support software Both satellite systems are on standby from launch and fully activated upon receipt of the deployment command Throughout the experiment the Hub acts as the primary experiment controller dictating the operation of the experiment depending on the experiment timeline and user commands from the ground support station Commands are received through the BEXUS E Link The logic and flow of the experiment can be seen in Section 4 8 Software Design BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH ADLR and SSC cooperation
190. ted in 10 This predicts inflated dimensions of length 14 9cm depth 5 9cm and height 9 9cm BX16_iSEDE_SEDv5 1 31JAN14 wo S e y EuroLAuUNcH Student Experiment Documentation Page 60 0 5cm 13cm K Ve a 18cm Figure 4 10 Deflated Cell 9 9cm Figure 4 11 Inflated Cell A fully inflated deployed structure with two columns of cells and no added mass would therefore have dimensions of 14 9x11 8x49 5cm With added mass around a 10 elongation is expected giving an inflated height of around 55cm The connection between the inflatable structure and the deployment module is through clamped plates BX16_iSEDE_SEDv5 1 31JAN14 cooperation Student Experiment Documentation Page 61 4 4 1 2 Actuation The actuation of the iSEDE inflatable is inspired by nature s heliotropism where motor cells in the plants stem change the pressure in between neighbouring cells and therefore make the stem of the plant flex in order for the flower head to follow the sun over the course of a day 9 This nature inspired principle is used for the shape alteration of the inflatable iSEDE satellite Initially the concept was based around micro pumps being attached between two adjacent cells to change their pressure and therefore their volume resulting in a deformation of the entire structure But due to the fact that the surface material is the rather inelastic Mylar another actuation principle was developed A solution is the use of so
191. tellite appendages external to the gondola are damaged upon landing v Any shape change must be completed within the experiments half hour long operational phase vi Electronics must have the capability to operate autonomously in the case that a communications link is lost with the ground station vii Electronics must not damage the surface of the inflatable material so as not to risk failure BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 24 3 PROJECT PLANNING 3 1 Work Breakdown Structure WBS The work breakdown structure in Figure 3 1 shows the main breakdown of tasks for the project L 2 Electrical 4 8 Mechanical Segen 3 Software Kees 5 Review 6 Post tlight 7 Outreach ces Structure 41 5 1 SEDv1 6 1 Data 81 Si SE PR Anes ees Le pes a en 2 2 Comms 3 2 Satellite 4 2 Electrical aera Sa Pua r2 Klee e ymi CDR Results Facebook Teamsite Modules 8 3 Work n 3 3 Ground 5 3 SED v3 6 3 Further 1 3 Satellites rcer station 4 3 Software PR Design 7 3 Articles Breakdown Structure 1 4 Camera 4 4 Full 5 4 SED v4 8 4 Gantt Housing 2 4 Sensors System EAR 7A Talks Chart 5 5 5 SED v5 Micropumps Post flight 7 5 Events 2 6 Camera ilk Figure 3 1 Work Breakdown Structure Figure 3 2 shows a further breakdown of tasks for each mechanical area of the project 1 Mechanical Structure 12 1 4 Camera 1 5 Soft 1 1 HUB Deployme
192. th a bandwidth of at least 75 kbps TTT All shape alterations should be completed in R A T under 20 minutes Differential pressure sensors must be capable R of measuring between 250 250 Pa Component temperature measurement must R be capable between 30 40 C The experiment shall be designed to work HAT within the temperature profile of the BEXUS balloon The experiment shall be designed to operate R A T in the vibration profile of the BEXUS balloon with special consideration given to the launch and landing stages The experiment shall be designed in sucha R 1 T way that it shall not disturb or harm the gondola or any other experiment BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation E UROLAUNCH Page 116 The deployment box for each satellite shall be no larger than 1U R Each satellite shall consist of ten interconnected inflatable cells One central control unit the Hub shall be located inside the gondola to control the experiment timeline and relay data up and down the BEXUS E Link Component circuitry shall be laid out in such a way to allow each satellite to be folded down into their deployment box before the experiment commences HAT TIT COTS components shall be used where applicable and affordable The experiment shall be mounted on the inside of the BEXUS gondola No components or parts shall become
