EarTh.HOrizon Sensor Manufacturing Status Review at University of Colorado Aerospace Engineering Sciences
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rizon
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Manufacturing Status Review
Manufacturing Status Review
Team
Noah Buchanan
Matthew Busby
Matthew Cirbo
Taylor Dean
Jesse Keefer
Patrick Klein
Thomas Konnert
Cole Oppliger
Neal Stolz
Customers
Joe Breno
Randy Owen
Advisor
Dr. John Farnsworth
10/8/2024
1
University of Colorado Aerospace Engineering Sciences
Outline
•
Overview
•
Schedule
•
Manufacturing
–
Software
–
Electrical
–
Algorithm
–
Mechanical
•
Budget
10/8/2024
2
University of Colorado Aerospace Engineering Sciences
CONOPS
10/8/2024
3
REFERENCE
PITCH DEFLECTION
ROLL DEFLECTION
University of Colorado Aerospace Engineering Sciences
CONOPS
10/8/2024
4
University of Colorado Aerospace Engineering Sciences
Camera Field of View
Sensor Housing
FBD
10/8/2024
5
University of Colorado Aerospace Engineering Sciences
Levels of Success
10/8/2024
6
LEVEL ONE
LEVEL TWO
SENSOR CAPABLE OF
COLLECTING DATA FROM
SIMULATED EARTH AT
ALTITUDE OF 250-750 KM
SENSOR CAPTURES
DATA AND RETURNS
DISPLACEMENT
VECTOR OUTSIDE OF
ECLIPSE
LEVEL THREE
INTEGRATED IN BASIC
HOUSING
TEST DEVELOPED TO
PROVE ECLIPSE
FUNCTIONALITY
LEVEL FOUR
HOUSING MEETS
WEIGHT AND VOLUME
REQUIREMENTS
CAPABLE OF
RECORDING 200
MINUTES OF HEALTH
TELEMETRY
SOFTWARE CAPABLE
OF DETERMINING
DISPALCEMENT
VECTOR TO WITHIN
0.5 DEGREES
POWER
REQUIREMENTS MET.
INPUT OF 22-34 V AND
MAX DRAW OF 5 W
COMMUNICATION
OVER CAN PROTOCOL
AT <388 KBPS
DISPLACEMENT
VECTOR DETERMINED
IN ECLIPSE REGION OF
35 MIN
University of Colorado Aerospace Engineering Sciences
Schedule
10/8/2024
7
MSR
SPRING
BREAK
University of Colorado Aerospace Engineering Sciences
Schedule
10/8/2024
8
Mechanical Manufacturing
Slightly ahead of schedule –
50% complete
Planned finish date: 27 FEB
MSR
SPRING
BREAK
University of Colorado Aerospace Engineering Sciences
Schedule
10/8/2024
9
Powerboard Manufacturing
Behind original schedule – 60% complete
Planned finish date: 27 FEB
Health Sensor Code
Planned finish date: 15 FEB
Physical Camera Interface
Board designed/ordered
Planned finish date: 20 FEB
MSR
SPRING
BREAK
University of Colorado Aerospace Engineering Sciences
Schedule
10/8/2024
10
Camera Interface Software
Slightly behind schedule – 50 % Complete
CAN Communications Code
Begin 3 Feb
Algorithm Production
100% complete
Will require minor adjustments
MSR
1 MAR
SPRING
BREAK
University of Colorado Aerospace Engineering Sciences
Schedule
10/8/2024
11
Software/Algorithm Integration
Passing variables and memory locations
Memory allocation
Timing adjustments and troubleshooting
Analog Video to USB connection
Existing COTS parts
Team experience with USB data transfer
Visual camera via USB
12 March
MSR
1 MAR
SPRING
BREAK
University of Colorado Aerospace Engineering Sciences
Schedule
10/8/2024
12
Full System Testing
MSR
1 MAR
15 APR
SPRING
BREAK
University of Colorado Aerospace Engineering Sciences
Software
10/8/2024
13
University of Colorado Aerospace Engineering Sciences
University of Colorado Aerospace Engineering Sciences
Software
Data Flow
2/
2
/2015
1.
The IR sensor captures a frame and begins
outputting to the DIO pins on the BeagleBone
Black.
2.
PRU0 acts as a software interface, and saves the
data to a buffer in RAM.
3.
Once an entire frame has been stored in RAM,
the CPU is prompted to begin calculating the
displacement vector.
4.
After the displacement vector has been
calculated, it is saved to an SD card with a time
stamp and flag.
