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Build and Test PrepDesign Review
HABIP High Altitude Balloon Instrumentation Platform
P17104 & P17105February 2, 2017
Sponsored in part by:
Team Members
2
Team Team Member Major Team Roles Other Roles
Communications
Adam Steenkamer EE Project Manager Component Standardization Manager
Connor Goldberg EE Lead Embedded Engineer Agency Compliance Manager
Ian Prechtl ME Lead Mechanical Engineer Thermal Manager
Matt Zachary EE Lead Hardware Engineer Wire Manager
Data Acquisition and Control
Systems
Sydney Kaminski ME Project Manager
Weight, Volume, and Other Shared Mechanical Attributes Manager
Lincoln Glauser EE Lead Embedded Engineer User Guide Documentor
Chris Schwab EE Lead Hardware Engineer Power Manager
Steven Giewont EE Lead Controls Engineer Instrumentation Package/Integrator
Agenda1. COMMS
a. Custom PCB development and review progressb. Custom PCB component placement c. New/updated status to Risksd. Problem Tracking assignmente. Test Plansf. Team Project Plan
2. DAQCa. Schematic Development and Review Progressb. Risk Management Updatesc. Problem Trackingd. Team Project Plan and Week5 Demo Plane. Test Plans
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COMMS Build & Test Prep
COMMS PCB Progress
• Schematic complete• Schematic peer-reviewed• Schematic review by Dr. Patru• Schematic review by Mark Indovina• Rough component placement complete• Full component placement in progress
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COMMS PCB Schematic Changes
• Added title page with table of contents• Added block diagram page• Added hardware watchdog timer• Modified 12V boost portion of schematic for more
current (for ATV Transmitter)• Added GPIO control to OSD 12V power• Added ferrite beads to I2C lines by GPS module• Created separate analog & digital grounds• Labeled more component parameters• Added Pi GPIO LED• Switched to SL and Mini-Fit Jr. Connectors
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COMMS PCB Schematic Changes
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Custom PCB Component Placement
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Platform Changes
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Harnessing & Parachute
● Preparing to go with ¼ Wet Environment Rope - rated for 800 lbs
● Expecting 3 feet minimum from harness connection to
parachute.● Possible parachute alterations may be necessary
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Harnessing through here
COMMS Risk Analysis
Remediated Risks:• Insufficient access to ATV transmitter (we found one)• System does not have qualified HAM operator (2 of us
have licenses)• Insufficient access to SMD equipment (SMD lab, and
METEOR lab equipment)
Modified Risks• Overweight risk likelihood increased• Insufficient time and funds risks likelihood increased• System power draw risk likelihood decreased
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COMMS Risk Analysis (cont)
Added Risks:• OSD system requires reboot (will be remediated by
adding reset functionality)• Raspberry Pi glitches/requires reboot when placed too
close to an active 2m transmitter (will be remediated by proper grounding)
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Problem Tracking
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Problem Tracking
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Platform Test Plans
● Harnessing rope rated for 800 lbs so we will be testing areas of the platform that will fail prior to the harness break
● Impact testing for tree/similar landings● Not “officially” planned but will test for
buoyancy. If resources allow for additional actions regarding this, they will be taken.
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Harness Testing
● Testing at the harness connection for abnormal bearing failure under sustained loading
● Applying a bearing load to the connection over a period of 3 hours - should be no yield, failure, etc...
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Harness Testing
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Impact Testing
● Mechanical Subsystem Testing (Currently): Testing for subsystem fidelity
● System Testing (Not currently): Component Integration testing
● Iterative system drops from increasing heights until pass/fail criteria met.
