1. High Altitude Balloon Payload Design Project Summer 2012

2. Dr. Brock J. LaMeres -Electrical & Computer Engineering
Design Team:
Jen Hoff (EE)
Kate Ferris (EE)
Alison Figueira (CS)
Makenzie Guyer (CS)
Kaysha Young (ME/MET)
Emily Bishop (ME)
Advisors:
Dr. Brock J. LaMeres -Electrical & Computer Engineering
Dr. Angela Des Jardins -Montana Space Grant Consortium
Hunter Lloyd -Computer Science
Robb Larson -Mechanical & Industrial Engineering
Sponsor:
NASA

3. Mission Objective
To collect measurements at high altitudes of atmospheric temperature and pressure, the internal temperature and dynamic movement of a payload that meets HASP flight requirements.
Budget: $500
Schedule: 8 Weeks
6/4/12 -7/27/12

4. Mission Requirements Functional Requirements Performance Requirements
Log/Store data from the sensors on a non-viotile storage device
Power Sensors and any electronics needed to run these sensors
Protect the system from environmental conditions
Protected from the impact upon landing/jerk from the balloon pop
Provide state of health information of the system
Performance Requirements
Consume 7 watts in order to accurately represent the research team’s thermal output
Log data from the temperature and pressure sensors at a rate of 1 measurement per second
Log data from the accelerometers at a rate of 3 measurements per second
Provide insulation to keep the internal temperature between -40 C and 60C
Must provide at least 4 hours of power for the duration of the setup, flight, and recovery time.
Must withstand an vertical force of 10 G and a horizontal force of 5 G
Physical Requirements
Must weight 1.62 kg
Maximum Total Volume: 15 cm x 15 cm x 30 cm
Must mechanically interface with the HASP payload plate in addition to the BOREALIS system
Reliability Requirements
Must be able to survive preliminary tests and two launches

5. System Architecture 2012 Payload Computer System Electrical System
Mechanical System

6. Computer System Computer System Logging Data Interpreting Data
2012 Payload
Computer System
Electrical System
Mechanical System
Computer System
Logging Data
Interpreting Data
Reading from Sensors
SD Card
SD Shield

7. Computer Design Specifications
Interpreting Data
Must be able to retrieve and store sensor data for 4 hours
Temperature data must be retrieved and logged every second
Pressure data must be retrieved and logged every second
Accelerometer data must be retrieved and logged 3 times every second
Gyroscope data must be retrieved and logged 3 times every second
Logging Data
SD Card
Must operate between -40C and 60C
Must have enough storage for data
Must be compatible with SD Shield
SD Shield
Must be compatible with computer board
Should have a Real Time Clock
Reading from Sensors
Must have enough I/O pins for sensors
Concept:
Interpreting Data & Reading from Sensors:
Computer Board
Logging Data:
SD Card
SD Shield

8. Computer Boards Choice 1: Arduino Mega 2560 Price: $54.95
Digital I/O: 54 pins
Analog I/O: 17 pins
Clock Speed: 16MHz
SRAM: 8KB
Flash: 256KB
Dimensions: 4” x 2.1”

9. Computer Boards (Cont.)
Choice 2:
Arduino Uno
Price: $29.95
Digital I/O: 14
Analog I/O: 6
Clock Speed: 16MHz
SRAM: 2KB
Flash: 32 KB
Dimensions: 2.7” x 2.1”

10. Computer Boards (Cont.)
Choice 3:
Orangutan SVP-1284
Price: $99.95
GPIO: 21
SRAM: 2KB
Dimension: 3.7” x 2.2”

11. Computer Board Decision

12. SD Shields Choice 1: Adafruit Data Logging Shield for Arduino
Price: $19.50
Dimensions: 2.7” x 2”
Additional: Real Time Clock

13. SD Shields (cont.) Choice 2: Seeed Studio SD Shield Price: $13.90
Dimensions: 2.25” x 1.8”
Additional: SDHC support

14. SD Shields (cont.) Choice 3: Your Duino SD Shield Price: $8.50
Dimensions:
Additional: Works with Arduino Uno

15. SD Shield Decision

16. SD Card Storage Pressure: Temperature: Accelerometer: Gyroscope:
Example Line: “2012/6/6 13:30:25,10”
20 characters + ‘\0’ + ‘\n’= 22B per line
Every Second, 14,400s (4hr) = 14,400 lines per file
316,800B per file
2 trips = 633,600B for 2 files
Temperature:
Same as Pressure, 2 sensors = 1,267,200B for 4 files
Accelerometer:
Example Line: “2012/6/6 13:30:25,10,10,10”
26 characters + ‘\0’ + ‘\n’= 28B per line
3 times every second, 14,400s (4hr) = 43,200 lines per file
1,209,600B per file
2 trips = 2,419,200B for 2 files
Gyroscope:
Example Line: “2012/6/6 13:30:25,10,10,10,10”
29 characters + ‘\0’ + ‘\n’= 31B per line
1,339,200B per file
2 trips = 2,678,400B for 2 files
6,998,400B = MB So the smaller SD cards (200MB to 500MB) should have enough storage.