14
University of Colorado Aerospace Engineering Sciences
Software
:
Status & Future Work
2/
2
/2015
15
University of Colorado Aerospace Engineering Sciences
Software
: Timing Diagram
10/8/2024
16
0
1
2
3
PRU Initialization
Wait for first falling edge
Save data to RAM
Skip chroma byte
Data is pulled from data lines
University of Colorado Aerospace Engineering Sciences
Software
:
Risk Mitigations
2/
2
/2015
17
Electrical
10/8/2024
18
University of Colorado Aerospace Engineering Sciences
Electrical System: Status
10/8/2024
19
University of Colorado Aerospace Engineering Sciences
Requirements
:
DR.2.2.1 – Monitor operating voltages
and currents
DR.3.5 – Use less than 5 W
DR.3.6 – Accept 22 – 34 V
- Must output 5 V for Tau 2 and BBB
Electrical System: Status
•
All parts have been purchased
•
Built on breadboard
–
Tested to take in 22 – 34 V and outputs a constant 5.06 V
10/8/2024
20
University of Colorado Aerospace Engineering Sciences
Electrical System: Future Work
Major Remaining Tasks
•
Integrate voltage/current sensors into circuit
•
Solder components onto a proto-board
•
Test for voltage transients upon initial power
on
–
If no transients, relays may not be necessary
•
Planned completion 27 Feb
10/8/2024
21
University of Colorado Aerospace Engineering Sciences
Algorithm
10/8/2024
22
University of Colorado Aerospace Engineering Sciences
Algorithm
10/8/2024
23
University of Colorado Aerospace Engineering Sciences
Purpose: To receive and process images from the camera and output pitch
and roll
displacement angles.
Major Requirements:
–
DR.2.1.1 Displacement outputs must be accurate to withing 0.5°.
–
DR.2.1.2 Displacement in pitch and roll must be determined.
–
DR.2.1.3 Displacement angles must be calculated at a rate of ≥ 12 Hz.
Algorithm: Status
10/8/2024
24
•
All major functions needed
for attitude determination
have been written and
tested on the BeagleBone
Black.
•
Algorithm requirements
are being met.
University of Colorado Aerospace Engineering Sciences
Major Remaining Tasks:
•
Manually read image from memory locations
•
Add assertions to check for anomalous
conditions
10/8/2024
25
University of Colorado Aerospace Engineering Sciences
Algorithm: Future Work
10/8/2024
University of Colorado Aerospace Engineering Sciences
26
Mechanical System
Mechanical
10/8/2024
27
University of Colorado Aerospace Engineering Sciences
10/8/2024
University of Colorado Aerospace Engineering Sciences
28
Housing
•
Machined out of Aluminum 6061
•
Dimensions: 4.21 x 3.74” x 2.48”
•
Camera mount redesigned to allow
access to back of camera
Test Stand:
•
Custom 2 DOF Gimbal
•
Machined out of Aluminum 6061
•
No major design changes
Mechanical: Design Solution
Housing
•
Purchased: Metal
•
Manufactured: Top, Bottom, Left,
and Right pieces. Mounting holes
to be drilled.
Test Stand
•
Purchased: Thin-Section ball
bearing and pitch ball bearings
•
Manufactured: Roll Bracket
–
Critical Element: Interference
fit with thin-section ball
bearing
10/8/2024
University of Colorado Aerospace Engineering Sciences
29
Mechanical: Status
•
Machined on CNC mill to 0.0004” tolerance
•
Initial machining attempt unsuccessful
•
Allows sensor housing to roll
10/8/2024
University of Colorado Aerospace Engineering Sciences
30
Roll Bracket (Picture)
Housing:
•
Purchase: Metal for camera mount & screws
–
Lead time: 1 week
–
Setback: None, already 1 week ahead of schedule
•
Manufacturing: CNC Final 3 pieces
–
Front, Back, & Camera Mount
–
Mount camera to within 1/32” in vertical direction
Test Stand:
•
Purchase: L brackets and bolts
–
Lead time: 1 week
–
Setback: none, planned into schedule
•
Manufacturing:
–
CNC face mount for sensor housing to 0.0004” tol
–
Manual milling machines for remaining pieces
–
Measure assembled housing height to 1/32”and
manufacture disk for calculated radius
–
“Earth Disk” manufactured
•
Planned finish 27 Feb
10/8/2024
University of Colorado Aerospace Engineering Sciences
31
Mechanical: Future Work
Future Expenses ≈ $885
10/8/2024
32
University of Colorado Aerospace Engineering Sciences
Budget Status
10/8/2024
33
University of Colorado Aerospace Engineering Sciences
Budget Progress
10/8/2024
34
University of Colorado Aerospace Engineering Sciences
Backup Slides
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10/8/2024
University of Colorado Aerospace
Engineering Sciences
35
•
Power Regulation Board (
DR.3.6)
–
Ensure 22-34V can be input and
converted into two 5V outputs
•
Algorithm (
DR.2.1
)
–
Verify algorithm functionality, speed,
and accuracy meets requirements
•
Inclinometer
–
Verify the functionality and calibrate
for use in manufacturing, camera/BBB,
and full tests
•
Manufacturing (
DR.3.3
)
–
Verify the dimensions of manufactured
components as well as the initial focal
point of the test stand on the disk
10/8/2024
University of Colorado Aerospace
Engineering Sciences
36
Upcoming Testing
Voltage Regulator Testing
10/8/2024
37
