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MAKE TO INNOVATE

MAKE TO INNOVATE. Final Review – Spring 2019 Eagle Eye. Project Overview. AGENDA. Activity Report. Design Review. Design Constraints Current Design Proposed Changes Design Risks. Budget Status. Conclusion. PROJECT OVERVIEW. Project Executive Summary. Project Photo. PROJECT OVERVIEW.

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MAKE TO INNOVATE

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  1. MAKE TO INNOVATE Final Review – Spring 2019 Eagle Eye

  2. Project Overview AGENDA Activity Report Design Review • Design Constraints • Current Design • Proposed Changes • Design Risks Budget Status Conclusion

  3. PROJECT OVERVIEW Project Executive Summary

  4. Project Photo PROJECT OVERVIEW From Left to Right, Top to Bottom: Amangeldy Ungarov, Kolton Underberg, Andrew Eschweiler, Kaleb Cornick, Matthew Porter, Josue Oyervides, Jared Witt, Zachary Zeller, Christopher Johannsen, Luke Schaeckenbach, William Steppick, Ryan Nasers, Alex Wagners, Zachary Koehler, Ryan Whitener, Robert Zartman, Christopher Kosirowski Make to Innovate (M:2:I)

  5. Project Faculty Adviser A Ram Kim PROJECT OVERVIEW Project Technical Advisers Matthew Nelson- ISU James Wingerter- ISU Project Team Lead Ryan Whitener- Aerospace Engineering Project Stake Holders Make2Innovate and Iowa Space Grant Consortium PROJECT OVERVIEW Make to Innovate (M:2:I)

  6. Project Organization Chart

  7. PROJECT OVERVIEW Project Objectives • Proof of concept for airborne Martian Rover Semester Goals • Prepare for high altitude testing Semester Deliverables • Finalized structure design and proven temperature capabilities Eagle Eye Spring 2019 Project Plan Make to Innovate (M:2:I)

  8. ACTIVITY REPORT Milestones, Tasks, and Health Report

  9. Mechanical Design

  10. Mechanical Fabrication

  11. Flight Systems

  12. TASK BREAKDOWN • Generated summary from Jira

  13. Cold Chamber Testing PROJECT HEALTH REPORT Tethered Test Flight • Overall, our project is staying on track and should have a successful semester Temperature and Air Density Testing

  14. DESIGN REVIEW Overview

  15. Mechanical Design The Design team is tasked with the responsibility of completing theoretical design of the vehicle. This includes computations, analysis, general design of the vehicle, and verification of the validity of the vehicle’s concept.

  16. Previous Work • Structure evaluation • Deflection • Weight reduction • Reduced to about 15 lbs • Mylar testing/Research • No reply • Returned to weather balloon • Parachute and balloon • Attachment and release • Landing

  17. Swivel Research • Desired Qualities • Supports ~22 lbs • Low Friction • Previous Testing • Successes • Supported max weight of craft (25 lbs) • Easy Attachment • Problems • No rotation under loading

  18. Attachment points and landing • Balloon attachment points • 4 attachment points • burning string for release • Parachute attachment points • 2 attachment points for stability • predictable landing orientation • Added legs on side of craft • opposite side of parachute • soften impact on more vital components

  19. Lift Calculations • 3,000 gram balloon • Payload mass of 25 lbs

  20. Thrust Calculations • Investigating thrust at altitude • Rotor dynamics • Low air density • Other considerations • Wind • Surface area of balloon and craft

  21. Weight Inventory • FAA Limitations • ~50 lb • Current Total Weight • 15.8 lb • Weight budget • Need weight for lift calculations • Reweighed all components for documentation • Design limitations • Under 15 lb

  22. Parachute Dimensions • Brand: Fruity Chutes • Type: Iris Ultra Compact with Spectral Lines • Estimated size at 20 pounds: 72 Inch diameter • Decent rate: 16.70 feet per second

  23. Heat Transfer & Cold Testing • Gondola • Holds avionics and electrical hardware • External motors and servos • Temperature ratings • current loss due to extreme cold • Comsol • Modeling of “Blue Foam” with Boundary conditions

  24. Mechanical Fabrication The Mechanical Fabrication team is tasked with the fabrication and assembly of the Eagle Eye vehicle. This includes material selection, construction, and mechanical testing.

  25. Previous Work • Fabrication of the gondola • Fiberglass side panels made with dimensions of 23.5”x20.5”x7” • Installment of blue styrofoam insulation • Used a 1:1 ratio of West Systems Hardener and Resin to adhere foam to fiberglass • Holes drilled in gondola • Drilled holes in the sides of the gondola for wires to connect to batteries • Development of filling system • Rubber plugs at the end of filling tubes to attach to the balloon

  26. Thermal Insulation Research • Boyd Corporation • Solimide AC-550(H) Insulation • https://www.boydcorp.com/datasheets/SOLIMIDE-AC-550-Data-Sheet.pdf • Temperature range: -200 to +200 degrees Celsius • Semi-open-celled foam which will allow for adjustments to pressure changes • R value of 3.33 per in. • Very expensive

  27. Blue Foam Insulation • R-value of 5 per inch of foam • Much cheaper than solimide ($10 - $20) • Familiarity with material because of use on previous gondolas • Light weight material (approximately 3.5 g/in^2)

  28. Air-tight Solution • Wire Hole Filler: Touch ‘nSeal insulation foam • Polyurethane foam • R-value of 7.12/inch • Enough of it to completely seal the holes • Crack between the lid and the sides • rubber seal meant for in windows • use of large rubber bands/bungee cords/duct tape to keep lid down