17. SD cards Choice 1: Themis Series Prices: $26 to $62
Storage: 128MG to 2GB
Write Speed: 17.21MB/s
Access Time: 1ms

18. SD cards (cont.) Choice 2: Delkin Devices Prices: $21.95 to $45.57
Storage: 512MB to 2GB
Write Speed: Not listed, probably ~17MB/s

19. SD cards (cont.) Choice 3: Sea Level Price: $34.95 Storage: 1GB
Write Speed: Not listed, probably ~17MB/s

20. SD Card Decision

21. Final Decision Computer Board: Arduino Uno
SD Shield: Adafruit Data Logger
SD card: Delkin Devices SD card

22. Design Start Retrieve Pressure Data
Setup: Define Sensors, start RTC and timers
Loop: Update Timers
A Timer goes off
Retrieve Pressure Data
Interpret Data
Store in RAM
Store on SD card, with timestamp
Back to main program
Event
Temperature
Accelerometer
Gyroscope
Functions follow same format as Pressure

23. Testing Test 1: Test 2: Test 3: Test 4: Connecting sensors to board
Reading from sensors and interpreting data into a useful format
Test 2:
Creating a timer for each sensor, testing efficiency
Test the Real Time Clock on SD shield
Test writing to the SD card
Test 3:
Testing each sensor individually with writing to the SD card
Testing each sensor individually with the timer and writing to SD card.
Test 4:
Testing all sensors and timers with writing to SD card.

24. Budget Material Cost Shipping Total Arduino Uno R3 $29.95 $13.25
$43.20
Adafruit Data Logger
$19.50
$0.00
Industrial SD Card
$62.70

25. Electrical System Electrical System Power System Sensors Interfacing
2012 Payload
Computer System
Electrical System
Mechanical System
Electrical System
Power System
Sensors
Interfacing
Batteries
Temperature
Pressure
Movement
Acceleration

26. External Temperature Sensor
Specifications
Must be able to operate and measure between -55C and 60C
Must be able to read from the sensor every second
Decision Points
Temperature Range
Accuracy
Cost

27. External Temperature Sensor
Choice #1
MAX6605
Price: $0.96
Range: -55 to 125degC
Temp. Error: +/- 5.8degC
Supply Voltage: 2.7V to 5.5V
Supply Current: 4.5 uA

28. External Temperature Sensor
Choice #2
TMP124
Price: $1.62
Range: -40 to 125degC
Temp. Error: +/- 1.5degC
Supply Voltage: -.3V to 7V
Supply Current: 10mA

29. External Temperature Sensor
Choice #3
DS18S20
Price: $5.19
Range: -55 to 125degC
Temp. Error: +/- 2degC
Supply Voltage: 3V to 5.5V
Active Current: 1mA to 1.5mA

30. External Temperature Sensor Decision Matrix
Sensors
Function Units
Temp. Range
Accuracy
Cost
Total
Importance 5 4
MAX6605
Rating 9 3 21
Factor 45 15 36 96
TMP124 2 20 10 91
DS1820 7 25 28
118
Final Selection: DS18S20 Temperature Sensor

31. Internal Temperature Sensor
Specifications
Must be able to measure in the range of -40C to 60C
Must be able to read from the sensor every second
Decision Points
Temperature Range
Accuracy
Cost

32. Internal Temperature Sensor
Choice #1
LM35CAZ
Price: $5.60
Range: -40 to 110degC
Temp. Error: +/- .3degC
Supply Voltage: 4V to 30V

33. Internal Temperature Sensor
Choice #2 ND
Price: $1.30
Range: -40 to 100degC
Temp. Error: +/- 1degC
Supply Voltage: 2.98V

34. Internal Temperature Sensor
Choice #3
LM35CH
Price: $11.35
Range: -40 to 110degC
Temp. Error: +/- .5degC
Supply Voltage: 4V to 30V

35. Internal Temperature Sensor Decision Matrix
Function Units
Temp. Range
Accuracy
Cost
Total
Importance 5 4
LM35CAZ
Rating 9 7 25
Factor 45 28
118 ND 23 36 98
LM35CH 6 22 35 24
104
Final Selection: LM35CAZ Temperature Sensor

