Revision / Description / Date
A/B / Conceptual and Preliminary Design Review / 9/15/10
C / Critical Design Review / 11/2/10
D / Analysis and Final Report / 12/04/10

Mission Statement

The BalloonSat “Cloud 9” will rise to an altitude near 30km in order to complete our two missions. Our first mission is a field test of In-Situ’s RDO pro optical oxygen sensor. Our second mission is to acquire 3D images at different elevations.

Mission Objectives

  1. Construct a BalloonSat by 11/5/2010 that will reach altitudes of 30km
  2. We will measure the amount of elemental oxygen in the air using an oxygen sensor
  3. Take 3D images of surroundings
  4. Measure the external relative humidity in the atmosphere

Mission Overview

The satellite on cloud 9 will be completing two independent missions. The first mission will be to test In-Situ’s RDO pro optical oxygen sensor in an open air environment as opposed to its normal application in a water environment. In-Situ Inc. wishes to expand the marketing platform to include atmospheric applications, and needs to verify the performance of the sensor.The second mission is to take 3D pictures from a high altitude balloon satellite. This is to explore methods of obtaining more effective visual data for UAV pilots.

Requirements for O2n Cloud Nine:

In order to achieve this mission the team has to meet requirements set both by the class and by the mission team. The requirements start at level zero, which are the ones that were given to us from class, and go up level by level so that we can meet the requirements set.

Level Zero Requirements

  1. The team shall construct a balloon sat that will ascend to 30km and fly for two hours and will take pictures during the flight
  2. The balloon sat shall weigh less than 850 grams
  3. The construction cost shall not exceed 300 dollars
  4. Satellite shall be built by November 5th, 2010
  5. The satellite shall carry a HOBO data logger and must perform another scientific experiment and will remain above -10 degrees Celsius

Level One Requirements

1.1 The balloon sat will be constructed from foam core, hot glue, and aluminum tape

1.2It shall be launched on a weather balloon on November 6th 2010 to reach the altitude of 30km

1.3The balloon sat shall carry a camera (model??) that will be taking pictures the whole flight

1.4The structure shall be tested in order to ensure that it will survive the atmospheric conditions and to ensure all of our hardware works

2.1 We shall use lightweight materials such as foam core

2.2 The team shall keep a strict weight budget to monitor the total weight

3.1 The team shall ask about possibility for donation of parts

3.2 The team shall keep a strict monetary budget plan to ensure we do not go over budget

3.3 All parts bought above budget shall come from team members

3.4 Any parts bought outside of class shall be verified and reimbursed with receipt

4.1 Team shall hold weekly meetings to work and build satellite and more meetings if needed

4.2 Team shall make a schedule to keep us on track of what should be done

5.1The satellite shall carry the HOBO data logger provided by the class that will record external temperature, internal temperature, and internal humidity

5.2The satellite shall carry an In-Situ oxygen sensor to measure external oxygen levels

5.3The satellite shall carry an Arduino Pro board that will be logging external humidity

5.4The satellite shall fly with a ceramic heater the team built

5.5Camera shall take 3-D pictures using a system of mirrors

Level Two Requirements

1.2.1 The satellite will have a flight tube constructed for the flight string

1.3.1 Camera shall be programmed to take pictures every 20 seconds automatically

1.4.1 Satellite shall pass the whip test, drop test, cold test, and full mission simulation

1.4.2 The hardware shall be tested separately and then, when fully integrated, shall be tested all together to simulate the flight

1.4.3 Camera shall be tested using the mirrors prior to launch

4.1.1 Team shall be split so that each person has parts they are responsible for so that we can split the workload

Technical Overview

Structural – The structure of our BalloonSat “Cloud 9” is cubic, with sides of 15 cm. The cubeis constructed of foam core with aluminum tape and hot glue to hold the edges. Glued onto the two lateral faces are additional foam core flaps measuring 15 cm by 20.2 cm, for the purpose of holding mirrors at 45-degree angles to the face holding the camera window, as shown in the drawings below. In order for our satellite to reach the target altitude we will attach it to a weather balloon by a nylon flight cord through an internal flight tube. The structure thermally isolates the interior by use of one-centimeter thick insulation glued onto the inside of the structure, in addition to a heater which will be discussed in the electrical section below.

Optical – Part of our experiment is to take 3D images throughout the flight. The design uses a digital camera aimed at a system of mirrors to create asimulating retinal disparity (or stereopsis), one of the cues used by human eyes to perceive depth. The camera, as shown in the drawings below, is placed on one end of the structure facing outward through a small holetoward a set of two mirrors fixed at a ninety degree angle to each other and at forty-five degree angles to the face holding the camera. These mirrors direct light into the camera lens from the sides, where two larger mirrors are placed. This second set of mirrors directs light from two parallel views pointing outward into the first set of mirrors and ultimately into the camera lens. The large mirrors are rectangles measuring 15 cm by 8.4 cm, and the small mirrors are 3.3 cm square. The effect of this design is to obtain images of two parallel views, splitting the image recorded by the camera into two separate, nearly identical images. The image recorded by the camera will be split and processed by free Start3D software to create a single image with a sense of depth based on the slight differences in the two images obtained. Because the box is not airtight, anti-fogging agent is applied in order to protect our optical system from condensation.

