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Engineering Team Training

Continue with Engineering Team Training. HABET Engineering Team Training. Engineering Team Training. Welcome to Engineering Team Training.

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Engineering Team Training

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  1. Continue with Engineering Team Training HABET Engineering Team Training Engineering Team Training Welcome to Engineering Team Training. This training is currently evolving and is not complete yet. Hopefully within the next few weeks/months it will be completed and everything will be made available to you. As the training is updated, it will be added to this presentation so that you may view it. Some of the links will go to blank pages, so don’t be concerned about that. The Technical Modules that are done so far are: Lithium Battery String Assembly, and Lead-Acid Battery Charging. The LSB-1 Module under Spacecraft types also has some good information in it. Return to the Main Training Menu HABETTeam Menu ESC

  2. HABET Engineering Team Training Engineering Team Training Background Procedures Technical Training Spacecraft Bus Types Sign-Off Return to the Main Training Menu HABETTeam Menu ESC

  3. HABET Engineering Team Training Background This training is meant to help you become a safe and effective member of the HABET Engineering team. The Engineering team’s primary job is the overall construction of flight spacecraft for every HABET mission. This includes the construction of the exterior “box”, the interconnection and testing of the bus (LSB or HSB), and the integration of any scientific or engineering hardware being flown as a payload. Their secondary job is to provide technical support for the Launch Team to ensure a successful launch and mission. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu ESC

  4. HABET Engineering Team Training Engineering Procedures MIB Briefing Spacecraft Bus Test Procedure (LSB-1) MRR Checklist Final Flight Assembly & Test FRR Checklist Engineering Launch Support Post-Flight Spacecraft Check-In Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu ESC