36. Gyroscope Specifications Decision Points
Must measure in a 3-D coordinate system
Decision Points
Interfacing
Sensitivity
Measurement Range
Temperature Range
Cost

37. Gyroscope Choice #1 551-1080-1-ND Price: $9.38 Range: +/- 2000deg/sec
Sensitivity: 1.33deg/sec
Operating Temp: -40 to 85degC
Voltage Supply: 2.5V to 3.0V
Size: 3.1x4.1x.83 mm^3

38. Gyroscope Choice #2 L3G4200D Price: $29.95 Range: +/- 2000deg/sec
Sensitivity: 70mdps
Operating Temp: -40 to 85degC
Voltage Supply: 2.4V to 5.5V
Size: .5x.9in

39. Gyroscope Choice #3 L3GD20 Price: $8.48 Range: +/- 2000deg/sec
Sensitivity: 70mdps
Operating Temp: -40 to 85degC
Voltage Supply: 2.4V to 3.6V
Size: 4x4x1 mm

40. Gyroscope Decision Matrix
Function Units
Interfacing
Temp. Range
Sensitivity
Measurement
Range
Cost
Total
Importance 5 4 ND
Rating 6 9 7 36
Factor 30 45 20 28
168
L3G4200D 39
183
L3GD20 8 38 25 32
175
Final Selection: L34200D Gyroscope

41. Sensor’s DC/DC converter
Specifications
Output Voltage: 3.3V
Decision Points
Interfacing
Power Rating
Output Current
Cost

42. Sensor’s DC/DC Converter
Choice #1
IK1203SA
Price: $5.00
Output Voltage: 3.3V
Output Current: 75.7 mA
Input Voltage: 10.8V to 13.2V
Power Rating: 250mW
Size: .24x.46 in

43. Sensor’s DC/DC Converter
Choice #2
 OKI-78SR-3.3/1.5-W36-C
Price: $4.39
Output Voltage: 3.3V
Output Current: 1.5A
Input Voltage: 7V to 36V
Power Rating: 4.95W
Size: .41x.65in

44. Sensor’s DC/DC Converter
Choice #3
 PT5103N
Price: $12.21
Output Voltage: 3.3V
Output Current: 1A
Input Voltage: 9V to 26V
Size: 1x1.02in

45. Sensor’s DC/DC Converter Decision Matrix
Voltage Regulators
Function Units
Power Rating
Interfacing
Output Current
Cost
Total
Importance 4 3
IK1203SA
Rating 9 8 7 33
Factor 36 32 21 27
116
 OKI-78SR-3.3/1.5-W36-C 5 31 20 24
107
PT5103N 30 28
105
Final Selection: IK1203SA DC/DC Converter

46. Computer’s DC/DC Converter
Specifications
Must give a steady output voltage between 7V and 12V
Want a Switcher
Decision Points
Interfacing
Power Rating
Output Current
Cost

47. Computer’s DC/DC Converter
Choice #1
 JCA0212D02
Price: $18.20
Operating Range: -40 to 60degC
Input Range: 9V to 18V
Power: 2W
Output Voltage: 12V

48. Computer’s DC/DC Converter
Choice #2
 ISP1212A
Price: $18.00
Operating Range: -40 to 60degC
Input Range: 9V to 18V
Power: 2W
Output Voltage: 12V

49. Computer’s DC/DC Converter
Choice #3
 NTFS1212MC
Price: $12.11
Operating Range: -40 to 60degC
Input Range: 9V to 15V
Power: 1W
Output Voltage: 12V

50. Computer’s DC/DC Converter Decision Matrix
DC/DC Converters
Function Units
Interfacing
Power Rating
Output Current
Cost
Total
Importance 4 5 3
JCA0212D02
Rating 8 6 7 31
Factor 32 30 24 21
107
ISP1212A 9 27
110
NTFS1212MC 35 36 45
132
Final Selection: NTFS1212MC

51. Accelerometer Specifications Decision Points
Measure in a 3D coordinate plane
Need to measure up to 8 G’s
Decision Points
Interfacing
Sensitivity
Number of Axes
Cost

52. Accelerometer Choice #1 ADXL312 Price: $11.16 Number of Axes: 3
Range: ±12g
Sensitivity: 39 LSB/g
Bandwidth: up to 3.2kHz

53. Accelerometer Choice #2 BMA180 Price: $29.95 Number of Axes: 3
Range: ±8g
Sensitivity: 1024 LSB/g
Bandwidth: up to 1.2kHz