193. the bottom cell it was changed to 25cm in actuation direction We just included in Chapter 6 as a requirement e More information is needed on the solenoid and the actuation device reference section 4 5 2 4 FRAZER Date 01 07 13 Comment Added descripton of how the solenoid and latch will work e The IPR should be the latest decision point for the Go pro vs 3D printed camera case FRAZER Date 01 07 13 Comment Amended e Does the HACK HD have the possibility of using a fish eye lens to increase the FoV and therefore decrease the necessary separation MAOMAS Date 04 07 13 Comment DONE The HackHD already has a fish eye lens Electronics Design e You may find it difficult to mount the Pi and allow easy access to the pins AND the SD card FRAZER Date 01 07 13 Comment DONE Description of how Pi will be mounted inside of hub e In general your mooting and internal mechanical design in terms of PCBs is far from clear Date 01 07 13 Comment DONE see point above e You should provide the automated timeline with notes on what triggers the events e g pressure sensors vs schedule for deployment SSSe0SSeeremlen e The attachment of the PCBs to the inflabtable material is critical this should be finalised before the IPR HOMAS Date 07 07 13 Comment DONE Chapter added on mounting of PCB on inflatables via srews e Why are there no schematics at all except for power DARRYL amp MAGO Date 06 07 13 Comment DONE Sche
194. the team Clarification of any technical queries directed towards the visiting expert Communication and functional testing Service system simulator testing and E link testing for REXUS and BEXUS respectively BX_IPR_Isede_V1 0_17Jul13 Doc BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 195 APPENDIX B OUTREACH AND MEDIA COVERAGE 20 06 2013 Mechanical and Aerospace Engineering Department University of Strathclyde STUDENTS ONE STEP CLOSER TO LAUNCH EXPERIMENT ONBOARD STRATOSPHERIC BALLOON On 30 May Craig Hay Adam Rowan Frazer Brownlie Darryl Black Tiago Queiroz and Thomas Sinn from Strathclyde s iSEDE experiment team were at the European Space Agency s ESA s European Space Research and Technology Centre in Noordwijk Netherlands for the Critical Design Review CDR of their experiment The iSEDE Inflatable Satellite Encompassing Disaggregated Electronics experiment has the purpose to deploy a shape changing inflatable structure with disaggregated electronics on its surface in the stratosphere Traditional satellites have a rigid structure defining the basic configuration of the satellite and holding in place all the subsystems A variation of the shape or configuration of the satellite is normally achieved through the use of deployable structures or appendices antennas solar arrays booms etc Although modern structural solutions are modular and multifunctiona
195. the temperature sensors and accelerometers is done using an DC bus each sensor has a communication protocol defined by its BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 104 manufacturer The pressure sensors are connected directly to arduino s analogue inputs The flow diagram is shown in Figure 4 51 AP Loop control Satellite Initialize Arduino s Hardware Initialize Sensors Start Watchdog Wait for commands Shutdown Shutdown all systems Watchdog time out Activate micro pumps Read AP sensors Report to Hub Reset PanStamp Adaptive phase Start adaptive phase AP AP control loop Shape within tolerance Deactivate micro pumps Report to Hub Data request Read Sensors Report to Hub Figure 4 51 Satellite s Flow Diagram BX16_iSEDE_SEDv5 1 31JAN14 E UROLAUNCH Student Experiment Documentation Page 105 4 8 4 2 Hub The Hub software is also developed based on a state machine State changes are driven either by commands sent by the ground station or when completing some tasks The states are e Initializing starts all arduino s and Raspberry Pi peripherals and sensors e Self diagnostic checks all voltage levels tests communication channels sensors and actuators e Housekeeping checks all voltage levels and communication with the sensors it also checks the