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Impact Testing
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Transceiver Test Plans• Ensure the transceiver operates on the correct
band (2m band is 144-148 MHz)• Transmit sequences of random or fake data
from the HABIP & make sure they can be received
• Transmit sequences of commands from the METEOR Lab and ensure that the platform receives them
• These tests will be performed over a period of time with long sequences
• These tests will be performed at a distance from the METEOR Lab
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Transceiver Test Plans
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OSD Test Plan
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Data Storage Test Plan
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APRS Test Plan
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Goal: To ensure reliable APRS location transmission throughout the duration of the flight, despite adverse environmental conditions
Testing Conditions:In movement, with speeds consistent with flightTemperatures and pressures consistent with flightFor (4) hours straight
APRS Test Plan
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Details:• The Tracksoar APRS is a fully standalone unit• It will be powered using a 2xAA battery pack• The METEOR lab will be setup as a 2m receiver• The test conditions described will be simulated• The APRS should transmit a correct location once every
minute
ATV Transmitter Test Plan
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Goal: To ensure consistent video transmission throughout the duration of the flight, despite adverse environmental conditions
Testing Conditions:Distances of 10 miles, 26.5 miles, and 35 milesTemperatures and pressures consistent with flightFor (4) hours straight
ATV Transmitter Test Plan
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Details:• The entire video chain will be
constructed• The METEOR lab will be setup
as a 70cm receiver (equipment available, but tbd)
• The test conditions described will be simulated, as we ensure proper video integrity
Team Project Plan
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Team Project Plan - Main Tasks• Develop software• Perform subsystem tests
– APRS– ATV Transmitter (full chain)– Transceiver (full chain)– Structure impact– Harness bearing
• Develop & review custom PCB layout• Prototype structure• Submit custom PCB orders?
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DAQCS Build & Test Prep
Schematic Development
• Schematics for all 3 boards are currently being finalized.
• All connectors have been switched to Molex SL type connectors.
• All schematics have been reviewed internally and externally
• Small changes and additional features have been implemented since last review
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Review Progress - Host Board
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Review Progress - Host Board• High Frequency External Oscillator
– originally had HF Crystal– Can also use the internal digitally controlled
oscillator (DCO) instead – 24 MHz oscillator will also be placed as backup
• Abracon, 24MHz CMOS MEMS (Silicon) Oscillator
• LF External Oscillator– will keep LF crystal– For low power modes of operation
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Review Progress - Host Board• Larger Capacitors near MSP430s
– added additional 1uF capacitor– recommended by Mark Indovina
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Review Progress - Host Board• Larger Capacitors near MSP430s
– added additional 1uF capacitor– recommended by Mark Indovina
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Review Progress - Host Board• Pulldown Resistor on Cutdown MOSFET
– need pull down to ensure MOSFET will not activate during MSP430 power up state.
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Review Progress - Host Board• Second IMU - LSM9DS1
– additional IMU added to act as backup and provide additional data such as magnetic field
– I2C interface– $6.40
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Review Progress - Host Board• Reaction Wheel Battery Voltage Sense
– battery does not have built in undervoltage protection
– Need to monitor the voltage across each cell (6 cells) with MSP430
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Review Progress - Host Board• Extra GPIO Headers
– unused pins on the MSP430 that were not used are pinned out to headers.
– Due to routing/layer constraints, may pin out less than 40
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Review Progress - RasPi Hat
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Review Progress - RasPi Hat
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Review Progress - RasPi Hat
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Review Progress - RasPi Hat
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Review Progress - RasPi Hat
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Review Progress - GRSS
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Risk Management UpdatesRisk #3: • The components do not maintain a temperature needed
to work due to the movement through the atmosphere.
Action to Minimize:• Design for insulating electronics. Testing of the entire
system and subsystems will be undergone prior to flight in an environmental chamber, which will hopefully show that the system is capable of withstanding endpoint temperatures. This testing should be completed prior to flight in MSD II.
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Risk Management UpdatesRisk #6: • The amount of money given by Boeing may not cover
all of the necessary materials and resources needed to create the instrumentation platform.
Action to Minimize:• Continuously assess our needs for procurement and
make necessary decisions to obtain additional money if required.
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Risk Management UpdatesRisk #10: • The team may not have enough time to build and test
subsystems, as well as have several flights of the entire high altitude balloon.
Action to Minimize:• Create and maintain an active gantt chart to meet
deadlines. Focus on creating reasonable goals.
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Risk Management UpdatesRisk #15: • The batteries begin to leak/break/not function properly
Action to Minimize:• Research / procure reliable batteries designed for harsh
near-space environments. Also, testing of system in chamber. Research insulating batteries
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Risk Management UpdatesRisk #19: • Circuit boards break/malfunction during bringup and
testing.
Action to Minimize:• Large effort into designing before testing to minimize
mistakes. Many external and internal reviews of schematics and layouts
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Problem Tracking
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Problem Tracking Ctd.
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ProblemNumber
Identifying & SelectingProblem
AnalyzingProblem
Generating PotentialSolutions
Selecting & PlanningSolution
1
The current budget may not be enough for the rest of the
components that need to be
bought.
The budget is being reworked and component prices are being
analyzed to determine
whether or not the budget needs to be increased or if there is a need for
redesign.
