2. Section 1: Mission Overview Mission Statement Mission Objectives Expected Results Functional Block Diagrams Section 2: Changes and Updates Since CDR System Modifications Project Management & Team Updates Schedule Updates 2

3. Section 3: Subsystem Test Reports Subsystems Overview Structural System (STR) Piezoelectric Actuator System (PEA) Electrical Power System (EPS) Visual Verification System (VVS) Section 4: Conclusions Plans for Integration Lessons Learned 3

5. Develop and test a system that will use piezoelectric materials to convert mechanical vibrational energy into electrical energy to trickle charge on-board power systems. 5

6. Demonstrate feasibility of power generation via piezoelectric effect under Terrier-Orion flight conditions Determine optimal piezoelectric material for energy conversion in this application Classify relationships between orientation of piezoelectric actuators and output voltage Data will benefit future RockSAT and CubeSAT missions as a potential source of power Data will be used for feasibility study 6

7. G-switch will trip upon launch, activating all onboard power systems Batteries power Arduino microprocessor and data storage unit Data collection begins Vibration and g-loads on piezo arrays create electric potential registered on voltmeter Current conditioned to DC through full-bridge rectifier and run to voltmeter Voltmeter output recorded to internal memory Data gathered throughout duration of flight 7

8. Data acquisition and storage will enable researchers to monitor input from multiple sources XY-plane vibrational energy Z-axis vibrational energy Researchers will determine if amount of power generated is sufficient for the power demands of other satellites Include visual verification of functionality Use energy from piezo arrays to power small LED Onboard digital camera will verify LED illumination 8

9. Piezoelectric beam array will harness enough vibrational energy to generate and store voltage sufficient to power satellite systems Anticipate output of 130 mV per piezo strip, based on preliminary testing. Success dependent on following factors: Permittivity of piezoelectric material Mechanical stress, which is related to the amplitude of vibrations Frequency of vibrations 9

10. 10 Piezoelectric Power Output Arduino Microcontroller Camera Power Supply Rectifier Piezoelectric Power Output LED Rectifier #1: 3-Axis Accelerometer #2: 3-Axis Accelerometer G-Switch Rectifier Piezoelectric Power Output

11. 11 Piezoelectric Wire Output LED EPS Power Supply Camera

12. 12

13. 13 InputOutputPurpose G-Switch T/FTrue/FalseWrite to SD when T Accelerometer 1 X Voltage Outputs All data output to SD card via “write to file” command Data Collection Accelerometer 1 YData Collection Accelerometer 1 ZData Collection Accelerometer 2 XData Collection Accelerometer 2 YData Collection Accelerometer 2 ZData Collection Bridge Rectifier 1Data Collection Bridge Rectifier 2Data Collection Time (>1000s?)True/FalseEnd write command when T

15. 15 EPS – Electrical Power Subsystem Includes Arduino microprocessor, g-switch, accelerometers, voltmeter, battery power supply, and all related wiring STR – Structural Subsystem Includes Rocksat-C decks and support columns PEA – Piezoelectric Array Subsystem Includes piezoelectric bimorph actuators, cantilever strips, mounting system, rectifier, and related wiring VVS – Visual Verification Subsystem Includes digital camera, LED, and all related wiring

16. 16 XY-plane and Z-axis PEA (top), ZX-plane PEA (left), and “Nonlinear” PEA (right) PEA orientation updates on lower flight deck, full assembly shown

17. 17 Team Kelly Collett – VVS, Testing Christopher Elko – STR, PEA Danielle Jacobson – EPS, Manufacturing Advisor Dr. Jin Kang NEW – Mentee Ian Bournelis Pre-Junior (grad 2014) Will be present at Wallops to help with testing and integration

18. 18 Schedule Currently on track Looking to start full system testing as early as the end of this week (Feb. 17) Concerns Vibe testing

20. 20 PEA – Piezoelectric Array Subsystem – Christopher STR – Structural Subsystem – Christopher EPS – Electrical Power Subsystem – Danielle VVS – Visual Verification Subsystem – Kelly

22. 22 PEA Stress Analysis Point load to simulate mass at end Uniform load to simulate G-loading Maximum stress does not exceed 2000 psi

23. 23 PEA Deformation Analysis Point load to simulate mass at end Uniform load to simulate G-loading Maximum deformation: 0.3 inches

24. 24 STR Stress Analysis Point load at electronic elements Uniform load to simulate G-loading Maximum stress does not exceed 649.6 psi

25. 25 STR Deformation Analysis Point load at electronic elements Uniform load to simulate G-loading Maximum deformation: 0.92 inches

26. 26 Preliminary piezo strip actuator voltage testing for PEA design Preliminary piezo strip actuator LED testing for PEA-VVS interaction

27. 27 Low-Amplitude Random Vibration Entire PEA subsystem assembled on lower deck and subjected to random vibrations. Range of output observed and recorded. Random Vibration Voltage Output Data Z-axisXY-planeZX-placeNonlinear Output Range (VAC) 0.13 - 0.1680.046 - 0.1020.024 - 0.0420.073 - 0.131

