Fall 2011 ASEN & ASTR 2500: Gateway to Space

Falling with Style

Fall 2011 ASEN & ASTR 2500: Gateway to Space

University of Colorado at Boulder

Balloon Satellite Proposal

Christopher Koehler

Project Falling with Style

Presented by: Infinity and Beyond

September 17th 2011

Team Members
Adam Archuleta
Katie Cartee
Logan Farley
Patrick Klein
Kamron Medina
Catherine Villa

Mission Statement
The objective of our mission is to test the practicality and capabilities of a near space return-to-Earth vehicle as it falls away from our BalloonSat at approximately eighty-five thousand feet. There are various reasons to develop a vehicle that can return objects to Earth from satellites; ranging from low orbit experiments to data retrieval from the primary satellite. A return to Earth glider can save companies millions of dollars in launch expense since they do not have to take down their orbiter if they need to retrieve a single component or even multiple sections of the satellite depending on the glider’s payload capabilities. For example, the HASP project would be able to send a package on the glider with one of the experiment components back to the laboratory without bringing the entire two ton experiment down (national.spacegrant.org). The primary goal of our mission shall be developing and constructing a vehicle that has the capabilities to survive the harsh conditions associated with high altitude missions and succeed in carrying a payload from a satellite back down to Earth in an affordable fashion. Our secondary objective is to use micro video cameras to create a video of the high altitude environment around the BalloonSat from the point of view of the glider during the ascent, and also record the fall back to Earth after detachment. The video that we capture using the micro video camera will provide the team with video evidence of the high altitude descent of the glider. These videos shall be studied to further the advancement of the glider design and the aerodynamics involved.
Overview
Launching a satellite into orbit is an expensive task requiring large sums of money and an extravagant time commitment. Satellite designers want to benefit as much as possible from each launch and an external drop module or glider provides a method to transport materials back to the surface if recollecting the entire satellite is not necessary, such as time sensitive experiments. A glider is a practical choice because its construction is relatively simple, light, inexpensive, and can travel great distances from the satellite back to a ground station, using little to no fuel. Another proposed method was to usea parachute dropped package. The problem with this idea is that the package would not be able to be directed back to a ground station while a glider has the capabilities to travel long distances during the descent. This is similar to NASA’s X-38 glider that was originally designed to return crew from the ISS (NASA.gov).
The glider that our team plans on producing will serve as a demonstration for the practicality of large-scale applications. The team’s glider will be constructed out of a very strong, lightweight material known as foam core. This small vehicle, with about a 45cm wingspan, will have a small payload consisting of one cell phone (for GPS tracking), and two micro video cameras: one facing forward and the other back so the detachment from the BalloonSat and flight back to Earth can be studied.

Technical Overview
The design of Team Infinity’s BalloonSat shall focus on preserving the success of our primary and secondary missions. Releasing the high altitude glider shall call for an electromagnet release mechanism (planned to release at about eighty-five thousand feet of altitude). The glider will have a unique body and wings that will maximize surface area to catch as much lift as possible. A GPS tracking device will be implemented on the glider in order to attempt a retrieval from its landing location. The GPS tracker will be a stripped cell phone (LX600 LG Lotus).Foam core for both the structure of the BalloonSat and glider will provide a lightweight material for construction.

The video surveillance of the ascent, release, and descent of the high altitude glider is intended to maintain a continuous video recording starting at launch, until its retrieval on the recovery site. Two video recorders shall be placed on the glider, providing a frontward and backward view of the flight path. The weights of the cameras affect the aerodynamics and weight, but testing should give enough data to find the optimal positions to provide the most stable flight path. The provided Canon still frame camera will be programmed to take pictures at regular intervals (every ten seconds). A hole in the side of the BalloonSat will be utilized for the camera to photograph the surrounding area.

After the conclusion of the launch and data analysis, a full report and video report showcasing the build process, launch, and recovery will be provided.