  29. Gondola Construction • Dimensions for the space given for the electronics is 15”x13”x4” inside the gondola • Using blue foam in place of solimide, due to price and R-Value • Being a max of 2 inches thick (blue foam), 2 additional layers are needed to make it a total of 5 in. thick • A 5” thickness is desired to keep the electronics just above 32 degrees fahrenheit • Cut each piece to size using hot wire and adjusting to proper size using sandpaper

  30. Cold Chamber Testing • Test will be at Winegard next semester • Simulates the temperatures we will encounter at 100,000 foot altitude • Temperature reaches approximately -50 degrees • Testing to check if gondola properly insulates the electronics

  31. Flight Systems The Flight Systems team is tasked with the operation and maintenance of all avionics components, flight software, flight procedures, and testing parameters for Eagle Eye. The avionics team is also tasked with the operation of the craft during test flights and the documentation of the results.

  32. Previous Work • Avionics Wiring • All power wires have been replaced • Reduced total weight of avionics systems • Wires with higher than needed gages were replaced with more maneuverable smaller gauge wires • Avionics Components • All necessary components owned or ordered • All components weighed and measured • Documentation • Expanded documentation of avionics layout • Increased software documentation including in-code comments and supplemental documentation • Determined camera attachment to rest of avionics

  33. Software Guide • Overview of all software implemented in the Eagle Eye Project • Describes purpose of all functions within the code • Tracks operation of code from start to end of execution

  34. Avionics Documentation • Improved documentation for flight system software and hardware • Clear wiring diagrams will help with future rewiring of craft • Added more inline comments to code base to help improve clarity • Added overview explanation for large blocks of code in the for of Markdown documents • Added rolling requirements document • All documentation updated on GitHub repository Mock up of Avionics System

  35. Avionics Wiring • Assembly of wires contingent on new gondola • Longer wires with smaller gage from ESCs to EDFs • Made a more segmented wire • Makes repair and assembly easier • Preparation for altitude • Must keep avionics above freezing temperature • Heat-sealed wires should withstand extreme low temperatures at high altitude • Sealing the box to retain heat • Can test operation of avionics at Winegard

  36. Avionics On-Board Camera • Resolution: 1080P HD • Frame Rate: 30 FPS (frames per second) • Aspect Ratio: 16:9 • Storage: External microSD Card (2GB - 32GB) • Lens: 2.5mm (EFL), F2.8, 160 degree (diagonal) wide angle lens • Video Output: Composite video • Power Supply: External 3.7V, 1100mAH minimum • Working Temperature: -10degC to +45degC We determined that it would be beneficial to include a flight camera to record our craft, mainly to determine how well it functions and identify problems. May require separate insulation or placement outside of the box due to the shortness of the lens length.

  37. Flight Test Procedures and Parameters • Will be based off of last flight procedure with some minor changes • Flight procedures will be informed by additional research on balloon flight operation • Coordinating with the FAA to decide parameters of the test flight.

  38. Craft Balance • Every Avionics component that will be inside the gondola is weighed and measured • Allows the weight distribution to be estimated mathematically • Avionics layout will be determined by balance and placement of the holes for power wires.

  39. DESIGN REVIEW Constraints

  40. DESIGN CONSTRAINTS • Temperature Insulation • Ranges from -50 degrees Celsius to 20 degrees Celsius • Air Density Performance • Must generate enough thrust to maneuver • Weight Limitations • FAA guideline weight limitation of 55 lbs

  41. DESIGN REVIEW Current Design

  42. CURRENT DESIGN • Weather Balloon Lift • Insulated Gondola • Servo mounted Prop motors • Carbon-Fiber Structure

  43. DESIGN REVIEW Proposed Changes

  44. PROPOSED CHANGES • Moving forward we are adjusting our design based on a redefined scope and enhanced mission statement: Eagle Eye's goal is to make a proof of concept vehicle for an airborne Martian rover that can maneuver in the Martian atmosphere and collect topographical and meteorological data. The end goal for Eagle Eye is for this project to be utilized by a space-bound organization to aid in spatial body exploration.

  45. Mechanical Design • Detailed weight inventory spreadsheet • Everything accounted for • Parachute attachment • Able to withstand opening force • Thrust calculations • Propellers at altitude • Thermal testing • Winegard • Prepare for testing

  46. Mechanical Fabrication • Revamp the gondola to be airtight • Change the insulation within gondola • Polystyrene Blue Foam Board Insulation • Higher R-Value than Solimide • Move away from using an envelop for the craft • Idea of using 1 bladder instead of 2 • Parachute attachment implemented onto the structure • Find best attachment point based on the forces being exerted by the parachute

  47. Flight Systems • Connect all power wires to the avionics systems through the new gondola • Finalize layout of avionics components within the gondola • Ensure balance of the gondola and the overall balance of the craft. • all avionics components must also be securely fastened and accessible • Complete operating and safety procedures for flight tests • Determine parameters for flight tests • Calculate the ability of the craft to move under its own power versus atmospheric conditions • Create list of craft functions to test during the limited flight window • Complete avionics hardware documentation and software user guide • Separate housing or insulation for flight camera

  48. DESIGN REVIEW Design Risks

  49. DESIGN RISKS • Temperature Issues • Servos rated for -20 degrees Celsius • Motor Thrust Values • Currently performing simulations to verify validity • Gondola Insulation

  50. BUDGET

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