196. ther experiments or the vehicle in the case of over charging Launch and operations SED chapter 6 o o o o It was clarified that the team intends to deploy but not inflate one of the two satellites before launch You should be aware of the increased stiffness of the cables when cold before deployment of the second satellite In the countdown schedule pg 88 at T 60 your attachment would be done well before this Latest access is T 60 minutes there is no access after this It is highly preferable to avoid access after pick up Organisation project planning A outreach SED chapters 3 1 3 2 amp 3 3 o o It is a good start and very clear Because of your schedule having a prototype before CDR you should also schedule time for design changes after CDRs if it is needed You say you are looking for new members but also some are leaving you should look carefully at this You could look at advertising on your blog and or facebook page for new members this has been successful in the past Include a table only for the budget do not just refer to it on a component list Don t wait too long to find sponsors Include the SSC logo on the blog Keep things updated especially the blog Keep the organisers informed of conferences send us a copy of the paper abstract 5 Internal Panel Discussion Summary of main actions for the experiment team o Address the issues related to the mechanical mounting 1
197. ting was carried out to establish how the inflatable structure material behaved in low temperature conditions and also to establish which glue worked best sealing the cells The thermal tests occurred between a temperature range of 21 8 C to 30 C Once the temperature reached 30 C the chamber was left at this temperature for 10 minutes before the cells were removed Different cell configurations were tested individual cells double cells and complete 10 cell structure For the individual cells a variety of glues were used to create the seal of the cells All of the cells were tested under the same conditions to keep the tests fair and valid Contents TTT a aE ee ee a eee ee ee eee ee eee 1 R T E 2 1 4 UHU Contact Power GIG ee ee eeccececececesnsesnsesnsnsnennsnsneneneneneseneneaeecececenececeasaencases 2 2 2 Double Sided Ti 2 1s SERR 2 14 Chabas aaa 3 a TT TT E 3 SC RR 3 3 1 10 Cell Structure with UHU Contact Power ele seeeececececeseccecececececececennnenennnnee 3 a AAAA EN OEA EE NEE VT EAE EOIN LES EAEE 4 BX16_iSEDE_SEDv5 1 31JAN14 Page 196 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 197 e Doc No TEST 001 Thermal Testing of Inflatable Cell Bond Lines 38 2 Date 12 05 2013 1 Single Cell 1 1 UHU Contact Power Glue Once removed from the thermal chamber it was found that the material of the cell did not fell any colder than before it went into thermal chamber
198. tle safety margin especially when the efficiency will most likely drop at low temperatures The decision was made to move the power circuitry to the HUB Verger ihe Saisie Baton Decision June 13 charging during mission unnecessary BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperatio Student Experiment Documentation Page 99 4 7 4 Power Distribution The power system is entirely hardwired There are 2 power buses running through the cells of each satellite with the 3 3V and 5V Each cell can then tap into the bus of the required voltage level and thus provide the correct power input for the cell s components The Hub has the power circuitry inside it and is hardwired directly to each of the satellites 4 7 5 Power Budget Breakdown Qu Operati Max Max Operatin Power Power anti ng Current Power gTime Consumptio Consumptio SAT ty Voltage mA mW hr n mWh n mAh Micropu mp 3 5 20 100 0 75 225 45 Communi cations Chip 1 3 3 26 85 8 0 75 64 35 19 5 Accelero meter 2 3 3 0 01 0 066 0 75 0 099 0 015 Temperat ure Sensor 4 3 3 0 01 0 132 0 75 0 099 0 0075 Pressure Sensor 3 5 5 75 0 75 56 25 3 75 Total 101 06 260 998 345 798 68 2725 x2 SATs 691 596 136 545 HUB Microcon troller 1 5 300 1500 1 1500 300 Temperat ure Sensor 1 3 3 0 01 0 033 1 0 033 0 01 Camera 2 5 550 5500 0 5 5500 550 Communi cations Chip 1 3 3 26 85 8 1 85 8 26 Total 1426 7085 83 70
199. tores it e Changing shape controls the changing shape phase Idle Waiting for commands There are two communication links the main link is wireless and it is connected to arduino s SPI bus the other one is a backup wired link connected to arduino s serial port also known as UART or USART Both satellites are connected to the same serial bus using tri state buffers controlled by the Hub to ensure that only one satellite is using the bus each time When activated the satellite goes to an initializing state where all arduino s peripherals sensors actuators and the watchdog are initialized After that the system goes to an idle state where it stays reading all sensors and sending the readings to the Hub Watchdog is a timer counter with a dedicated clock that allows a software interruption and also a system reset if the counter is not reset before it finishes counting In the satellite the Watchdog is responsible for identifying communication problems and tries to reconnect to the Hub When working normally the Watchdog counter is reset when a command arrives and during long states so if the Watchdog interrupt occurs it is because there are communication problems The satellite tries to reconnect to the Hub if it fails it goes either to a safe mode which means return the satellite to a default shape and keeps trying to reconnect with the Hub or to a time and altitude based autonomous experiment mode The communication with