Functional Block Diagram – Satellite

Functional Block Diagram – Glider

Build process
Construction of the satellite entails a structure being built first. The foam core shall be made using a single piece of foam core, with 45 degree angles cut into it (with an X-ACTO knife) at where the edges will be on the cube. Hot glue provides a strong adhesive for the edges. Aluminum tape shall allow for further adhesion on the edges. Inside of the BalloonSat, a thin layer of insulation along with a heater kit is expected to provide enough protection from the elements of the upper atmosphere. A dry ice test shall confirm this once the electronic components have been implemented. A failure of this test will mean a redesign in the heating and/or insulation. Problems arising in structural integrity or complete failure during tests shall mark a rebuild of the cube with a greater emphasis on structure.
Electronics on the interior of the BalloonSat shall then be installed, including the Canon camera with a hacked firmware allowing for an interval between shots. A hole on the side shall be cut to allow a clear view of the camera shots. Afterwards the HOBO, 9V batteries, and its sensor probes will be set in place, with the internal temperature and relative humidity in open areas in the interior, while the exterior temperature probe will be placed through a snugly fit hole and have approximately two inches exposed in the atmosphere. Appropriately sized holes shall be made to accommodate the aluminum tube housing the string. A washer as well as a paper clip may provide enough safety assurance that the knot will not slide through the tube. Two switches and LED on the exterior will be used to control each system and ensure power on the BalloonSat.
An electromagnet provides a necessary hold on the glider, allowing for a clean precise release once the appropriate time is reached on a timing circuit. The time has been calculated using a constant rate of ascent approximating the altitude. Twelve volt batteries will be used to power the electromagnet until the time of release. A metal plate shall be necessary on the bottom of the glider to hold it to the electromagnet. The actual glider shall have the stripped cell phone and cameras attached by a hot glue gun onto the foam core fuselage. Each component carries an internal battery source.
The exterior requires a thermal blanket for insulation. Aluminum tape can be adequately used to adhere the blanketing onto the structure. Stickers of the contact information of the team leader and a United States flag will be visibly taped onto the outside of the structure.

Catherine Villa will manage our budget. She will make sure our team has enough money to buy any more items and keep track of everything already purchased. She will hold onto receipts and record all purchases in an Excel spreadsheet.

Testing

Testing is one of the most important procedures that must be performed on any mission based program because testing is the single most effective method in identifying design and/or build problems. Along with identifying the problems, testing the device gives a simulation of how the BalloonSat will perform in each tested condition. Each system will be rigorously tested individually for all questionable upcoming conditions on the flight. Not only will each system be tested individually, all systems will be combined in the BalloonSat and will be tested extensively to ensure each system works together. The tests that will be performed include: freeze tests, camera tests, drop tests, whip tests, free-fall tests, release tests, and aerodynamics tests.
For the freeze test, each system will be placed in a cooler containing dry ice. While not in direct contact with the ice, each system will experience similar temperatures (-10°C approx.) to expected internal flight temperatures and will be examined for functionality at these temperatures to simulate the temperature inside the BalloonSat near the edge of the troposphere, when the temperature is the coldest. This test will have duration equal to that of our flight, about 2.5hrs while the BalloonSat is operating. During this test, we can make sure we will have sufficient battery life for our cameras. However, the release mechanism needs to be tested at even colder temperatures (-50°C approx.) because the release will be taking place outside of the insulated BalloonSat and will experience much lower temperatures.

The cameras on board have a unique set of requirements that must be met. The still frame camera must take pictures at specific time intervals (every 10 seconds) for the entire flight. This means the camera must be tested to ensure it will take the pictures as programmed for the entire flight. To run the test, the camera’s specific programming will be run while the camera undergoes the freeze test so the team can ensure proper functionality throughout the most difficult conditions. The video cameras will be tested on the same terms as the still frame camera but with some extra testing included: determining the angles to ensure an appropriate field of view of the glider. To do this, the video camera will take a short video while attached to the glider during a test flight.
Structure is a crucial element of our BalloonSat because it protects all of the systems and the mission itself. Because of this, the structure will undergo two tests for durability. The first is known as the drop test, where the structure will be dropped from a height of two stories (6 meters) to simulate a rough landing. Another version of the drop test that will be conducted is dropping the BalloonSat down a flight of stairs so ensure the structure can withstand any number of variable landings, such as bouncing, rolling, or dragging upon landing. The final structural test is the “whip test”, where the BalloonSat will be tied to a string and then swung around to simulate extreme g-forces experienced soon after the balloon burst. Throughout the structural testing, an equal mass inside the BalloonSat will be achieved using weights or rocks that will be positioned similarly to our systems positioning to account for the center of gravity and overall mass.