28. 28 Low-Amplitude Random Vibration Lessons learned Due to relatively low magnitude of vibration shock (< 1G), actuators did not reach maximum output Masses must be added to improve low-G response, wait to vibe test with higher amplitudes to decide Higher specific voltage output with deflection of “nonlinear” simply supported beam Architecture promotes higher magnitude of elongation strain than free-ended cantilevers

29. 29 PEA Wiring Connection Test Determination of wiring scheme Connected actuators in series, then in parallel Subjected to random deflection to find optimal scenario Lessons learned Better to keep each piezo line separate Because of random vibration, output of one actuator can be out-of-phase with another’s, leading to destructive interference Also enables specific output to be more closely monitored and correlated with accelerometer data Consider adding capacitors to smooth out voltages

30. 30 PEA Fracture Test Determination of bending limits of piezoelectric bimorph actuator strips Secured strip to flat surface with clamp Put end of spindle micrometer in contact with free end of strip, noting starting point Gradually tightened micrometer to failure point of strip PEA Fracture Test setup.

31. 31 DeflectionNotes 1 mm No sign of fracture. 2 mm Design deflection. 3 mm No sign of fracture. 4 mm More torque required. 5 mm Protective layer begins tearing. 6 mm Audible “crackle” ≈ 5.85 mm. 7 mm Increased frequency of crackling 8 mm Tearing becoming visible. 9 mm More audible crackling. 10 mm More audible crackling. 12 mm Voltage output compromised. Will it break?

32. 32 PEA Fracture Test Lessons learned PZT-copper-PZT sandwich designed for maximum deflection of approximately 2 mm without degradation in output Actual safe deflection found to be approximately 5.6 mm, on average Audible PZT fracture began between 6 and 8 mm of deflection, and continued to end of test, around 13.5 mm Despite degradation of PZT crystalline structure, output of fractured actuators remained impressively high, with only about a 40% loss in potential compared to non-deformed strips.

33. 33 Thermal Adhesive Tests Thermal tests will be used to determine thermal expansion of the piezos once adhered to the cantilever. This will ensure that the piezos don’t crack once adhered. Results will determine adhesive to be used. Test Plan Adhere piezo actuator to cantilever material Subject assembly to cyclic thermal environment Bake in oven, then put in freezer

34. 34 Thermal Adhesive Tests Oven heated to 385°F Freezer steady at 25°F No noticeable effects on cantilever integrity Piezoelectric strip exhibited no apparent degradation in output Piezo cantilever assembly in oven (top) and freezer (bottom)

36. 36 Changed sampling rates from 300 bps to 115,200 bps Program to test data transmission: 110,000 characters Data transmits flawlessly at 9600 bps Default rate of our SD card breakout chip

37. 37 Over 140 iterations for data recording Voltage of 3.3V = 686 in data file V= α*Output Where α = 0.0048

38. 38 Demonstrative Video If you would like to see the video, we would be happy to send it to you as a separate file! File is ~57MB

40. 40 Camera Activation Tests will ensure camera relays function properly. Power down requirement includes camera. Camera will be relayed to g-switch to be activated upon launch. Test Plan Connect camera to G- switch, click system on and check that camera turns on and records. Check that video saves at the end.

41. 41 Lessons Learned Good solder connection is crucial Hot glue everything! Camera has wide Field of View Not a bad thing, but something we weren’t expecting We’d put a video here, but it’s ~40MB. If you’d like to see it let us know and we can send it separately. We’d put a video here, but it’s ~40MB. If you’d like to see it let us know and we can send it separately.

43. 43 Plan: Hoping to integrate everything next week We already integrated the PEA and VVS subsystems with the EPS for testing, everything else is mostly hardware and mounting releated Concerns: Vibe testing

44. 44 Vibration Testing Tests will ensure system is structurally sound during vibration. Test Plan Construct and connect full system Use vibe table to simulate Terrier-Orion flight vibration conditions Monitor system connections and structural integrity throughout test Check for data collection on Arduino board and camera at end of tests

45. 45 Spin Testing Tests will ensure system is structurally sound during spin. Test Plan Construct and connect full system Use spin table to simulate spin of Terrier-Orion rocket Monitor system connections and structural integrity throughout test Check for data collection on Arduino board and camera at end of tests

46. What was learned Programming takes forever. Solder joints are fragile—reinforce with hot glue. Don’t put twinkies on your pizza. Do differently Measure twice, cut once. Have an EE member on the team. What’s worked well Coffee. Lots of coffee. 46

48. Reuben Krutz for assistance and guidance with programming Marc Gramlich for assistance with camera teardown and integration Brandon Terranova & Tyler Douglas for allowing us borrow their lab’s precision solder station and helping set up destructive testing 48

49. Concerns Vibe testing 49