200. tures Documentation 15 Insert Anti freeze to Camera Anti 30 FB soft robotics Pictures freeze Documentation 16 Check that the soft Camera NA 10 FB robotic actuators and pictures micropumps are documentation working 17 Attach hub to roof Wrench hub 10 FB mount tubes Camera mounting Pictures plate x2 Documentation M8 Nyloc Nut x4 18 Begin to fold satellites Camera NA 20 FB into deployment Pictures boxes until top cell Documentation 19 Attach deployment M8 Allen key Filler Plate 20 FB boxes to roof mount Camera x2 Dep tubes pictures Box documentation mounting plate x2 BX16_iSEDE_SEDv5 1 31JAN14 and SSC cooperation Student Experiment Documentation Page 144 M8 bolt short x8 M8 Nyloc nut x8 20 Finish folding satellite Camera RBF Pin 10 FB into box top cell and Pictures close doors insert Documentation RBF pin 21 Check that roof tubes M8 Allen key Roof tube 20 FB with deployment wrench mounting boxes attach to Camera plates gondola pictures x4 M8 documentation bolt long x8 M8 Nyloc nuts x8 22 Check that camera M8 Allen key Camera 10 FB tubes mount to wrench Mounting gondola Camera Plate x4 pictures M8 bolt documentation short x4 M8 Nyloc nut x4 23 Confirm camera view Camera NA 30 FB angle with pictures Eurolaunch documentation 24 Erase Memory from Laptop micro NA
201. type B 1 RS Components 21 60 21 60 17 Dec 12 Arduino Ethernet without PoE 1 RS Components 34 40 34 40 17 Dec 12 ACS712 Low Current Sensor Breakout 1 Active robotics 10 91 10 91 17 Dec 12 Digital Temperature Sensor Breakout 1 Active robotics 8 10 8 10 17 Dec 12 TEMT6000 Interface Board 1 Active robotics 3 70 3 70 26 Feb 13 Wood for test stand 1 Hardware Store 31 50 31 50 26 Feb 13 Cornerpieces 1 Hardware Store 18 50 18 50 26 Feb 13 FTDI Basic Breakout 5V 1 Active Robotics 11 83 11 83 05 Mar 13 Zulu 868 Transeiver Module 1 Farnell 37 00 37 00 12 Mar 13 ADXL345 Accelerometer Breakout 3 Active Robotics 19 04 57 12 12 Mar 13 MOSFET N Channel 50V 0 22A SOT23 1 RS Components 0 18 0 18 13 Mar 13 TMR 6 0510 Regulator 1 RS Components 17 00 17 00 13 Mar 13 TMR 3 1210WIE Regulator 1 RS Components 11 40 11 40 BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH ADLR and SSC cooperation Student Experiment Documentation Page 29 13 Mar 13 AAT3683 Charging IC 1 RS Components 1 31 1 31 15 Mar 13 HackHD Camera PCB 2 HackHD com 119 27 238 54 15 Mar 13 GoPRO Skeleton Housing 2 gopro com 45 99 91 98 17 Mar 13 868 MHz BEAD Antenna 3 RF Solutions 17 70 53 10 20 Mar 13 Socket Solder Tail Single Row 1 Digi Key 11 76 11 76 20 M
202. udent Experiment Documentation Page 4 Figure 1 3 Artist view of Bigelow module attached to ISS source Bigelow Various space structures are serving just one specific purpose in space systems nowadays By developing a structure that can adapt itself to various mission stages the flexibility of the entire mission can be enhanced With applying smart structures the spacecraft can easily adjust itself to the space environment and expensive on ground simulation to verify the accuracy of the structure when subjected to the harsh space environment will become no longer necessary These kind of smart structures have various applications in space systems Examples of these structures range from telecommunication over earth observation to human space missions For example these structures can form antennas or concentrators which are able to adjust their focal point autonomously depending on their orientation towards the sun or their position in orbit By using a smart membrane as a substructure for a solar sail attitude control of the solar sail can be achieved by changing the shape of the structure and therefore varying the area subjected to the solar wind This area change will result in an attitude change of the space craft By distributing the electronics now over the surface of the inflatable smart structure a very lightweight giant structure in space can be created without having the need for any rigid heavy substructures which would be dead wei