University of Colorado Aerospace Engineering Sciences
Ringing in Camera Lines
Problem:
Due to impedance differences between the camera
and the BBB, ringing in lines
may
occur
Testing for Problem
:
Connect BBB and camera and probe with o-scope
Mitigating the Problem
:
-Keeping the lines short
-Digital Line Drivers
-Series resistors in lines to match impedances
10/8/2024
38
University of Colorado Aerospace Engineering Sciences
Power Board with Relays
10/8/2024
39
University of Colorado Aerospace Engineering Sciences
Algorithm Settings
•
Algorithm settings are stored in shell environment variables
•
Environment variables are loaded into globals to reduce the frequency of memory allocation
to increase execution speed
10/8/2024
University of Colorado Aerospace
Engineering Sciences
40
University of Colorado Aerospace Engineering Sciences
Software
: Assembly Code
2/
2
/2015
41
All Test Plans
•
Power Regulation Board
–
Ensure 22-34V can be input and converted into two 5V outputs
•
Algorithm
–
Verify algorithm functionality, speed, and accuracy
•
Software
–
Verify BeagleBone correctly computes algorithm and uses specified components,
communication with camera, health data, and CAN functionality
•
Inclinometer
–
Verify the functionality and calibrate for use in manufacturing, camera/BBB, and full tests
•
Manufacturing
–
Verify the dimensions and weight of manufactured components as well as the initial focal
point of the test stand on the disk
•
Camera/BBB
–
Verify the reception and saving of camera data via the BBB, the functionality of the algorithm
on the BBB
•
Full Test
–
Validate the functionality of all aspects of the project as an integrated unit and determine
what level of success is met
10/8/2024
University of Colorado Aerospace
Engineering Sciences
42
Power Regulation Board Test
•
Purpose
: Ensure the Power Regulation Board takes an input of 22-
34V and outputs 5V for both the camera and microcomputer. The
Board should output 5V regardless of input voltage.
•
Materials
:
–
Power Supply from Trudy’s lab
–
Any lab with proper outlet
–
Voltmeter
–
Completed Power Regulation Board or prototype
10/8/2024
University of Colorado Aerospace
Engineering Sciences
43
Algorithm Test
•
Purpose
: To verify the algorithm produces a reasonably
accurate output less than .5ᵒ at a rate between 12 and 30
Hz. To ensure its functionality prior to larger scale testing.
•
Resources Needed
:
–
BeagleBone Black microcomputer loaded with algorithm
–
Other computer for microcomputer output
–
Group members to critique code
10/8/2024
University of Colorado Aerospace
Engineering Sciences
44
Manufacturing Test
•
Purpose
: Verify the manufactured components of the project (test stand, Earth disk, and sensor
enclosure) closely align to the calculated values. Calculate the error introduced by manufacturing.
•
Materials
:
–
Sensor Enclosure
–
Earth Disk
–
Test Stand
–
Level
–
Inclinometer
–
External Computer
–
Tape Measure
10/8/2024
University of Colorado Aerospace
Engineering Sciences
45
Inclinometer Test
•
Purpose
: Verify the functionality and calibrate for use in manufacturing,
camera/BBB, and full tests
•
Materials
:
•
Inclinometer (ADIS16209)
•
BeagleBone Black
•
External Computer
•
Assembled Test Stand
•
Process
:
–
Connect inclinometer to BeagleBone Black
–
Use written software to establish communication between inclinometer and
BeagleBone Black
–
Run software to collect inclinometer data
–
Verify output is received by BBB with external computer
–
Calibrate inclinometer for zero degrees of displacement at test stand
horizontal perturbation
10/8/2024
University of Colorado Aerospace
Engineering Sciences
46
Test Stand Scaling
10/8/2024
47
University of Colorado Aerospace Engineering Sciences
α
Focal Point
Height
Horizon Disk Radius
Boresight
University of Colorado Aerospace Engineering Sciences
Height Measurement
10/8/2024
48
University of Colorado Aerospace Engineering Sciences
Distance From
Front of Sensor
Housing
Measure distance
between front of
sensor box and
Horizon disk
Total distance of
disk to focal point
< 1/16
th
”
University of Colorado Aerospace Engineering Sciences
Error in Stand Height
10/8/2024
49
•
|
α
–
β
| = Angular Error
•
Stand Height = 4.52”
•
Focal point height must be known to 1/16”
to keep total error below 0.5°
University of Colorado Aerospace Engineering Sciences
Error in Disk Radius
10/8/2024
50
University of Colorado Aerospace Engineering Sciences
•
Disk Radius = 16.00” for 250 km
= 9.07” for 750 km
•
φ
is smaller than pixel resolution for both
250 and 750 km disks
•
Manufacturing tolerance governed by pixel
resolution
•
0.30” for 250 km
•
0.11” (a little less than 1/8
”
)for 750 km
Analog to Digital Test
10/8/2024
51
University of Colorado Aerospace Engineering Sciences
A cheap analog to digital converter has been tested and has shown that it is
possible to use the BeagleBone Black to pull images from the converter.