54. Accelerometer Choice #3 ADXL345 Price: $7.75 Number of Axes: 3
Range: ±8g
Sensitivity: 57 LSB/g
Bandwidth: up to 3.2kHz

55. Accelerometer Decision Matrix
Function Units
Interfacing
Sensitivity
Number of Axes
Cost
Total
Importance 3 5 4
ADXL312
Rating 7 9 27
Factor 21 20 45 28
114
BMA180 6 33 24
141
ADXL345 29 36
122
Final Selection: BMA180 Accelerometer

56. Pressure Sensor Specifications Decision Points
The pressure sensor must be able to measure the pressure at 30,480m or 100,000ft above sea level
Decision Points
Interfacing
Range
Sensitivity
Cost

57. Pressure Sensor Choice #1 SSCSANN005PG3A3 Price: $30.05
Operating Range: -20 to degC
Input Voltage: 3.3V
Accuracy: 2%
Measurement Range: 0psi to 15psi

58. Pressure Sensor Choice #2 MPX5100 Price: $9.27
Operating Range: -40 to 125degC
Input Voltage: 5V
Accuracy: 2.5%
Measurement Range: 0 to 100kPa

59. Pressure Sensor Choice #3 HSCDANN030PGAA5 Price: $35.45
Operating Range: -20 to 85degC
Input Voltage: 5V
Accuracy: 1%
Measurement Range: 0psi to 30psi

60. Pressure Sensor Decision Matrix
DC/DC Converters
Function Units
Interfacing
Range
Accuracy
Cost
Total
Importance 4 5 3
SSCSANN005PG3A3
Rating 8 9 29
Factor 32 45 27
113
MPX5100 6 24 40 15
103
HSCDANN030PGAA5 7 25 21
107
Final Selection: SSCSANN005PG3A3

61. Batteries Specifications Decision Points
Must supply up to 4hrs of power
Must supply between 9V and 18V
Decision Points
Weight
Interfacing
Temperature Range
Cost

62. Batteries Choice #1 Energizer Advanced Lithium Price: $1.69/battery
Range: -40 to 60degC
weight: 14.5g
Output Voltage: 1.5V

63. Batteries Choice #2 Energizer Ultimate Lithium Price: $2.27/battery
Range: -40 to 60degC
weight: 14.5g
Output Voltage: 1.5V

64. Batteries Choice #3 Kodak Max Lithium Price: $1.97 /battery
Range: -40 to 60degC
weight: 12g
Output Voltage: 3V

65. Battery Decision Matrix
Battery Names
Function Units
Weight
Temp. Range
Interfacing
Cost
Total
Importance 4 5 3
Energizer Advanced Lithium
Rating 8 9 35
Factor 32 45 27 36
140
Energizer Ultimate Lithium 7 33 28
132
Kodak Lithium 6 18
131
Final Selection: Energizer Advanced Lithium Batteries

66. Testing Burn In Test DC/DC converter test Cold test
Breadboard the design and power the circuit and see how long the batteries will last.
DC/DC converter test
Test to make sure the DC converters are outputting the right values.
Cold test
Put the fully manufactured circuit inside the enclosure and place the enclosure inside the cold lab.

67. Budget
Sensors(+shipping): $ Batteries: $80.00 Battery Boxes: $6.00 PC Board: $12.00 Wires: $7.00 Total: $257.85

68. Mechanical System Mechanical System Structural System Thermal
2012 Payload
Computer System
Electrical System
Mechanical System
Mechanical System
Structural System
Thermal
Enclosure
Vibrations
Material
Structure
Temperature
Attachment
Impact

69. Mechanical Systems Requirements
Thermal
Must be similar to the MSU HASP Research Team structure materials
Polystyrene must be used for the insulation (approx. 1 cm thickness)
A shiny reflective aluminum coating should be applied
Additional material or support structures will be needed to make the structure strong
The internal temperature of the payload must be kept between -40 C and 60 C
Structural System
Enclosure
The external volume may not exceed in x in x 11.8 in (15 cm x 15 cm x 30 cm)
The internal volume must be at least in3 : in x 4.5 in x 6.5 in
Vibrations
Must be able to withstand frequencies of Hz
Attach Enclosure Structure
HASP
Enclosure must securely attach to HASP Plate and not be disconnected for the duration of the flight
Must be easily attached and unattached from the ASP plate for ease of assembly and disassembly
BOREALIS
Must attach to the BOREALIS rope connection system
Impact Forces
Must withstand a vertical impulse force of 10 G’s
Must withstand a horizontal impulse force of 5 G’s
Must withstand a force of 7.25 G’s due to cross winds at 100 Mph