The team is brainstorming
multiple solutions to the problem,
including redesign and asking Dr. DeBartolo for more money.
The team is currently undergoing an analysis
of the costs for this project and the current
budget. No decision has been reached yet.
Problem Tracking Ctd.
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ProblemNumber
Identifying & SelectingProblem
AnalyzingProblem
Generating PotentialSolutions
Selecting & PlanningSolution
ImplementingSolution
2
Due to the boards and other
components not being completed, a true plant model for
the entire instrumentation
platform will not be able to be
determined until much later in the design process.
This will cause issues with the
reaction wheel's accuracy and may delay the project.
There are several solutions to this
problem: wait until the entire instrumentation
platform is done or complete a prototype of the instrumentation platform, simulating
its weight and inertia.
The solution that was selected was the simulation
of the instrumentation platform. This will allow for an estimated plant model
and controller to be determined, which would hopefully decrease the
amount of issues that may be arise. This model and
controller will also hopefully only need minor tweaking once the entire platform is
created.
A motor test stand is currently being built, along
with a simulated instrumentation platform.
Problem Tracking Ctd.
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ProblemNumber
Identifying & SelectingProblem
AnalyzingProblem
Generating PotentialSolutions
Selecting & PlanningSolution
ImplementingSolution
3
This project is very complex and the time allotted for MSD is not very
long in regards to this project.
The remaining tasks are being written
down and determined to figure out how much of the project is left to be
completed. The project is very
complex and a lot of work still remains to
be completed,
The main solution to this problem that was
determined was to write out all remaining
tasks and to create due dates for
individual members so that the project will
remain and be completed on time.
Other options include reducing the
complexity of the project or increasing the amount of time
allotted for completion.
The solution that was selected was to complete
the list of tasks and to create a Microsoft Project
document, as well as utiize Trello so that team
members are reminded of upcoming deadlines.
Tasks are currently on Trello and beginning to be
worked on in order to complete them on time.
Problem Tracking Ctd.
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ProblemNumber
Identifying & SelectingProblem
AnalyzingProblem
4
Due to the space constraints, the board sizes are becoming an
issue.
The team is working with mechanical designs to identify how much area is
allowed for each board. Defined constraints for board sizes based on this
data are being created.
Problem Tracking Ctd.
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ProblemNumber
Identifying & SelectingProblem
AnalyzingProblem
Generating PotentialSolutions
Selecting & PlanningSolution
5
The components do not maintain the temperature needed to work
due to the movement through the atmosphere.
The team is working with COMMS to identify any temperature
issues.
Potential solutions include providing
insulation or aluminum foil
throughout the structure or
around certain components (e.g.
batteries).
The team is currently working to determine
the path moving forward through
theoretical calculations and possible testing in a pressure and thermal
chamber.
Problem Tracking Ctd.
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ProblemNumber
Identifying & SelectingProblem
AnalyzingProblem
Generating PotentialSolutions
Selecting & PlanningSolution
ImplementingSolution
6
Cut-down mechanism may require a slip-ring
between the balloon and the platform.
The team might want to isolate the rotation of the balloon from the instrumentation platform to help the
reaction wheel. If we wanted to do this, would also need to isolate the wire for
the external pressure sensor and cutdown
mechanism
One idea is to use a slip ring to isolate the motion of the platform
and allow the wires for the pressure
sensor to rotate freely without getting
tangled. Another solution would be to
make the wires leading up to the
balloon long enough such that the
movement of the platform will not be
affected and the wires will have
enough slack in them to not get tangled
To keep things simple, a slip ring will not be used and the rope will just be made long enough such
that motion of the platform will not be significantly affected by the balloon.
Currently designing the platform and external
pressure sensor using the single rope design
Problem Tracking Ctd.
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ProblemNumber
Identifying & SelectingProblem
AnalyzingProblem
Generating PotentialSolutions
Selecting & PlanningSolution
7
Circuit boards malfunction/break during testing or
bringup
The most likely risk of boards not working will originate in the designs
themselves
Ensure all schematics and board layouts are
checked internally by all team members and by external parties. Have
necessary resources to properly assemble and
bringup board.