The converter used had
the wrong chipset for
use with linux, but an
image was still
received.
Good images should be
possible using the
correct chipsets.
Algorithm Settings
10/8/2024
52
University of Colorado Aerospace Engineering Sciences
•
Algorithm settings are stored in shell environment variables
•
Environment variables are loaded into globals to reduce the frequency of memory allocation
to increase execution speed
Error Reduction Polynomials
10/8/2024
53
University of Colorado Aerospace Engineering Sciences
•
Record output over roll and pitch angles between 0°
and 20° at various altitudes
•
User polynomial interpolation to fit an equation to
the measured angle vs actual angle data
•
Interpolate between the polynomial coefficients in
order to come up with equations that give the error
correction polynomial coefficients vs altitude
Error Reduction Polynomials
10/8/2024
54
University of Colorado Aerospace Engineering Sciences
Provide pitch and roll error correction coefficients for a given altitude.
Error Reduction Polynomials
10/8/2024
55
University of Colorado Aerospace Engineering Sciences
Given the measured pitch or roll and the error correction polynomial
coefficients, determine the actual pitch or roll angle.
Algorithm Overview
10/8/2024
56
University of Colorado Aerospace Engineering Sciences
Determining Roll Angle
10/8/2024
57
Roll is the angle between
the sensor y-axis and the
vector from the center of
the sensor frame to the
center of the least squares
circle, (x
c
, y
c
)
University of Colorado Aerospace Engineering Sciences
(x
c
, y
c
)
x
y
Determining Pitch Angle
10/8/2024
58
Calculate Height:
Calculate Pitch Angle:
University of Colorado Aerospace Engineering Sciences
Earth center
y
x
Pitch and Roll Errors
10/8/2024
59
University of Colorado Aerospace Engineering Sciences
Pitch and roll errors are
negligible after error
reduction equation.
DR.2.2.1
Displacements
have errors less
than 0.5
o
Error correction
polynomial reduces
errors to
≤ 0.06
o
University of Colorado Aerospace Engineering Sciences
Software
:
Line Timing, CMOS Protocol
2/1/2015
8-bit Double-Clocked YCbCr CMOS mode (‘YCbYCr’ 4:2:2 Cosited)
10/8/2024
60
University of Colorado Aerospace Engineering Sciences
Software
:
Frame Timing, CMOS Protocol
2/1/2015
10/8/2024
61
University of Colorado Aerospace Engineering Sciences
Software
:
Timing Scheme for CPU and PRU0
2/1/2015
10/8/2024
62
University of Colorado Aerospace Engineering Sciences
Software
:
FBD for CAN communication
2/1/2015
1.
A CAN message is received from the simulated
satellite bus through the DIO pins, which interrupts
the CPU.
2.
The CPU determined if the message is intended for
ETHOS, and saves the message to a buffer in RAM.
3.
If the message is commanding a displacement
vector output, the CPU will finish computing the
displacement vector for the current frame. If the
message is commanding a health telemetry output,
the CPU will sample the voltage and current.
4.
The CPU will send the commanded data over the
CAN bus.
10/8/2024
63
University of Colorado Aerospace Engineering Sciences
Mechanical: Face Mount
2/2/2015
64
5.00”
This comprehensive status review covers various aspects of the EarTh.HOrizon sensor manufacturing project at the University of Colorado Aerospace Engineering Sciences. The status of manufacturing, software development, electrical components, algorithms, mechanical aspects, and budget allocations are detailed through images and descriptions of different phases. The team members involved, customers, and advisor are also highlighted. Progress updates, schedule milestones, and levels of success criteria are outlined, indicating the project's successful advancement in areas like sensor capabilities, housing requirements, telemetry tests, and software functionality. Specific focus areas like sensor data collection, weight/volume requirements, power input/output, and communication protocols are addressed in the context of achieving project objectives.