70. Thermal Considerations
Temperature profile
Estimated outside Temperature of the Box
Radiation Energy from Space
&
Radiation Energy from Earth
(from ambient Temperatures of the Earth and Sun)
Tearth = 293 K
Tspace = 2 K

71. Thermal Considerations
Energy Balance
(Sun hitting 3 sides)
(Sun hitting 1 side)
Average theoretical Temperature inside the box with Rvalue = 3 m^2*K/W
Trange1 = ( 40, -10 ) °C
Trange2 = ( 33, -32 ) °C

72. Reflective Aluminum Foil tape Silver Reflective Tape
Surface Properties
Reflective Material
Emissivity (ε)
Absorptivity (α)
α/ε
Aluminum Foil
0.05
0.15 3
Reflective Aluminum Foil tape
Silver Reflective Tape
0.02
0.0044
0.22

73. Decision Matrix – Reflective Material
Weight Factor
Aluminum Foil
Enerflex
Reflective Foil Tape
Silver Reflective Tape
Number
Total
Cost 4 5 20 2 8 16
Ease Manufacturability 3 12
Compliance w/ Research Team 25 15
4.5
22.5
Emissivity (lower = better)
3.5
17.5
Availability
Reliability 18
Compatible with electronics
Totals
134
87.5
137.5
130

74. Decision Matrix - Insulation
Weight Factor
Polystyrene - Extruded
Polystrene - Expanded
Polyisocyanurate
Number
Total
Cost 4 3 12 16
Ease Manufacturability
Compliance w/ Research Team 5 25 20
Weight 9
Reliability
Surface tape can stick to
Compatible with electronics
Totals
110
114
105

75. Material Configuration
Reflective Material
Reflective Material
Insulator Material
Insulator Material
Plaskolite
B.)
D.)
Fiber Glass Cloth
Reflective Material
Reflective Material
Insulator Material
Fiber Glass Cloth
Insulator Material
Plaskolite

76. Decision Matrix – Structural Support
Decision Matrix: Structural Support - any number of these can be combined
Weight Factor
Rebar (3/8)
Rebar Wire
Plaskolite
Fiber glass cloth
L Bracket
Number
Total
Cost 4 16
4.5 18 2 8
Ease Manufacturability 3 12
Added Strength
3.5 14
Interference with thermal properties of insulation (lots of interference = bad) 1 5 20
Ease of integrating with other materials
10.5
Weight (low = better)
Availability 25
Reliability
Totals
111.5
137
131
122
129

77. Structure Configurations
L Brackets for stability and form
Rebar wire for stability and form

78. Preferred Configuration – Material Placement
Reflective Material
Plaskolite Shell
Polystyrene - Extruded

79. Preferred Configuration – Structural Support

80. Mechanical System - Testing
Type of Test
*Drop Test
*Vibrametor Test
*Long Term Thermal Test
*Emittance Test
*Surface Thermal Test
What will be Tested
- Accelerometers
- Structure components
-Structure components
-Insulation
Reflective coating’s surface properties
Heat transfer and absorptivity of insulation and reflective coating

81. Mechanical Systems Mass Budget
Quantity
Weight/Piece (g)
Total Weight
Extruded Polystyrene 1
150
Plaskolite Polystyrene Light Panel 73
16.5 gauge Rebar Tie Wire 8
0.9925
7.94
Brackets 4
22.68
90.72
Bracket Mounting Hardware
26.84
214.72
HASP Mounting Material
232
CCA Stack Mounting Standoff 16
5.9
94.4
Total Mass
862.78

82. Mechanical System Budget
Material
Cost
Extruded Polystyrene
$12.25
Plaskolite Polystyrene Light Panel
$6.47
16.5 gauge Rebar Tie Wire
$4.25
Reflective Aluminum Foil tape
$12.99
Assembly Materials
$38.40
Emergency Funds
$30.64
Total
$105.00

83. Over-all Preliminary Preferred Configuration

84. Project Mass Budget PROJECT MASS BUDGET System Mass (g)
May Not Exceed 1620 g
System
Mass (g)
Mechanical Systems
862.78
Computer Systems
90.72
Electrical Systems
400
Systems Total
1353.5
Mass to be Added
266.5

85. PROJECT BUDGET PROJECT BUDGET System Cost ($) Mechanical 105.00
Not to exceed $500
System
Cost ($)
Mechanical
105.00
Computer Science
62.70
Electrical
257.85
Total
425.55
Additional Funds Available
74.45

86. Project Schedule