203. ult tree analysis and fault management analysis Having experienced a failure during operational phase the team sat down and developed a recovery plan in order to have the best chance of identifying what the cause was of the latch failing to open Having discussed this plan as a team a meeting with Simon SSC Alex Kinnaird and ESA stakeholders was arranged in order to report to them on the issues that were faced by the team during the operational phase and Frazer gave a short presentation on what our plan of action was Alex suggested a full Fault Tree Analysis in order to get to the root cause of the failure A failure investigation was started to obtain the root cause of the failure All available data was gathered in order to try and find the cause A What s Different Analysis was also conducted to aid in the investigation This is where we highlighted any differences in the experiment or the environment between the last successful test FCP and the failure flight This discussion revealed a number of differences Some causes of failure discussed were e short circuit due to moisture no current at solenoid e cold caused mechanical jam ice e hinge manufacturing defect e cold stopped solenoid from firing e transistor failure e inflation due to vacuum caused excessive friction in latch mechanism solenoid not capable of overcoming force e latch manufacturing defect point of rotation e loose wire solenoid wire or i
204. ures is the exploitation of inflatables Reasons for the use of inflatable structures range from their low cost over exceptional packaging efficiency deployment reliability and low stowage volume to low weight Over the last few decades inflatable structures became an emerging field to overcome launch vehicle payload size restrictions 13 Research in inflatable structures can be dated back to the 1950s The first major developments during this time showing the potential of these novel structural concepts were the Goodyear antennas in the early 1960s and the Echo Balloon series from the late 1950s to the early 1960s The Contraves antennas sunshades and the L Garde Inc inflatable decoys followed in the 1970s and mid 1980s 14 The biggest achievement up to date is the Inflatable Antenna Experiment IAE of L Garde which was launched from a Space Shuttle in May 1996 15 w EN Figure 1 1 Inflatable Antenna Experiment IAE deployed in 1996 source NASA Research has been undertaken in various institutions all over the world in the field of inflatable structures 16 18 new membrane materials have been BX16_iSEDE_SEDv5 1 31JAN14 EuroLAUNCH A DLR and SSC coopera Student Experiment Documentation Page 3 discovered that can withstand the space environment advanced simulation tools were developed that capture the highly non linear behavior of the inflation process and rigidization techniques have been investigated making the
205. wards This GANTT chart updates the full GANTT chart BX16_iSEDE_GANNTv1_13MAY13 on the teamsite BX16_iSEDE_SEDv5 1 31JAN14 EurRoLAUNCH A DLR and SSC cooperation Student Experiment Documentation Page 27 mm a m 4 Gantry Ke 2013 Vorgang Anfang lt E TET mR Electronics 10 07 13 09 08 13 Lem e iSEDE on breadboard 10 07 13 17 07 13 PCB Fabrication 18 07 13 02 08 13 PCB Assembly 06 08 13 09 08 13 e Vacuum bread board 18 07 13 01 08 13 Mechanics 10 07 13 09 08 13 e Fabrication structure 10 07 13 24 07 13 e Assembly 25 07 143 02 08 13 e Softrobotic Design Im 10 07 13 02 08 13 e Sofrobotics Fabrication 05 08 13 07 08 13 H Cell Fabrication with a 08 08 13 09 08 13 Software 10 07 13 19 08 13 e compelte iSEDE com 10 07 13 17 07 13 ul e Automated Timeline 18 07 13 02 08 13 Groundstation all data 18 07 13 02 08 13 e Mission Groundstation 05 08 12 19 08 13 Assembly Mech Electr 12 08 13 16 08 13 H P Testing 19 08 13 06 09 13 e Timeline 20 08 13 21 08 13 8 e Actuation Sensors 22 08 13 23 08 13 E S g e Vacuum 26 08 13 26 08 13 e Themal 27 08 13 27 08 13 a S Procedures writing 19 08 13 06 09 13 e Buildspareinflatbles 02 09 13 06 09 13 EAR 09 09 13 43 09 13 Experiment Shipment 16 09 13 23 09 13 e Packing 16 09 13 18 09 13 Shipment 19 09 13 23 09 13 i Launch Campaign 04 10 13 14 10 13 BSS Figure 3 5 GANTT chart after IPR After
206. ware specialist DH EE tc PE80 unable to attend launch D Medium i work with ground control campaign system SOVAS specialist Applications sent for travel PE81 unable to attend launch D E f e funding campaign See Travel funding received PE82 unable to attend launch A 6 from department campaign SC10 Long delivery time for D Medium Order components atan components early stage of the project All critical components are f ordered Only expendables L t f SC11 ang Selver ane tor 3 available in every components electronic shop need to be ordered Early workshop SC20 Workshop 3 Medium submission If necessary manufacturing delays use a variety of university workshops Drawings submitted and manufacturing started Warki constant updates from SC21 3 workshop and individual manufacturing delays components can be collected once manufactured SC30 Lack of spare parts nl Order sufficient number of before mission spare parts Delay in PCBs SC40 manufactured by Cc 3 Gelle ot Geen early as possible external company BX16_iSEDE_SEDv5 1 31JAN14 Student Experiment Documentation Problems in electronic EurRoLAUNCH ADLR and SSC cooperation Page 45 Purchase development SC50 design stalling software boards for key development components Funds being made eren No additional funding available by Department made available of Mechanical and Aer
