design review build and test prepedge.rit.edu/edge/p17105/public/build_test... · matt zachary ee...

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

3

4

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

5

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

6

COMMS PCB Schematic Changes

7

Custom PCB Component Placement

8

Platform Changes

9

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

10

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

11

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)

12

Problem Tracking

13

Problem Tracking

14

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.

15

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...

16

Harness Testing

17

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.

18

Impact Testing

19

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

20

Transceiver Test Plans

21

OSD Test Plan

22

Data Storage Test Plan

23

APRS Test Plan

24

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

25

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

26

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

27

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

28

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?

29

30

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

31

Review Progress - Host Board

32

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

33

Review Progress - Host Board• Larger Capacitors near MSP430s

– added additional 1uF capacitor– recommended by Mark Indovina

34

Review Progress - Host Board• Larger Capacitors near MSP430s

– added additional 1uF capacitor– recommended by Mark Indovina

35

Review Progress - Host Board• Pulldown Resistor on Cutdown MOSFET

– need pull down to ensure MOSFET will not activate during MSP430 power up state.

36

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

37

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

38

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

39

Review Progress - RasPi Hat

40


41


42


43


44

Review Progress - GRSS

45

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.

46

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.

47

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.

48

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

49

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

50

Problem Tracking

51

Problem Tracking Ctd.

52

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.


53

ProblemNumber


AnalyzingProblem



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.


54

ProblemNumber


AnalyzingProblem




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.


55

ProblemNumber


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.


56

ProblemNumber


AnalyzingProblem



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.


57

ProblemNumber


AnalyzingProblem




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


58

ProblemNumber


AnalyzingProblem



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

59

Team Project Plan

60

Team 5 Week Project Plan

61

5 Week Subsystem Demo Plan

62

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

63

Reaction Wheel Test Plan

64

● 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.

65

GRSS Test Plan

66

● 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.

67

Center of Gravity Test Plan

68

● 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

69

● 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

70

● 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

71

Communication between COMMS and DAQCS Test Plan

72

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.

73


74


• 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.

75


76

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

77

Battery Lifetime Test Plan

78

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

79

Moisture Invasion Test Plan

80

Budget

• PRP and email with MSD office stated $1,500• MSD Office now tells us $1,000• We will need $2,000

– Projected spending:

81

82

Questions?

83

EDGE Page Links

COMMS Team

DAQCS Team

http://edge.rit.edu/edge/P17104/public/Build%20%26%20Test%20Prep?rev=0




design review build and test prepedge.rit.edu/edge/p17105/public/build_test... · matt zachary ee...

Documents