Currently ensuring designs are correct and verifying that we can minimize the risk of
failure
Problem Tracking
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Team Project Plan
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Team 5 Week Project Plan
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5 Week Subsystem Demo Plan
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5 Week Subsystem Demo Plan
• Have the bare-boards back next review• Firmware completed for sensor
acquisition for both Raspberry Pi and MSP430
• Prototype cutdown mechanism
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Reaction Wheel Test Plan
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● Test Set-Up: ○ Instrumentation platform will rest on two rotating bearing plates.○ Digital angle gauge set up so that it is measuring around the axis of
rotation and is zeroed so that it shows no initial displacement.○ IMU (ADIS16350/ADIS16355) set up so that it will provide angular
displacement throughout test.○ Stopwatch will be held by the performer of the test.
● Test Plan:○ Set up the equipment and parts as described above.○ Turn on digital angle gauge and zero. ○ Begin data collection.○ Spin instrumentation platform, writing down final angle measurement.
Repeat.○ Write down the time it takes to reach an allowable angular
displacement, as well as the time it takes to settle at a final position.
Reaction Wheel Test Plan Ctd.
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GRSS Test Plan
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● Test Plan:○ Place buzzing buzzer in an
open area. Walk away until the buzzer can longer be heard or the nominal value has been achieved.
○ Place lit lights in an open area. Walk away until the lights can no longer be seen or the nominal value has been achieved.
GRSS Test Plan Ctd.
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Center of Gravity Test Plan
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● Test Plan:○ Open Autodesk Inventor and
open "Properties" tab. From there, the center of gravity may be seen. Click "update" if it has not been updated since last viewing. Write down the center of gravity.
Safety/Functional Test Plan
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● Test Plan:○ Ensure specific test points
that are important to the safety of the system are at their initially designed values.
○ Mostly Power Circuitry and system inputs.
Weight Test Plan
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● Test Plan:○ Utilize the pulley in
METEOR to obtain the weight of the entire platform to ensure within 8-10 lbs.
Communication between COMMS and DAQCS Test Plan
• Test the SPI communication between the two subsystem boards • In order to test SPI communication between the two devices, the
MSP430 will need to be configured to be a slave device and the COMMS Raspberry Pi will be configured to be a master.
• The data rate will be tested by having the COMMS Raspberry Pi acquire and timestamp when the data was stored.
• For both devices, test with running additional tasks to see how speed is affected
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Communication between COMMS and DAQCS Test Plan
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Video Quality and Recording Ability Test Plan
• Connect the camera and cable to the Raspberry Pi Zero. Create a script (Bash/Python) to continuously record video for four hours.
• Allow the script to run for four hours. Ensure that the Raspberry Pi will have a steady supply for power for the entirety of this test. After four hours, identify the video file and determine the size of the video file.
• Using this data, calculate how much space will be required to record for four hours. Be sure to round up to the next standard uSD card size to pick the necessary uSD required.
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Video Quality and Recording Ability Test Plan
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Video Quality and Recording Ability Test Plan
• Each sub test will ensure the sensor data from each sensor can be acquired, how fast it can be acquired and how much memory will be consumed by acquiring this data.
• Timestamps for each data acquisition must be included when writing the data to the card. The timestamps will be able to show how long the actual acquisition of data takes and the frequency at which the data can be acquired.
• This will show how fast the MSP430 and Raspberry Pi will be able to acquire all of the data. Extrapolating the size of the acquired data will confirm that the SD card will have enough storage to write data for a 3-4 hours mission.
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Video Quality and Recording Ability Test Plan
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Battery Lifetime Test Plan
• Concern– Batteries do not have enough capacity to function for a
3- hour flight.• Solution
– Efficiently designed power stages, use of low power electronics, and power monitors.
• Test– Use simple Time-to-Shutdown Test with stopwatch /
timestamps. For detailed discharge curve, use one of the below methods:• HK-010 Wattmeter• I2C Power Monitor• Sense resistor and differential oscilloscope
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Battery Lifetime Test Plan
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Also, test over temperature!!!
Moisture Invasion Test Plan
• Concern– Thermal cycling during flight will cause moisture buildup
on the payload electronics.• Solution
– To mitigate the change of electrical shorts and board damage, all PCBs will be conformal coated.
• Test– Place boards in a simulated flight environment.
• Spray bottle with tap water acts as a mist dispenser• Temperature chamber (with humidity control)• Thermal shock chamber
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Moisture Invasion Test Plan
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Budget
• PRP and email with MSD office stated $1,500• MSD Office now tells us $1,000• We will need $2,000
– Projected spending:
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Questions?
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EDGE Page Links
COMMS Team
DAQCS Team