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Presentation Transcript
EarTh HOrizon Sensor Manufacturing Status Review Team Noah Buchanan Matthew Busby Matthew Cirbo Taylor Dean Jesse Keefer Patrick Klein Thomas Konnert Cole Oppliger Neal Stolz Customers Joe Breno Randy Owen Advisor Dr. John Farnsworth 1 University of Colorado Aerospace Engineering Sciences 10/8/2024
Outline Overview Schedule Manufacturing Software Electrical Algorithm Mechanical Budget Outline Schedule Manufacturing Budget 10/8/2024 University of Colorado Aerospace Engineering Sciences 2
CONOPS REFERENCE PITCH DEFLECTION ROLL DEFLECTION Outline Schedule Manufacturing Budget 3 University of Colorado Aerospace Engineering Sciences 10/8/2024
CONOPS Sensor Housing Camera Field of View Outline Schedule Manufacturing Budget 4 University of Colorado Aerospace Engineering Sciences 10/8/2024
FBD Outline Schedule Manufacturing Budget 5 University of Colorado Aerospace Engineering Sciences 10/8/2024
Levels of Success LEVEL TWO LEVEL THREE LEVEL FOUR LEVEL ONE POWER SENSOR CAPABLE OF COLLECTING DATA FROM SIMULATED EARTH AT ALTITUDE OF 250-750 KM HOUSING MEETS WEIGHT AND VOLUME REQUIREMENTS INTEGRATED IN BASIC HOUSING REQUIREMENTS MET. INPUT OF 22-34 V AND MAX DRAW OF 5 W SENSOR CAPTURES DATA AND RETURNS DISPLACEMENT VECTOR OUTSIDE OF ECLIPSE CAPABLE OF RECORDING 200 MINUTES OF HEALTH TELEMETRY TEST DEVELOPED TO PROVE ECLIPSE FUNCTIONALITY COMMUNICATION OVER CAN PROTOCOL AT <388 KBPS SOFTWARE CAPABLE OF DETERMINING DISPALCEMENT VECTOR TO WITHIN 0.5 DEGREES DISPLACEMENT VECTOR DETERMINED IN ECLIPSE REGION OF 35 MIN Outline Schedule Manufacturing Budget 6 University of Colorado Aerospace Engineering Sciences 10/8/2024
Schedule MSR SPRING BREAK Financial Algorithm Test Mechanical Electrical Software Uncertainty Outline Schedule Manufacturing Budget 7 University of Colorado Aerospace Engineering Sciences 10/8/2024
Schedule MSR SPRING BREAK Financial Algorithm Test Mechanical Electrical Software Uncertainty Mechanical Manufacturing Slightly ahead of schedule 50% complete Planned finish date: 27 FEB 8 University of Colorado Aerospace Engineering Sciences 10/8/2024
Schedule MSR SPRING BREAK Powerboard Manufacturing Behind original schedule 60% complete Planned finish date: 27 FEB Health Sensor Code Planned finish date: 15 FEB Financial Algorithm Test Mechanical Electrical Software Uncertainty Physical Camera Interface Board designed/ordered Planned finish date: 20 FEB 9 University of Colorado Aerospace Engineering Sciences 10/8/2024
Schedule MSR SPRING BREAK 1 MAR Financial Algorithm Test Mechanical Electrical Software Uncertainty Camera Interface Software Slightly behind schedule 50 % Complete CAN Communications Code Begin 3 Feb Algorithm Production 100% complete Will require minor adjustments 10 University of Colorado Aerospace Engineering Sciences 10/8/2024
Schedule MSR SPRING BREAK 1 MAR Software/Algorithm Integration Passing variables and memory locations Memory allocation Timing adjustments and troubleshooting Financial Algorithm Test Mechanical Electrical Software Uncertainty Analog Video to USB connection Existing COTS parts Team experience with USB data transfer Visual camera via USB 12 March 11 University of Colorado Aerospace Engineering Sciences 10/8/2024
Schedule MSR SPRING BREAK 15 APR 1 MAR Financial Algorithm Test Mechanical Electrical Software Uncertainty Full System Testing 12 University of Colorado Aerospace Engineering Sciences 10/8/2024
Software Outline Schedule Manufacturing Budget 13 University of Colorado Aerospace Engineering Sciences 10/8/2024
Software Data Flow 1. The IR sensor captures a frame and begins outputting to the DIO pins on the BeagleBone Black. 2. PRU0 acts as a software interface, and saves the data to a buffer in RAM. 3. Once an entire frame has been stored in RAM, the CPU is prompted to begin calculating the displacement vector. 4. After the displacement vector has been calculated, it is saved to an SD card with a time stamp and flag. Outline Schedule Manufacturing Budget 14 University of Colorado Aerospace Engineering Sciences 2/2/2015
