Helios Critical Design Review Calder Lane, Courtney Ballard, Ian Thom, Thomas Green, Matt Cirbo, Janelle Montoya Fall 2011 Rev A

Mission Overview Objective: To send a BalloonSat capable of wireless energy transmission to an altitude of 100,000 feet and record data on the efficiency of transmission. Purpose: To evaluate the efficiency of wireless energy transfer at high altitudes for possible application on a larger scale. Hypothesis: The BalloonSat will transmit energy at a moderate efficiency to another satellite and provide it with electricity. Wireless energy transfer would negate several of the problems with photovoltaic arrays today. Weather, atmosphere and other events that block electromagnetic radiation render solar panels on the ground totally useless. However, in space, in the correct orbit, a solar cell bearing satellite could provide and endless stream of energy to Earth through any condition. With several receiving stations, or a high power microwave generator, energy could be produced constantly and consistently.

Requirement Flow Down 1Final flown weight of BalloonSat Helios shall not exceed 850 grams aLightweight materials shall be utilized in lieu of heavier selections. However, such materials shall be durable enough to ensure the satellite remains intact during launch and descent. bAll electrical components shall be designed and arranged in such a manner as to minimize the size of the external structure to reduce weight and increase durability without additional structure where possible. 2A maximum of $250 provided by the class shall be used in purchasing necessary components. aResearch shall be done to identify and purchase quality components for low prices. bWhere possible, components shall be made and/or assemble by the team to eliminate costs of pre-fabrication. For example, the circuit board for transferring power from the solar panels to the laser shall be etched on campus instead of ordered. 3BalloonSat Helios shall be able to record 90 minutes of data during its ascent to 30 km and remain intact during the following descent. aDurable materials that can withstand the shock experienced during burst and the continuous motion during all other points of the flight shall be used. bA carbon-fiber rod shall be used to maintain alignment between the two satellite structures, and the entire structure shall be tested to ensure it maintains its integrity during ascent and does not harm itself during descent. cFoam shall be used to ensure all electrical components are insulated from shock due to motion of the BalloonSat. dAll electrical components shall be able to continue their proscribed tasks at temperatures down to -10 o C, and shall have little to no drop in performance due to temperature where possible. eAn active heating system shall be fabricated and utilized to maintain a temperature of more than -10 o C in the top structure. fA radiating heating system shall be utilized in the bottom box to keep the microcontroller functioning and recording data. gInsulating foam shall be used to maintain a temperature above -10 o C in the upper box and in an appropriate range for the effective use of all electrical components. 4BalloonSat Helios shall record data on the efficiency of transfer of energy with lasers. aA system of six solar panels on the top of the first structure shall gather energy from the sun during ascent. The gathered energy shall then be run through a system designed and built by the team to provide energy to a 50mW laser. bA 50mW laser shall be emitting light from the bottom of the first structure toward a filtered solar panel on the top of the second structure. cThe energy collected by the solar panel on the second structure shall be measure with a volt and ammeter to provide the necessary data for the calculation of watts. dUpon retrieval, the data shall be collected and analyzed. The watts received by the lower panel shall be compared to the known and tested emissions from the laser. This data will also be compared to testing done on the ground to compare the change in efficiency. 5During the fight, a HOBO data logger shall collect internal and external temperature data. aThe HOBO shall be preprogrammed and placed in the top structure of BalloonSat Helios with a temperature probe within and a second sticking out of the structure about 1-2 cm. 6During flight, a Canon SD780 shall take pictures of the exterior environment. aThe Canon SD780 firmware shall be hacked to allow the camera to record images at 10 second intervals during the entire flight.

Design (Proposal Requirements Met) Testing efficiency of laser transfer of Energy Solar panels (both structures) Laser diode Volt-ammeter Satellite shall not exceed 850 grams Lightweight, sturdy materials (i.e. carbon fiber) Effective use of space in structures Data collected during ascent and descent HOBO, temperature cable Canon SD780 (also lightweight) Heater to maintain internal temp (make testing possible) Satellite will remain intact Durable materials Foam for insulation and to avoid shock

Design (Structure) Helios will integrate two separate boxes One box will be used for energy transmission (Sat 1) Sat 1 will be a 15cm cube One will be used to receive energy (Sat 2) Sat 2 will be 9x9x5cm rectangle Sat's 1 and 2 will be connected on the flight string and with two carbon fiber tubes to ensure energy transmission.

