High Altitude Balloon Payload Design Project Summer 2012

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

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

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

System Architecture 2012 Payload Computer System Electrical System Mechanical System

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

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

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”

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”

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

Computer Board Decision

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

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

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

SD Shield Decision

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 = 6.67419434MB So the smaller SD cards (200MB to 500MB) should have enough storage.

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

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

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

SD Card Decision

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

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

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.

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

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

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

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

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

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

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

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

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

Internal Temperature Sensor Choice #2 497-1583-1-ND Price: $1.30 Range: -40 to 100degC Temp. Error: +/- 1degC Supply Voltage: 2.98V

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

Internal Temperature Sensor Decision Matrix Function Units Temp. Range Accuracy Cost Total Importance 5 4 LM35CAZ Rating 9 7 25 Factor 45 28 118 497-1583-1-ND 23 36 98 LM35CH 6 22 35 24 104 Final Selection: LM35CAZ Temperature Sensor

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

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

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

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

Gyroscope Decision Matrix Function Units Interfacing Temp. Range Sensitivity Measurement Range Cost Total Importance 5 4 551-1080-1-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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Pressure Sensor Choice #1 SSCSANN005PG3A3 Price: $30.05 Operating Range: -20 to 60degC Input Voltage: 3.3V Accuracy: 2% Measurement Range: 0psi to 15psi

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

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

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

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

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

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

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

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

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.

Budget Sensors(+shipping): $152.85 Batteries: $80.00 Battery Boxes: $6.00 PC Board: $12.00 Wires: $7.00 Total: $257.85

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

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 5.875 in x 5.875 in x 11.8 in (15 cm x 15 cm x 30 cm) The internal volume must be at least 131.6 in3 : 4.5 in x 4.5 in x 6.5 in Vibrations Must be able to withstand frequencies of 20-2000 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

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

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

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

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

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

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

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

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

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

Preferred Configuration – Structural Support

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

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

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

Over-all Preliminary Preferred Configuration

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

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

Project Schedule