Software: Status & Future Work Projected Completion Date Task Testing Enable PRU & load code Write & test code with LED Feb 1st Load drivers to enable DDR access for PRU Save data to RAM, access from CPU Feb 8th Control LED based on CPU interrupt from PRU pin Interrupt CPU from PRU Feb 15th Configure and receive data from IR camera Correctly display images from IR camera on CPU Feb 25th Trigger horizon algorithm using PRU data Mar 20th Outline Schedule Manufacturing Budget 15 University of Colorado Aerospace Engineering Sciences 2/2/2015
Software: Timing Diagram PRU Initialization Wait for first falling edge Save data to RAM Skip chroma byte Data is pulled from data lines 0 1 2 3 Outline Schedule Manufacturing Budget 10/8/2024 16 University of Colorado Aerospace Engineering Sciences
Software: Risk Mitigations Risk Mitigations Add instruction delay instead of waiting for falling edge 8-bit double-clocked YCbYCr 4:2:2 (45.73 ns) is too fast Mask data on CPU Try 14-bit or 16-bit YCbCr CMOS mode 4:2:2 (95.062 ns) Outline Schedule Manufacturing Budget 17 University of Colorado Aerospace Engineering Sciences 2/2/2015
Electrical Outline Schedule Manufacturing Budget 18 University of Colorado Aerospace Engineering Sciences 10/8/2024
Electrical System: Status Requirements: DR.2.2.1 Monitor operating voltages and currents DR.3.5 Use less than 5 W DR.3.6 Accept 22 34 V - Must output 5 V for Tau 2 and BBB Tau 2 Camera Vin Voltage Regulator 22 34 V 5 V Vin Vout BBB GND Von Vin GPIO R 3.3 V C Outline Schedule Manufacturing Budget 19 University of Colorado Aerospace Engineering Sciences 10/8/2024
Electrical System: Status All parts have been purchased Built on breadboard Tested to take in 22 34 V and outputs a constant 5.06 V Power Board Issues Solution Implemented Yet? Add a capacitor that is charged via 3.3 V pin on BBB. This means the chip is always on Regulator chip needs Von (< 6 V) to let power through Yes Use BBB controlled relays to prevent unregulated voltages from hitting camera Switching Regulators do NOT regulate until there is a load on them No Purchased adjustable regulator chip instead of fixed output Use resistors in feedback loop to control output voltage Yes Outline Schedule Manufacturing Budget 20 University of Colorado Aerospace Engineering Sciences 10/8/2024
Electrical System: Future Work Major Remaining Tasks Integrate voltage/current sensors into circuit Solder components onto a proto-board Test for voltage transients upon initial power on If no transients, relays may not be necessary Planned completion 27 Feb Outline Schedule Manufacturing Budget 21 University of Colorado Aerospace Engineering Sciences 10/8/2024
Algorithm Outline Schedule Manufacturing Budget 22 University of Colorado Aerospace Engineering Sciences 10/8/2024
Algorithm Purpose: To receive and process images from the camera and output pitch and roll displacement angles. Major Requirements: DR.2.1.1 Displacement outputs must be accurate to withing 0.5 . DR.2.1.2 Displacement in pitch and roll must be determined. DR.2.1.3 Displacement angles must be calculated at a rate of 12 Hz. Outline Schedule Manufacturing Budget 23 University of Colorado Aerospace Engineering Sciences 10/8/2024
Algorithm: Status All major functions needed for attitude determination have been written and tested on the BeagleBone Black. Algorithm requirements are being met. Max Error [deg] Max Corrected Error [deg] Mean Error [deg] Mean Corrected Error [deg] Roll 0.8606 0.1256 0.1825 0.0257 Pitch 1.9207 0.0688 1.1090 0.0265 Requirements Current Status DR.2.1.1 Accurate to within 0.5 degrees Successful: Max error = 0.1256 degrees DR.2.1.2 Determine displacement in pitch and roll Successful DR.2.1.3 Calculate displacement with a rate of >= 12 Hz Successful: Average rate = 400 Hz Outline Schedule Manufacturing Budget 24 University of Colorado Aerospace Engineering Sciences 10/8/2024
Algorithm: Future Work Major Remaining Tasks: Manually read image from memory locations Add assertions to check for anomalous conditions Outline Schedule Manufacturing Budget 25 University of Colorado Aerospace Engineering Sciences 10/8/2024
Mechanical System Outline Schedule Manufacturing Budget 26 10/8/2024 University of Colorado Aerospace Engineering Sciences
Mechanical Outline Schedule Manufacturing Budget 27 University of Colorado Aerospace Engineering Sciences 10/8/2024
Mechanical: Design Solution Power Regulator Board BeagleBone Black Housing Machined out of Aluminum 6061 Dimensions: 4.21 x 3.74 x 2.48 Camera mount redesigned to allow access to back of camera Test Stand: Custom 2 DOF Gimbal Machined out of Aluminum 6061 No major design changes Camera 4.21 Camera Mount Outline Schedule Manufacturing Budget 28 10/8/2024 University of Colorado Aerospace Engineering Sciences