207. y analyses Risk associated to possible material release was raised at PDR but an answer not found A folding test is identified but how to fold the balloons and to ensure the last folding will be properly done procedure same person is not identified and is recommended to be included You should be consistent with the location of the hub some parts of your document state the gondola rails You should definitely document the distance required between the camera and the middle cells Include more details on the roof mount clamps and the camera mounts in terms of material type bolt specifications You should be aware of thermal issues in your mechanical attachments including your door mechanism You should rigorously test the opening mechanism in the environment conditions You should update the document to reflect the final choice for camera casing You should be sure of the start up of the pumps in lower pressure Your experiment component list does not meet the requirements of the guidelines order status specification Electronics and data management SED chapter 4 2 2 4 2 3 4 5 amp 4 7 o A grounding scheme should be followed o Itis clear the satellite hamessing is still to be confirmed o The physical position of wires in the satellites should be documented including their attachment o You will need to apply for frequency permission from the PTS you should include the radiated power bandwidth antenna type a
208. y given in section 3 Project Planning This table details the possibility of interference with other experiments in the BEXUS gondola and possible safety risks when manufacturing and integrating the final build Premature deployment SF10 may compromise other experiments Test release mechanism Liaise 3 with other experiment teams RBF strap attachment iSEDE wireless link may SF20 interfere with other experiments Collaborate with 4 SSC DLR and other teams Premature wireless transmissions may interfere with BEXUS or other experiments SF30 Experiment on 4 standby until float altitude BX16_iSEDE_SEDv5 1 31JAN14 EurROoLAUNCH ADLR and SSC cooper Student Experiment Documentation Page 140 Ensure temperature Failure or leak of range of batteries can batteries may cause handle expected SF40 damage during B 4 Low temperature during integration transport or all transport and flight mission phases Test batteries in vacuum Failure or leak of batteries may cause one No more batteries in SR EE Se Si iSEDE experiment integration transport or flight Injury while Consider safety SF50 manufacturing and B 5 before using tools or integration moving heavy objects Ground experiment and operator electrostatic wrist band SF60 Electrostatic Discharge C 3 As a safety precaution and to ensure a safe handling of the i
209. yment on board a BEXUS balloon The idea is to use inflatable cellular structures as support for all the subsystems composing a typical nano satellite Each subsystem and component is mounted on a different cell Cells are both individually inflated and individually controlled The aim is to design and build a prototype for this new type of satellite demonstrating the deployment and communication among components Traditional satellites have a rigid structure defining the basic configuration of the satellite and holding in place all the subsystems A variation of the shape or configuration of the satellite is normally achieved through the use of deployable structures or appendices antennas solar arrays booms etc Although modern structural solutions are modular and multifunctional still the structure of a satellite represents a significant portion of its mass and a limitation on the achievable configuration extension of deployable components and packing efficiency during launch The idea of this project is to replace classical structures with cellular ones Cellular structures are made of a number of light weight cells individually inflated When deflated cellular structures can be packed to occupy a very small volume Once the structure is deployed in space it can extend to a large area with a small mass In order to allow high packing efficiency during launch subsystems like computer cameras gyroscopes accelerometer etc need to be min

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