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ZAMBONI

ZAMBONI. Zippy Aerospace Module Broadcasting Observed Not-so-bad Images Senior Design Presentation. Design Team. Mechanical Engineering Jon Fargo Katie Kirchner Andrea Mattern Electrical Engineering Mike Hoffmann Jon Lovseth Chris Schmidt Jason Senti Warren Wambsganss Faculty

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  1. ZAMBONI Zippy Aerospace Module Broadcasting Observed Not-so-bad Images Senior Design Presentation 9 December 2002

  2. DesignTeam Mechanical Engineering Jon Fargo Katie Kirchner Andrea Mattern Electrical Engineering Mike Hoffmann Jon Lovseth Chris Schmidt Jason Senti Warren Wambsganss Faculty Arnie Johnson Richard Schultz Will Semke Chang-Hee Won 9 December 2002

  3. KatieKirchner 9 December 2002

  4. What is a CubeSat Idea originated at Stanford University by Professor Robert Twiggs California Poly responsible for launch integration Size ~ 10 cm (4”) Cube Mass ~ 1 kg 9 December 2002

  5. Mission • Successfully build and launch a CubeSat • Transmit a single digital image from space and receive the image on Earth 9 December 2002

  6. Goal Orbit Earth for approximately 8 months Transmit numerous digital images to Earth Transmit health/status data to Earth Transmit data from a commercial/ government sponsored payload to Earth 9 December 2002

  7. System Overview 9 December 2002

  8. Specifications • Structure Material • Aluminum 6061 or 7075 suggested • Must have same coefficient of thermal expansion as Aluminum 7075 (P-POD) • Tolerances of 0.1 mm • All edges must be rounded with 2 mm radius • Dimensions given for all outer surfaces • Legs • Outer Rails 9 December 2002

  9. Frame Design Ideas Modular Cube Design • easy access • solar cells not attached until very end • testing problems • difficult to machine 9 December 2002

  10. Frame Design Ideas Thin Frame Design • access to interior • easy to machine • thick enough for screws • solar cells can be included in testing • high mass 9 December 2002

  11. Frame Design Ideas Square Hollow Tube Design • solar cell attachment • easy to machine • mounting of components on interior • no access to the interior 9 December 2002

  12. Frame Design Ideas Modular Four Rail Design • lightweight • access to interior • good for tolerances • mounting of components on interior • many different parts to machine 9 December 2002

  13. JonFargo 9 December 2002

  14. Mass Budget oz. gm. 9 December 2002

  15. Mass Budget 9 December 2002

  16. SizeBudget Total volume available = 10 *10*20 cm = 2000 cm^3 Total Volume Used = 680.3 cm^3 66% Volume Remaining Does not include wires and other misc. connections 9 December 2002

  17. Prototypes Rapid Prototyping Machine Full size and scale models ABS Plastic 9 December 2002

  18. P-Pod Aluminum 7075-T6 Spring Deployed Heat activated line cutter Internal railings Interface port (access CubeSat while in P-Pod) 9 December 2002

  19. Testpod Internal Dimensions same as launcher tube Will accommodate double and triple cubes Designed and manufactured at UND 9 December 2002

  20. Testpod Launch Condition Testing Needs two mounting plates Bolts to Shaker table 9 December 2002

  21. Testing Cold Thermal Testing Standard 5.0 cu. ft freezer Desired temp: -40° C Achievable temp: -37° C, -67° C with dry ice Relay equipped for DAQ card control Temperature sensors throughout freezer 9 December 2002

  22. Testing Vacuum Chamber • Custom built from acrylic by Plastics Plus – Bismarck, ND • 5.5” inside diameter • Can achieve vacuum of less than 0.2 inches of mercury 9 December 2002