Electrical – The heater within our satellite is powered by three nine-volt batteries, which are mounted on the inside of our structure. The heater is placed near the electrical components so they do not get colder than 0 degrees Celsius. This subsystem is wired to a switch that is on the outside of our structure so that we can power it on and off.

The HOBO data logger has an internal power source that will allow this system to remain functional for the duration of the flight, but in order to make sure that it does not run out of battery mid-flight we have programmed it to delay the start of data collection until the time of launch. This system logs the external temperature by means of an external probe sticking one inch out of the structure, the internal temperature sensor by means of a thermometer mounted within the HOBO, the internal relative humidity by means of another sensor mounted within the HOBO casing. Our experiment also uses the HOBO data logger to record data from a separately powered oxygen sensor, which is mounted within the box except for a small portion of the sensor that pokes out into the air through a hole in the structure. The oxygen sensor is hooked up to the HOBO via a 4-20mA connection. The power of this system comes from two nine-volt batteries that will be mounted inside our structure using Velcro.

The next subsystem is our camera. We will use our mirrors in order to get one picture split into two parallel views from similar vantage points. The camera uses a 2 GB memory card and has an internal rechargeable battery. Because the camera takes pictures every twenty seconds and will run for about two hours, we expect to take no more than 500 in-flight images, which will fit on the memory card provided.

The last subsystem is our external relative humidity sensor. This is connected to an Arduino Pro board powered by a nine-volt battery connected to a switch in order to log our data. The Arduino Pro board is equipped with its own internal memory that will store the data for the duration of the flight. The Arduino will be mounted to the inside of the structure using Velcro.

Final Parts List

  • $ 0 – Oxygen Sensor donated by In-Situ Inc.
  • $ 0 – HOBO provided by Gateway to Space class
  • $ 0 – External temperature probe
  • $ 0 – Internal temperature probe
  • $ 0 – Relative humidity probe
  • $ 0 – Camera provided by Gateway to Space class
  • $ 9.99 – Mirrors bought from Home Depot (cut two large, two small)
  • $ 0.90 – Bolt and washers for camera mounting
  • $ 16.95 – Relative humidity sensor (HIH 4030 Breakout) from Sparkfun Electronics
  • $ 19.95 – Arduino Pro board (328 – 3.3V/8MHz) from Sparkfun Electronics
  • $ 0 – 1 2 GB memory card donated by Gateway to Space class
  • $ 0 – 6 nine-volt batteries provided by Gateway to Space class
  • $ 34.00 – 4-20mA cable from HOBO Onset Corporation
  • $ 0 – Plastic flight tube provided by Gateway to Space class
  • $ 0 – Foam core provided by Gateway to Space class
  • $ 0 – Aluminum tape provided by Gateway to Space class
  • $ 0 – 2 Washers and paper clips for flight tube and rope attachment provided by Gateway to Space class
  • $ 0 – Heater provided by Gateway to Space class (assembled by team)
  • $ 0 – Insulation provided by Gateway to Space class
  • $ 0 – 2 Switches provided by Gateway to Space class

Illustration and Special Features of our Design

The team’s design includes a digital camera with a system of angled mirrors, which will allow for stereoscopic imaging and provide some sense of depth in the images of clouds obtained. The slanted side on which the mirrors are mounted will allow the camera to point downward toward the clouds in the troposphere for a longer interval. There is an oxygen (O2) sensor and a relative humidity sensor that will take measurements outside the structure.

Budget and Weight Overview

We shall keep our budget by minimizing the cost of all the supplies we require. This can be accomplished by shopping around to find the best value for the components we need. Another step we will follow to avoid going over budget is by going through an approval process for all purchases outside what is built into our budget andBen Woeste will control the purchasing power.

Item / Cost / Subtotal / Purchase Location
O2 Sensor / ~$2250 Donated / $ 0.00 / In-Situ Inc
Glass cutter / $ 3.79 / $ 3.79 / Home Depot
Mirror / $ 9.99 / $ 13.78 / Home Depot
4 to 20 amp cable with built in resistor / $ 34.00 / $ 49.78 / Onset
Arduino Pro 328 - 3.3V/8MHz / $ 19.95 / $ 69.73 / Spark Fun
Humidity Sensor - HIH-4030 Breakout / $ 16.95 / $ 86.68 / Spark Fun
Velcro Strip / $ 5.95 / $ 92.63 / Home Depot
Camera mount hardware / $ 0.90 / $ 92.53 / Home Depot
Total / $ 92.53
Weight (g) / Subtotal (g)
Camera / 130 / 130
HOBO / 35 / 165
Heater / 46 / 211
Oxygen Sensor / 37 / 248
Additional power / 276 / 524
Structure / 180.1 / 704.1
Humidity and arduino / 30.3 / 734.4
Glass Mirrors / 221.8 / 956.2
Mylar mirrors* / ~30
Switches / 15 / 971.2 / 5 each
Flight Tube / 8.4 / 979.6
Total

*Mylar mirrors will replace glass mirrors when they arrive.