Mechanical: Status Housing Purchased: Metal Manufactured: Top, Bottom, Left, and Right pieces. Mounting holes to be drilled. Top Test Stand Purchased: Thin-Section ball bearing and pitch ball bearings Manufactured: Roll Bracket Critical Element: Interference fit with thin-section ball bearing Bottom Left Right Outline Schedule Manufacturing Budget 29 University of Colorado Aerospace Engineering Sciences 10/8/2024
Roll Bracket (Picture) Machined on CNC mill to 0.0004 tolerance Initial machining attempt unsuccessful Allows sensor housing to roll Outline Schedule Manufacturing Budget 30 10/8/2024 University of Colorado Aerospace Engineering Sciences
Mechanical: Future Work Housing: Purchase: Metal for camera mount & screws Lead time: 1 week Setback: None, already 1 week ahead of schedule Manufacturing: CNC Final 3 pieces Front, Back, & Camera Mount Mount camera to within 1/32 in vertical direction Test Stand: Purchase: L brackets and bolts Lead time: 1 week Setback: none, planned into schedule Manufacturing: CNC face mount for sensor housing to 0.0004 tol Manual milling machines for remaining pieces Measure assembled housing height to 1/32 and manufacture disk for calculated radius Earth Disk manufactured Planned finish 27 Feb 2.23 Power Regulator Board BeagleBone Black Camera 4.21 Camera Mount Outline Schedule Manufacturing Budget 31 10/8/2024 University of Colorado Aerospace Engineering Sciences
Budget Status Future Expenses $885 Sensor and Housing, $2,125.84 Margin, $1,985.00 Testing Materials, $626.54 Printing, $50.61 Electronics, $212.01 Outline Schedule Manufacturing Budget 32 University of Colorado Aerospace Engineering Sciences 10/8/2024
Budget Progress $4,124.93 $3,230.92 $3,015.00 $215.92 Projected Total Expected Expenses for Parts Purchased Actual Expenses for Parts Purchased Budget Variance Outline Schedule Manufacturing Budget 33 University of Colorado Aerospace Engineering Sciences 10/8/2024
34 University of Colorado Aerospace Engineering Sciences 10/8/2024
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Upcoming Testing Power Regulation Board (DR.3.6) Ensure 22-34V can be input and converted into two 5V outputs 5V Sensor Power Regulation Board Algorithm (DR.2.1) Verify algorithm functionality, speed, and accuracy meets requirements 22-34V Microcomputer 5V Power Regulation Board CONOPs Inclinometer Verify the functionality and calibrate for use in manufacturing, camera/BBB, and full tests Inclinometer Boresight Manufacturing (DR.3.3) Verify the dimensions of manufactured components as well as the initial focal point of the test stand on the disk Focal Point Height Horizon Disk Radius Inclinometer and Manufacturing CONOPs University of Colorado Aerospace Engineering Sciences 36 10/8/2024
Voltage Regulator Testing 37 University of Colorado Aerospace Engineering Sciences 10/8/2024
Ringing in Camera Lines Problem: Due to impedance differences between the camera and the BBB, ringing in lines may occur Testing for Problem: Connect BBB and camera and probe with o-scope Mitigating the Problem: -Keeping the lines short -Digital Line Drivers -Series resistors in lines to match impedances 38 University of Colorado Aerospace Engineering Sciences 10/8/2024
Power Board with Relays 39 University of Colorado Aerospace Engineering Sciences 10/8/2024
Algorithm Settings Algorithm settings are stored in shell environment variables Environment variables are loaded into globals to reduce the frequency of memory allocation to increase execution speed University of Colorado Aerospace Engineering Sciences 40 10/8/2024
Software: Assembly Code Outline Schedule Manufacturing Budget 41 University of Colorado Aerospace Engineering Sciences 2/2/2015
All Test Plans Power Regulation Board Ensure 22-34V can be input and converted into two 5V outputs Algorithm Verify algorithm functionality, speed, and accuracy Software Verify BeagleBone correctly computes algorithm and uses specified components, communication with camera, health data, and CAN functionality Inclinometer Verify the functionality and calibrate for use in manufacturing, camera/BBB, and full tests Manufacturing Verify the dimensions and weight of manufactured components as well as the initial focal point of the test stand on the disk Camera/BBB Verify the reception and saving of camera data via the BBB, the functionality of the algorithm on the BBB Full Test Validate the functionality of all aspects of the project as an integrated unit and determine what level of success is met University of Colorado Aerospace Engineering Sciences 42 10/8/2024