  23. AndreaMattern 9 December 2002

  24. Testing Vibration Testing Shaker Table: MB Dynamics C10E shaker & M6K amplifier system 9 December 2002

  25. Testing Vibration Testing Launch Vehicle Unknown Vibration and Qualification Test at UND • 125% Launch Loads • 12.5 Grms maximum • Sine Sweep • 50 Hz to 2000 Hz • Random Vibrations • +/-6 dB/oct abort limits Random Vibration Levels for Various Launch Vehicles 9 December 2002

  26. Testing Vibration Testing Vibration Acceptance Test at Calpoly • 100% Launch Loads • 10 Grms maximum 9 December 2002

  27. Testing Adhesive Testing Purpose: 1. Verify adhesive properties for Cubesat applications  Securely adhere solar cells to aluminum, varying thicknesses  Insulate solar cells from conductive structure with layer .005” thick 2. Create Procedures  Surface preparation  Mixing/Application  Accelerated curing  Pre-cured layer application 3M Scotch-Weld Epoxy Adhesive, 2216 B/A Gray 9 December 2002

  28. Finite Element Analysis Preliminary Analysis Three Rail Models 1. Rail with circular holes 2. Rail with square holes 3. Rail with no holes Conditions Axial loading Static maximum testing load = 18Gs Constrained on bottom surface for all DOF Free mesh Solid 187 and Solid 45 elements used 9 December 2002

  29. Finite Element Analysis 9 December 2002

  30. Finite Element Analysis Future Analysis Create entire model in ANSYS Rail with square holes Mapped mesh Solid 45 elements Simulate launch and test loads along the x, y, and z axes 9 December 2002

  31. JonLovseth 9 December 2002

  32. Components Camera: Olympus D-360L Microcontroller: MSP430F149 TNC: PicoPacket (replaced) Radio: Yaesu Vx-1R Hamster: for power 9 December 2002

  33. Interface 02000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D831805FFFF 1B5306000011020000001300 1B43060000040C0000001000 1B43060000040B0000000F00 1B4303000202000400 00 02000008FF08FF4402851234AB386510D0385610834D831805… Fullpic3 06 05 15 06 02000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D831805FFFF 02000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D83180502000008FF08FF4402851234AB386510D0385610834D831805FFFF 02000008FF08FF4402851234AB386510D0385610834D831805… 02000008FF08FF4402851234AB386510D0385610834D831805… Subliminal Message 9 December 2002

  34. Not-so-badImages Thumbnail 4kbytes SQ resolution 50-64kbytes 9 December 2002

  35. Things to Keep in Mind Component overheating Half Duplex data transfer Buffer size Link budget Download opportunities 9 December 2002

  36. MikeHoffmann 9 December 2002

  37. Ground Station Data received in hexadecimal Contains header and footer information (must be parsed) 9 December 2002

  38. Ground Station 9 December 2002

  39. Image Reception Header and footer analyzed to determine how to process image Remaining image data is output as a viewable JPEG image 9 December 2002

  40. Image Reception Ground Station 9 December 2002

  41. Image Reception Ham Radio Info is Removed 9 December 2002

  42. Image Reception UND header is interpreted and removed 9 December 2002

  43. Image Reception End of File Indicator is interpreted and removed 9 December 2002

  44. Image Reception Packet headers are interpreted and removed 9 December 2002

  45. Image Reception Image is displayed 9 December 2002

  46. WarrenWambsganss 9 December 2002

  47. Attitude Control Magnetic torque rods Uses magnetic torque to point satellite Gravity gradient Uses boom (weight) to align with Earth’s gravity gradient Magnetic alignment Makes use of a magnet to align with the Earth’s magnetic field Decreasing Complexity Active Passive 9 December 2002

  48. Active Control Relies on global position system data (GPS) 9 December 2002

  49. Magnetic Alignment Extremely strong Rare-Earth magnets Larger magnets produce more torque Probability of “seeing” Earth increases from 95.88% to 99.25% at 800 km orbit 9 December 2002

  50. Attitude Control • Orientation with magnetic alignment Picture footprint 9 December 2002

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