  5. HABET Engineering Team Training MIB Briefing The Mission Initiation Board (MIB) is the first time that an actual mission purpose will have been determined by the EMT. A MMGR for the specific mission will be introduced at this time. Volunteers will be asked to fill the position of Launch, Flight, Recovery, and Engineering Director. At this time there will be a general statement about the purpose of the mission and the Principal Investigator (PI) will give a brief description of the science or engineering portion of the mission. The SSOL Engineering Projects Director will briefly outline the capabilities of the spacecraft and any modifications or new circuitry that must be made to accommodate the PI and the mission parameters. After the MIB has been completed and an ED assigned, it will be the job of the Engineering Team to implement the hardware necessary to make the flight a success! Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  6. HABET Engineering Team Training Spacecraft Bus Test Procedure (LSB-1) The Spacecraft Bus Test Procedure is used to determine if the basic bus is ready to be used for a mission. This procedure will determine if all functions of the LSB are performing within normal parameters. It will check for telemetry transmission, GPS lock, pinhole video, etc. This is to make sure that the particular bus assigned to the mission is flight ready. This procedure may be performed anytime after the MIB, but MUST be done before the MRR. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  7. HABET Engineering Team Training HABET has five complete LSB-1’s. One (and sometimes two) is always being prepared for a mission. The third is used exclusively for the AerE 265Xclass. The fourth is used mostly for development testing by the Engineering Team. The fifth is currently being used by the RGS system. The flight spares and development LSB-1’s are stored in a locked cabinet above the HABET workbench. Retrieve the LSB-1 that has been designated for your particular mission. (You will need the HABET Manager or the SSOL Engineer to open the cabinet for you) Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  8. HABET Engineering Team Training Both battery strings should be measured with a multimeter to ensure that the charge they have left will be enough to perform the tests necessary for this procedure. The battery voltages should be: 12 Volt - at least 11.5 Volts on the meter 9 Volt - at least 8.5 Volts on the meter You will need to get a power source for the LSB-1. There are old batteries (from previous missions) kept on the HABET workbench. These are strictly for testing purposes. You will need one 12 Volt battery and one 9 Volt battery to complete this procedure. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  9. 9 Volt Connector 12 Volt Connector HABET Engineering Team Training The test battery strings can now be connected to the LSB-1. The power connectors are on the bottom side of the LSB-1 mainboard. The 12 Volt connector is the two-pin 0.093 Molex locking connector with red and black wiring. The 9 Volt connector is a three pin 0.062 Molex connector with blue and black wiring. Each of these are unique, so there is no way to install them in the wrong spot or to reverse the wiring. Once the wires are connected, push the batteries against the velcro to hold them in place. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  10. Transceiver connections Solder Joints HABET Engineering Team Training Complete a visual inspection of of all wiring harnesses and connectors at this time. - Check all the 12 Volt and 9 Volt power connectors and wires to make sure they are tight - Check the serial connectors to the RS-232 interface to make sure they are seated properly - Check the 5 Volt connections on the regulator board to make sure they are seated in their connectors properly - Visually inspect the solder joints on the MIM Module to ensure all of them are making contact - Check the connectors to the transceiver to make sure they are tight Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  11. Dummy Load HABET Engineering Team Training Connect the output of the Transceiver (BNC antenna connection) to the large dummy load on the workbench. Use the coaxial cable that is connected to the dummy load. This will absorb the RF radiation being transmitted, so that it will be safe to work on the LSB-1 in the lab. Connect the coaxial cable output of the Emergency Radio Beacon to the coaxial cable connected to the workbench VCR. This will allow you to test the pinhole camera video output to ensure proper operation. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  12. Reset Switch Set (Test Set) External Power Relay Harness HABET Engineering Team Training Install the test set of reset switches. This will allow the LSB-1 to power-up under external power conditions and turn all of the systems on (just as you would during the pre-Launch part of a mission). They can also be used to reset the power to the LSB-1 any time during testing (after disconnecting the external power supply). Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  13. GPS Antenna Connector GPS Antenna Cable HABET Engineering Team Training Locate the antenna cable for the GPS antenna on the roof. It is located on the RGS test bench (directly behind the HABET test workbench). Carefully uncoil the cable and stretch it over to the testing area for the LSB-1. Connect the antenna cable to the GPS receiver on the LSB-1. Make sure the connector is inserted fully to ensure proper contact and good signal propagation to the receiver. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  14. 12 Volt Power Supply Lock Indicator HABET Engineering Team Training Locate the 12 Volt Power Supply on the RGS workbench. It is used to supply power to the GPS antenna on the roof. Turn on the power - the red LED on the Power Supply should be on. Check the black box directly above the Power Supply. It is the unit that routes the power up to the antenna. The green ‘LOCK’ indicator light should be on. This indicates that the antenna is receiving power and should be providing a GPS signal to the receiver at this time. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  15. 12 Volt Lead-Acid Battery Power Connector HABET Engineering Team Training Connect a 12 Volt Lead-Acid battery to the external power connector. HABET test batteries are located on the workbench and are usually kept fully charged. Once the battery has been connected, the cooling fan on the Transceiver should be running. This will be the only outward sign that the system is on. The next step will be to power on the test equipment to verify proper operation of all systems. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  16. HABET Engineering Team Training Power-up the VCR on the workbench. It should be set for channel 59 - if it is not - use the remote to set the channel. The video monitor above the VCR should be showing a picture at this time. If it is not: - Double check the VCR/monitor connections - Double check the connection between the Radio Beacon transmitter and the VCR - Check the 9 Volt battery for proper voltage - Check the power connector at the pinhole camera to ensure the Relay Board is working - Use an oscilloscope to verify that a video signal is coming from the pinhole camera Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  17. HABET Engineering Team Training Power-up the Radio Scanner on the workbench. Set the scanner to the frequency 446.375 MHZ - this is on channel 2. If the scanner is not on channel 2, press the Manual button then the Up or Down arrow to indicate direction of channel change. Press the Manual button until you reach channel 2. Power-up the TNC. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  18. HABET Engineering Team Training On Jupiter, start a terminal program to view telemetry. If in Windows, you may use Hyperterminal. From the Start menu select Programs, Accessories, Hyperterminal. There is a HABET icon in the folder that has all of the test station defaults set for proper reception of data. You may also exit to DOS and use the terminal program TELIX (the same as Flight and Recovery use). If any of this equipment is malfunctioning, you may use the standard Flight gear in the Flight Console area for testing purposes. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  19. HABET Engineering Team Training Allow the LSB-1 under test to run for a minimum of 15 minutes. After this period of time, check the following: - Proper telemetry format on Jupiter or console data computer - Callsign is correct - Analog/digital data appears to be correct - Pinhole video reception is clear on video monitor - Lock has been obtained by the GPS board – this is indicated on the GPS telemetry as a change from 0 to 1 in data field #6 Power down the LSB-1 - Disconnect external 12V lead-acid battery and depress reset switches - Disconnect all test cables - Tag external power connector with green wire tie tag - Place LSB-1 in cabinet Power down test equipment and store cables Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  20. HABET Engineering Team Training MRR Checklist Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  21. HABET Engineering Team Training Final Flight Assembly & Test Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  22. HABET Engineering Team Training FRR Checklist The Flight Readiness Review (FRR) is the last check before flight. The Engineering Team must have the spacecraft that is assigned for the mission ready to go. That means it is ready to fly as if you were going to launch at the end of the FRR. Prior to the FRR, the Engineering Team will need to power-up the spacecraft on external power. This will allow the Flight and Recovery Teams the chance to test their equipment to insure it is flight-ready. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  23. HABET Engineering Team Training Engineering Launch Support After the FRR, the spacecraft that is being flown becomes the responsibility of the Launch Team. However, the Engineering Team will have at least one individual assigned as a Launch support person. The Launch Support Engineer will be responsible for helping the Launch Team determine if the spacecraft is functioning within the parameters determined before flight. They will also be responsible for making sure that the Launch team remembers perform any necessary functions prior to launch. These can include things such as reset buttons pushed, audio beacon turned on, drain plug removed for ballast dump, etc. All of these things will be non-typical for any given flight, and the Launch Team may not be equipped (trained) to perform the necessary functions. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  24. HABET Engineering Team Training Post-Flight Spacecraft Check-In Once the mission has been completed, a Post-Flight Spacecraft Check MUST be performed. Return to the Main Training Menu HABET Eng Procedures Menu HABETTeam Menu HABETEngineering Menu ESC