Power Regulation Board Test Purpose: Ensure the Power Regulation Board takes an input of 22- 34V and outputs 5V for both the camera and microcomputer. The Board should output 5V regardless of input voltage. Materials: Power Supply from Trudy s lab Any lab with proper outlet Voltmeter Completed Power Regulation Board or prototype Measurement How it s Verified Requirement Supply Output Voltmeter measured to be between 22-34V DR.3.6 PRB Outputs Voltmeter measured to be 5V DR.3.6 University of Colorado Aerospace Engineering Sciences 43 10/8/2024
Algorithm Test Purpose: To verify the algorithm produces a reasonably accurate output less than .5 at a rate between 12 and 30 Hz. To ensure its functionality prior to larger scale testing. Resources Needed: BeagleBone Black microcomputer loaded with algorithm Other computer for microcomputer output Group members to critique code Measurement How it s Measured Requirement Pitch/Roll Angle Output Speed Image processing by the algorithm DR.2.1.2 Recorded after vector data is output DR.2.1.3 Error Calculated vector data is compared to actual vector DR.2.1.1 University of Colorado Aerospace Engineering Sciences 44 10/8/2024
Manufacturing Test Purpose: Verify the manufactured components of the project (test stand, Earth disk, and sensor enclosure) closely align to the calculated values. Calculate the error introduced by manufacturing. Materials: Sensor Enclosure Earth Disk Test Stand Level Inclinometer External Computer Tape Measure Measurement Enclosure Focal Point Height Disk Radius Experimental Expected Value 2.48 x 4.21 x 3.74 4.52 .0625 16 .11 ;9.07 .11 90 tan 1?????? How it s Verified Measured value compared to expected value Measured value compared to expected value Measured value compared to expected value Use for comparison to inclinometer angle for test stand error ??? ? (16 ) (9.07 ) 15.79 .14 26.52 .14 Compared to calculated angle, yields error Compared to calculated angle, yields error University of Colorado Aerospace Engineering Sciences 45 10/8/2024
Inclinometer Test Purpose: Verify the functionality and calibrate for use in manufacturing, camera/BBB, and full tests Materials: Inclinometer (ADIS16209) BeagleBone Black External Computer Assembled Test Stand Process: Connect inclinometer to BeagleBone Black Use written software to establish communication between inclinometer and BeagleBone Black Run software to collect inclinometer data Verify output is received by BBB with external computer Calibrate inclinometer for zero degrees of displacement at test stand horizontal perturbation University of Colorado Aerospace Engineering Sciences 46 10/8/2024
Test Stand Scaling Boresight Focal Point Height Horizon Disk Radius Altitude Scaled Horizon Radius Focal Point Height Alpha * Measured by inclinometer 250 km 16 0.30 4.52 0.09 15.79 750 km 9.07 0.11 4.52 0.09 26.52 47 University of Colorado Aerospace Engineering Sciences 10/8/2024 University of Colorado Aerospace Engineering Sciences
Height Measurement Focal Point Distance Relative to Rear Distance From Front of Sensor Housing Measure distance between front of sensor box and Horizon disk Total distance of disk to focal point < 1/16th University of Colorado Aerospace Engineering Sciences 48 University of Colorado Aerospace Engineering Sciences 10/8/2024
Error in Stand Height Change in Height Focal Point Height Bore Sight Nominal Focal Point Height | | = Angular Error Stand Height = 4.52 Focal point height must be known to 1/16 to keep total error below 0.5 Test Horizon Half-Disk Radius 49 University of Colorado Aerospace Engineering Sciences 10/8/2024
Error in Disk Radius Camera Focal Point Focal Point Height Error in Radius Test Horizon Half-Disk Radius Disk Radius = 16.00 for 250 km = 9.07 for 750 km is smaller than pixel resolution for both 250 and 750 km disks Manufacturing tolerance governed by pixel resolution 0.30 for 250 km 0.11 (a little less than 1/8 )for 750 km University of Colorado Aerospace Engineering Sciences 50 10/8/2024