Schedule

Organizational Flow Chart

Lea Harris (612-730-3570)

- Team Leader and managing director of the teams, coordinating the team and helping in any of the building, structure, electric, or science teams.

Ian Barry (970-372-7883)

-Head of Structures team, designing the basic plot of the structure and the technical design of how to make our satellite fit to the double camera and multiple sensors.

Ben Woeste-(303-257-6931) Head of the Optical team. Researcher and head of the optical design team for the satellite’s 3-D picture data and constructing the plans for the space inside our box to put the cameras.

Brodie Schulze-(970-629-3832) Head of the Power Team. He will be controlling the research and construction of how the three sensors will be connected to batteries, the two cameras, and the thermal heater. One job will be helping the structures team to place the power components in the satellite.

Caitlyn Cooke-(530-249-2354) Head of the Electrical team that connects the Oxygen sensor to the HOBO sensors and the two cameras to the power. Caitlyn is also the main Software Head for the specialized sensor that requires special data retrieval.

Sebastian-Johannes Lorenz-(303-618-3160) Head of the Thermal Crew. Designating where and how we wish to use the thermal temp controller. Designing the cold tests, and making sure each subsystem is safe while in flight.

Megan O’Sullivan- (832-656-9096) Head of the Health/Safety and Science crew. Megan will be the safe keeper on hand, with help from Lea to control all possible injuries or stress factors. Megan is also the Head of the Science Research to control our satellite’s main systems. This subject is the outer science research that will link all of the different crews together to construct the details of the satellite that don’t fall under the Electric, Optical, Managing, Thermal, and Structural teams.

Testing of our design

There are several tests that were done on our BalloonSat to prepare it for flight. Here is a description of each and how the data acquired helped get our satellite ready for flight. During all of the tests that involve the structure strength we simulated the mass by placing rocks inside.

-The Drop Test:

One stage of this test was dropping our structure down a flight of stairs to simulate the impact on the structure as it hits the ground when it lands. Our structure withstood the impact from the stairs, so we are sure that it can survive the impact with the ground.The second stage of this test was dropping it off a second story ledge to simulate the impact of the landing. Our structure also survived this test with only minor corner damage, so we believe that it will remain intact upon landing. Both tests were done with mass simulations, secured inside our box using Velcro in a similar fashion as our actual flight. One special aspect of our design is that we have an external mirror assembly, which does not need to survive the impact with the ground.

Box after several drops

-The Whip Test:

In this test we attached a flight string to our satellite and swung it around in circles. This test provided two results, one that our flight string interface is strong enough to endure the forces that will be exerted on it from launch and the fall back to the ground. It also told us that our structure will withstand the forces acting upon it during the flight. This test was also done with mass simulations to test the strength. Our structure and mirror assembly survived this test, so most likely it will remain intact for the flight.

-The Cooler Test:

In this test we verifiedthat our internal technology and our insulation will withstand the extreme cold of high altitude. We placed our satellite with all of our technological components inside a cooler with dry ice for three hours to simulate our entire flight.Our HOBO’s internal temperature sensor was running for the test and it verified that with our heater operating we maintained a temperature above 0 degrees Celsius.

-Camera Test

In this test we ensured that our 3D pictures worked, and we tested all the software needed to make the 3D image. We took our camera and mirror assembly, now a right angle and 45 degree angle assembly, and tested taking pictures. Our new assembly works and we are able to get two slightly differing images of a single object. With these two images we can use the online software to create our 3D images.

-Oxygen Sensor Test

We tested our oxygen sensor and its ability to connect with the HOBO by connecting it to the HOBO and running it while plugged into the Boxcar program. We observed that the partial pressure of oxygen dropped when the sensor was introduced to concentrations of nitrogen, as it was supposed to. This test showed that our sensor is properly working and is properly calibrated for our mission.

-Full Mission Simulation:

We also tested our satellite as a whole, to make sure that all the components worked together. Everything worked and everything is now mounted in place, and all switches are mounted on the outside of our structure.

Expected Results

Although our mission has changed slightly, we still expect relatively the same results. We have several sensors on our craft that we expect results from: our oxygen sensor, our humidity sensor, our optical sensor (3D Images). From our oxygen sensor we expect to find an inverse relationship between oxygen levels and elevation. We expect that the oxygen sensor will perform just as well in atmospheric conditions as seen in water environments, and In-Situ will be able to promote this application in any environment. From our humidity sensor we also expect to find an inverse relationship between humidity levels in the atmosphere and elevation. We assume this because we know that, as you get higher in the atmosphere temperatures decrease, and thus water will condense leaving only dry air. We expect that the air will be dry enough to accommodate In-Situ’s testing requirements.