  25. HABET Engineering Team Training Engineering Technical Training Lithium Battery String Assembly Lead-Acid Battery Charging Wire Harness and Connector Assembly Spacecraft Enclosure Assembly Soldering Circuit Board Design and Layout Circuit Board Etching Cutdown Coil Assembly Lab Equipment Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu ESC

  26. HABET Engineering Team Training Lithium Battery String Assembly HABET uses Lithium Sulphur Dioxide (LiSO2) batteries for all flights. These batteries are lightweight and very powerful. The battery packs for flights are assembled in the lab from military surplus batteries. These batteries come in groups of ten and must be broken apart and then reassembled into the appropriate voltage packs needed by HABET. This segment of training will completely describe this process. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  27. HABET Engineering Team Training Each cell (approx. the same size as a flashlight D-cell) in the surplus package is capable of providing 3V DC. Thus any battery packs made will be a multiple of 3V (i.e. - 3, 6, 9, etc.). Each cell is also capable of providing 7000 milliamphours of power. What this means is that each cell could provide 7000 milliamps of continuous power for one hour before being drained, or 1000 milliamps of continuous power for 7 hours before being drained. As stated earlier, these batteries are very powerful. Contacting the positive and negative terminals together will cause sparking and possible explosion. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  28. HABET Engineering Team Training THESE CELLS ARE NOT RECHARGEABLE!!!!!!! BOOM! Attempts to recharge these batteries will lead to explosion and fire, along with possible personal injury - DO NOT MAKE THIS MISTAKE! Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  29. HABET Engineering Team Training Caution should always be exercised when handling, assembling, and connecting these batteries - they can be hazardous. The picture shown below is evidence of what can happen. This is what was left after a 9V battery pack exploded. It had been mistakenly hooked up to be recharged! Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  30. HABET Engineering Team Training First, the existing surplus batteries must be broken apart so that they may be reassembled into something HABET can use. Cut open the plastic bag and remove the white battery box. Then open the white outer box and remove the battery pack - save the white box - it will be used later in this process. Carefully slice open the lithium battery box at both ends. Remove the battery cells from the box. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  31. Finished battery cell separation HABET Engineering Team Training Carefully pry the rows of cells apart. Cut any wiring that is hanging from the connections - this will include the fuse connector block and the other wiring. Cut the cells apart at the spots shown - leave the other connections between the cells. This will make assembly into battery packs easier later on. There should be four groups of cells: 2 groups of two and 2 groups of three. Cut battery tabs here Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  32. HABET Engineering Team Training Select the appropriate number of cells to make the battery pack (this example will use 4 cells - making it a 12V pack). Align the cells to make their interconnection easier. The positive connection is in the middle of the cell and the negative is along the outside edge of the cell. Connections will be made ‘+’ to ‘-’ to achieve 12V. White cardboard from outer box Cut a piece of cardboard from the white box saved earlier - this will serve to support the cells and keep them from moving. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  33. HABET Engineering Team Training Using the piece of cardboard as a support, tape the cells together with gray duct tape.Be sure to use the gray tape! The battery pack will be color-coded at the end of this procedure with the appropriate color. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  34. HABET Engineering Team Training Cover the bottom of the battery pack with gray duct tape also. Using two pieces of tape, make approximately a double width strip of tape that will cover the bottom plus extra on the end. Place the battery pack in the middle of the tape and fold over the sides. Cut the ends at the points shown to aid in the folding of the tape. The taped battery pack should look as shown below. Cut tape here Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  35. Negative terminal of battery pack Positive terminal of battery pack HABET Engineering Team Training The cells must now be connected to complete the battery pack. The cells that already have their connection strips in place will not need to be altered. However, where the cells have no connection to other cells, they will need to have wiring soldered to them to complete the battery pack. A wiring harness will also be soldered to what will become the positive and negative terminals of the battery pack (see the technical section on soldering for more details on how to solder).Note: the positive terminal of each cell is the middle terminal and the negative terminal of each cell is on the edge of the cell. Interconnection required to complete battery pack to 12V Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  36. Terminals to be connected Duct tape insulation HABET Engineering Team Training Place small pieces of duct tape to insulate the area to be interconnected and soldered.THIS IS CRITICAL! Because these cells are powerful - shorts in wiring can be dangerous and can happen fairly easily (not to mention the fact that failure in flight would be extremely bad!!). Insulation is important to keep this from happening. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  37. Tinned tabs HABET Engineering Team Training Use the heavy-duty soldering gun to make the connections to the cells - they absorb heat very well and the small soldering iron cannot provide enough heat for solder to stick to the metal. Tin (apply solder) the metal tabs that are to be connected - make sure the solder flows well and leave an adequate amount for the wire connection to be made later. Cut a short piece of 18 gauge wire (enough to connect the two tabs). Strip the ends and tin them with solder. Place the wire on the tabs and heat with the soldering gun to make the connection. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  38. Tinned tabs Wire harness (centered) HABET Engineering Team Training Visually inspect the connections for tightness - wiggle the wires to make sure they will not come loose in flight. Cover the connections with another layer of duct tape for insulation. Tin the positive and negative battery pack terminals with solder. Make a wiring harness for the battery pack (see the technical section on Wire Harness and Connector Assembly). Measure the ends so that the main wiring harness will be in the center of the battery pack as shown. The length of the harness that extends from the battery will vary depending on the application. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  39. HABET Engineering Team Training Strip the ends of the wiring harness, ten tin the ends with solder. Solder the wiring harness to the battery pack. Make sure to attach the red wire to the positive terminal and the black wire to the negative terminal -THIS IS CRITICAL!! Once the wiring harness has been soldered in place, double check the connections to make sure they are secure (wiggle and tug on them!). The completed battery pack should look like the one shown below. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  40. HABET Engineering Team Training Cover the top of the battery pack with another layer of duct tape. A double width strip should be used to help protect the terminals and hold the wiring in place. Cut the tape to allow the wiring harness to extend through. When finished the battery pack will look like the one shown below. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  41. HABET Engineering Team Training The battery pack needs to have its final layer of duct tape (finally!). The color of duct tape selected will be based on the voltage of the battery pack - this allows users to visually tell what the voltage is without having to measure the voltage. The color-code is as follows: Blue - 9 Volts Yellow - 15 Volts Red - 12 Volts Green - 24 Volts Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  42. HABET Engineering Team Training Once the colored tape has been applied, write the current date near the bottom of the battery pack with a permanent marker. Check the voltage at the connector end of the battery pack to ensure that all cells are correctly connected and functioning. Once this is done, place the battery in the HABET Engineering cabinet in the appropriate container. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  43. HABET Engineering Team Training Wire Harness & Connector Assembly HABET uses many different types of wiring harnesses for its spacecraft. There are a number of standard types (power supply wiring, etc.). There are also many custom made harnesses for many different purposes - these are usually mission specific and made for each flight. When deciding what type of connector and wire to use, there are a number of factors that will impact what connectors you will use. Wire size will be determined by the amount of current that will be running in the circuit. Connector type will be determined by the set of standard connectors, and what they will be used for. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  44. HABET Engineering Team Training Lead-Acid Battery Charging HABET uses two different types of Lead-Acid batteries during a typical mission. The small battery shown at right is used for such things as the external power for the spacecraft during the fill process. It is also used for powering the Radio Telemetry Unit that the Recovery Team uses. The Recovery Team also uses a large gel-cell Lead Acid battery for powering the video monitor and VCR that are used for pinhole video capture. Proper recharging of these batteries is VERY IMPORTANT! Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  45. Power Supply Multimeter Wire Harness HABET Engineering Team Training To charge the smaller Lead-Acid batteries, you will need the following items: - Elenco Model XP-650 Variable Power Supply - HP 3490A Digital Multimeter - Battery charging wire harness (this should be already attached to the power supply and multimeter) All of these items are on the HABET Test Bench in room 2352. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  46. HABET Engineering Team Training Double check the connections to the Power Supply and the Multimeter. On the Power Supply: - black wire to green (-) terminal - red wire to red (+) terminal On the Multimeter: - orient the connector as shown Double check that the Power Supply and Multimeter are both turned off. Connect the battery to the white two-pin connector. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  47. Voltage Adjust Current Adjust HABET Engineering Team Training Turn on the Multimeter. The voltage shown will be the actual voltage of the battery (before charging starts). On the Power Supply, adjust the voltage knob (left-hand) fully counter-clockwise. This will adjust it to zero volts output Adjust the current knob (right-hand) fully clockwise. THIS MUST BE DONE BEFORE THE POWER SUPPLY IS TURNED ON!! Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  48. Power Switch Current Meter HABET Engineering Team Training Turn on the Power Supply. Carefully adjust the voltage control knob clockwise until the current meter starts to move. The current meter is the one on the right hand side labeled D.C.AMPERE. DO NOT EXCEED 1.0 Amps on the scale reading!!! This could cause the battery to explode and cause serious damage. At the same time, check the voltage on the Multimeter DO NOT EXCEED 14.5 Volts as shown on the Multimeter or explosion and damage may result. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  49. HABET Engineering Team Training Periodically, you will have to check the current and voltage levels on the Power Supply and the Multimeter. As the battery charges, the voltage will increase and the current will decrease. Keep increasing the voltage knob clockwise on the Power Supply until the voltage reading on the Multimeter has reached 14.50 Volts. DO NOT Exceed 1.0 Amps! Once this voltage has been reached, leave the battery connected until the current meter has reached zero. Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

  50. HABET Engineering Team Training Fill in the information on a Battery Recharge Tag. This sheet is on the HABET Engineering workbench area in the middle near the technical notebooks, etc. Apply the Battery Recharge Tag over the end of the battery connector. This will allow anyone to see that the battery has been charged. Once this has been completed return the battery to it’s proper location (i.e. - the Launch Team Box, Recovery Team Box, etc.). Return to the Main Training Menu HABETTeam Menu HABETEngineering Menu HABET Eng Technical Menu ESC

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