Dropping a glider from a BalloonSat is one of the most difficult operations that could be performed. Because of this, the glider, release mechanism, and the total apparatus must be tested thoroughly to ensure proper function. At launch of the BalloonSat, the glider will be attached to the side of our BalloonSat. This brings up the matter of launch and ascent survival. As the BalloonSat ascends, it will experience average speed of about 5.5 m/s. We will test the apparatus in the wind tunnel to ensure the glider will not release during the climb. Once at altitude, the release of the glider is crucial. We will test the release mechanism at very low temperatures (around -50°C) to ensure the release of our glider in the appropriate environment. The final test the glider needs to undergo is what we are calling the “freefall test”. The main reason for this test is to observe how the glider will react after release. When released, the glider will be facing the ground with very little air present. We will be dropping the glider from approximately 21 meters in the same fashion that the glider is going to release from the BalloonSat in order to observe whether or not the glider will stabilize and glide as required by the mission.
Safety
Safety is a primary concern regarding the building, testing, and launch of our satellite. Many precautions shall be taken to ensure the safety of the building team and bystanders. No horseplay shall be allowed at any time. While soldering, one shall use protective eye-wear as well as bystanders in immediate area. When cutting with an X-acto knife, one will cut away from themselves at an angle and make sure they are a safe distance from bystanders. Gloves and long sleeved clothing shall be worn while cold testing and dealing with dry ice to prevent burns. Extra caution shall be taken during structure testing to ensure bystanders shall be aware of flying objects and other hazardous *things*. To avoid electrocution during electrical tests, testers and bystanders shall wear protective clothing and use extra caution in the immediate area. During launch day cold weather clothing shall be worn to keep everyone at a healthy temperature.
Schedule:
9/16 12:00 PM Proposal Due
9/20 7:00 AM Conceptual Design Presentation Due
9/25 5:00-9:00 Foam Core Structure and Glider Prototype
10/2 5:00-9:00Drop, Stairs, Whip Tests
10/3 5:00-7:00 Acquire All Hardware
10/4 2:00-5:00 Foam Core Structure Complete
10/9 5:00-9:00 Glider Complete (start testing)
10/10 5:00-7:00 Freefall Test
10/13 7:00 AM Design Document Rev. A/B and Critical Design Presentation Due
10/17 5:00-7:00 BalloonSat Construction Complete
10/18 9:30 AM MID-Semester Team Evaluations Due
10/182:00-5:00 Freeze and Release Mechanism Tests
10/25 2:00-5:00 Glider Camera and BalloonSat Testing Complete
10/27 9:30 AM In-Class Mission Simulation Test (bring “Ready to Go” BalloonSat)
11/01 7:00 AM LRR Presentations and Design Document Rev. C Due
11/04 2:00 PM Final Balloon Sat Weigh In and Turn In and LRR Cards Due
11/05 6:50 AM Launch BalloonSats
11/29 7:00 AM Final Presentations Due and All Data Due in Class
12/03 9:00-4:00 ITLL Design Expo (Design Documents Rev. D and Team Videos Due)
12/06 9:30 AM Hardware Turn In
Team meetings will be ever Sunday from 5-9 PM and every Monday and Tuesday from 5-7 PM Team meetings are tentative due to outside scheduling conflicts and potential necessity for more meetings. Due dates are definite and all requirements will be completed at the designated time.

Bios
Adam Archuleta - Team Leader and Testing Specialist
Adam is currently a freshman at the University of Colorado at Boulder. Studying Aerospace engineering, he enjoys working on miscellaneous home projects ranging from table tennis ball retrieval systems to working grenade launchers. Born and raised in Arvada, CO near West Woods, he spends most of his free time outdoors. A special skill Adam possesses is his ambidexterity, making right and left handed tasks equally stress-free. In the future, Adam hopes to work for or perhaps even start a commercial space program while skiing on weekends.
16240 West 76th Avenue, Phone: (720) 371-2658

Arvada CO 80007 Email:
Katie Cartee- Design and Planning
Katie was born and raised in Anchorage, Alaska and is currently a student at the University of Colorado at Boulder studying Engineering Physics. She enjoys road biking and mountain biking in her spare time.
9119 Andrews Hall Phone: (907) 947-3102
Boulder, CO 80310 Email:
Logan Farley - Troubleshooting and Electronics
Logan is a freshman from the University of Colorado at Boulder currently pursuing a degree in aerospace engineering. He enjoys sports, designing just about anything, and thinking about the universe. A couple special skills of his are the ability to play the cello and sketch/visualize just about anything. He was born in Phoenix AZ.and raised in Boise, Idaho.
5550 N Tumbleweed Pl. Phone: (208) 631-9843
Boise, ID 83713
Patrick Klein - Technician
Pat is an aspiring Aerospace Engineer freshman attending CU-Boulder and intends on getting a BS/MS in 5 years in this discipline. As a member of Colorado Crew, his dedication to an integrated team setting is strong and always willing to become better. His experience includes eleven years of playing with Legos, and a love for Science Channel documentaries. His special skills include (but are not limited to) left-handed guitar and beginning level programming. He was born in Alaska, and raised in Montana.
9178 Cheyenne Arapahoe Hall Phone:(406) 529-7874
Boulder, CO 80310-0008 Email:
Kamron Medina- Structural Engineer and Scheduling Manager
Kamron is a freshman in Aerospace Engineering at the University of Colorado at Boulder. Although he was born in Aurora, he considers Gunnison, Colorado his hometown. The activities he enjoys include spending time with his friends and family, listening to music, and various recreational activities. On this project he will be constructing both the BalloonSat structure as well as the structure of the glider. He will also be in charge of remembering deadlines and scheduling the content of each team meetings. His special skills include sheet metal fabrication and shop experience.