Design (Power) Power will be provided by 9 solar cells Solar cells will feed a 3.7 volt 2600mah lithium battery A 3-6 volt 650nm 50 mw red laser will transfer power, wirelessly between the two satellites. Sat 2 will receive power using a 10 th solar cell and route it through a Microprocessor and Volt/Ammeter PCV board A red light filter will be incorporated into Sat 2 for ambient light filtration

Design (Thermal) Three 9 volt batteries in Sat 1 will power a heater Internal Infrared insulation and ambient heat will be used to heat both satellites Sat 2 will integrate extra internal infrared insulation and “waste” heat from the microprocessors. Both satellites will use external insulation as well.

Design (Data Storage) Data will be stored on a 2 Gigabyte micro SD card. Card will be contained within an Arduino card shield Data will be measured by a PCB board with both volt and amp analog outputs. Data will be processed using an Arduino Uno microprocessor. These parts will all be contained within Sat 2

Design Renderings

Box Diagram Volt/Ammeter PCB Board Switch Arduino Uno and Micro SD card Onboard Heater Switch Rechargeable Battery 3x9V Batteries mw Laser Diode Photovoltaic Panel Rechargeable Battery Camera Solar Cells Switch 3.7 Volt lithium battery 2600 mah 2 Gigabyte SD card HOBO Thermometer Barometer Hygrometer Switch

Parts Used Arduino Uno: Arrived 10/3 AttoPilot Sense Breakout 180: Arrived 10/3 MircoSD Shield: Arrived 10/3 3.7 Volt 2600 mAh LG Li-Ion Battery with PCB and Wires Ordered and expected to arrive 10/6-10/7 Solar Cells: Ordered and expected to arrive 10/5-10/7 50mW 650nm laser: Ordered and expected to arrive 10/12 Carbon Tubing: Ordered and expected to arrive 10/5-10/7

Testing We will conduct the drop test, roll test, whip test, and cold test (roll, drop, and whip all on 10/13 and cold on 10/20) We will test the efficiency of the solar cells (10/11) We will test the filter by emitting it to the sun and testing to see how much energy is being produced by just the light from the sun (10/11) We will test to make sure that the solar panel is able to generate energy using the laser (10/20) We will test the alignment of the laser and the solar cell by using the vibration table in the ITLL (10/20)

NameContact InfoMain PositionSecondary Position Calder Lane Team Leader Structure Science Courtney Ballard ThermalElectrical Thomas Green ElectricalProgramming Ian Thom ScienceSafety Matt Cirbo ProgrammingThermal Janelle Montoya Management and Budget Structure Team Organization Chart

Schedule DateTask:Due Fri 9/9-HW 03 Sun 9/11-Project decision - Distribution of proposal responsibilities Tues 9/13-Unification and editing of proposal rough draft -Proposal questions -Discuss date for ITLL shop certification Th 9/15-Finalization of project proposal for turn-in, Assign specializations -HW 04, CoDR Slides Fri 9/16-Turn in project proposal to Prof. KoehlerProposal Fri9/6-Unification of CoDR Presentation Final Draft. -Assign presentation speaker order/run through pres. Th 9/22-Finalize HW 04 -HW 06 Tues 9/27-Meet with Prof. Koehler to order hardware and turn in HW 04 -Distribute responsibilities for CoDR after appointment HW 06 (Before class) HW 04 (At appt.) Th 9/29-HW 05 (Due 10/11) -DD Rev A/B -Begin Construction on structures and electronics Tues 10/4-Pre-Critical Design Review (pCDR)DD Rev A/B

Th 10/6-pCDR Th 10/6-Construction (cont.) Sun 10/9-Have all components to assemble -Construction (cont.) -Ground test laser and solar panels Th 10/13-Complete prototyping design -DD Rev C Th 10/20-Complete cold test -LRR Presentation Tues 10/25-Pre-Launch Inspection (Bring all hardware) Th 10/27-In-Class Mission Simulation Test (Bring BalloonSat) Th 10/27-Finish LRR Presentation Tues 11/1-Launch Readiness Review (LRR)LRR Pres. and DD Rev C 7AM Th 11/3-Design Review -LRR Cards Fri 11/4-Final Weigh-in and Turn In BalloonSatBalloonSat DLC 270A & LRR Cards Sat 11/5-LAUNCH DAY Th 11/10-Data Analysis, Begin DD Rev D Th 11/17-Final Presentation, Assign speaking roles Th 11/24-Finalize Final Presentation/run through pres. -Finish DD Rev D Tues 11/29 & Th 12/1 -Final presentations and reportsFinal Pres 7 AM) Sat 12/3-Design ExpoDD Rev D, Team Vids Tues 12/6-Hardware Turn-In

Budget

Expected Results We expect the satellite to receive low amounts of power in the form of laser radiation and convert it back into useable electricity. This will then be measured in real time and stored for later analysis.

Biggest Worries The laser doesn’t transfer the energy to the solar panel. The carbon tubes are not stable enough to keep the laser pointed to the solar panel. Making the programing compatible to all the components.