Team Vision for Detailed Design Phase
During the detailed design phase, the team continued to build upon the preliminary review to set the scope of work for MSD II, as well as order all necessary items BEFORE winter break
Ideal Function
Bill of Material (BOM)
Purchased Materials
| Subsystem | Item | Qty | Unit Cost | Total Cost | Vendor | Ordered | Received | Website |
|---|---|---|---|---|---|---|---|---|
| RF | Glass Mount All-Band Scanner Antenna | 1 | $14.45 | $14.45 | Home Depot | 11/9/2017 | 11/16/2017 | https://www.homedepot.com/p/Tram-Glass-Mount-All-Band-Scanner-Antenna-Tram-1199/300026042 |
| Robustness | Anemometer Wind Speed Sensor | 1 | $44.95 | $44.95 | Adafruit | 11/16/2017 | 11/21/2017 | https://www.adafruit.com/product/1733 |
Electrical BOM
Mechanical BOM
| Subsystem | Item | Qty | Unit Cost | Total Cost | Vendor | Website |
|---|---|---|---|---|---|---|
| Case Management | Aluminum Panel 12x24 0.032 3003 Aluminum Plate 24'' | 1 | $11.24 | $11.24 | SpeedyMetals | https://www.speedymetals.com/pc-98-8373-0032-3003-h14-aluminum-sheet.aspx |
| Case Management | 1/8" {A} x 1" {B} x 1" {C} Angle 6061-T6 Aluminum, Extruded | 1 | $2.34 | $2.34 | SpeedyMetals | https://www.speedymetals.com/pc-2181-8344-1-x-1-angle-6061-t6-aluminum-extruded.aspx |
| Case Management | ICY DOCK 2 x 2.5 Inch to 3.5 Inch Drive Bay SATA SSD/HDD Mounting Kit / Bracket / Adapter - EZ-FIT MB082SP PRO | 1 | $12.97 | $12.97 | Newegg | https://www.newegg.com/Product/Product.aspx?Item=N82E16817994141&cm_re=ssd_mounting_bracket-_-17-994-141-_-Product |
| Case Management | ORICO Tool Free 2.5 inch USB 3.0 SATA External Hard Drive Enclosure for 2.5" SATA HDD and SSD Support UASP and 8TB Drive Max -Black | 1 | $9.99 | $9.99 | Newegg | https://www.newegg.com/Product/Product.aspx?Item=9SIA1DS0JJ2628&cm_re=external_ssd_enclosure-_-0VN-0003-000H1-_-Product |
Link to full BOM
Test Plans
Test Plan and Engineering Requirement Table
| Test Plan Number | Test Plan Name | NOTES | Eng. Requirement Number | Importance | Source | Function | Engineering Requirement (Metric) | Unit of Measure | Marginal value | Ideal value | Applicable Standard |
|---|---|---|---|---|---|---|---|---|---|---|---|
| N/A | N/A | Test not necessary | ER01 | A | CR1 | Functionality | Hardware integration | Pass/Fail | Hardware connected and functional | Hardware integrated and functional. System is robust. | N/A |
| N/A | N/A | Test not necessary | ER02 | A | CR1, CR2 | Ease-of-use | Single Executable for all functions | Method | Standalone File Called by LabView | Seamless Integration with LabView | N/A |
| N/A | N/A | Test not necessary | ER03 | A | CR2 | Accessibility | Point and click GUI | Frustration | Medium | Low | N/A |
| N/A | N/A | Test not necessary | ER06 | B | CR11 | Reliability | Spare parts | Coverage | Consumables+Likely Points of Failure | Complete duplicate for backup | N/A |
| N/A | N/A | Test not necessary | ER14 | B | CR12 | Ease-of-use | Documentation | Coverage | User Manual | User, Service, and Step-by-Step Instruction Manual | N/A |
| N/A | N/A | Compare system against standard | ER05 | A | CR11 | Safety/Reliability | Verify ESD grounding | Pass/Fail | Fail | Pass | ANSI C63.16-2016 |
| TP01 | Auto Calibration Test | Check that switch cycles sources, check dish and ambient data | ER04 | A | CR3, CR4 | Ease-of-use | Auto Calibration | Method | Manual Start | Fully Autonomous | |
| TP02 | Enclosure Test | Standard ordered from outside library, enclosure claims IP66 | ER07 | B | CR11 | Resist Environmental Conditions | Water Resistance | IP Rating | IP54 | IP65 | IEC 60529 |
| TP02 | Enclosure Test | Standard ordered from outside library, enclosure claims IP67 | ER08 | B | CR11 | Resist Environmental Conditions | Dust Resistance | IP Rating | IP54 | IP65 | IEC 60529 |
| TP02 | Enclosure Test | Standard ordered from outside library | ER09 | B | CR11 | Resist Environmental Conditions | Snow/Ice Rating | Nema Rating | Nema 3 | Nema 3S | NEMA 250-2014 |
| TP03 | Lightning Arrestor Test | ER10 | B | CR11 | Resist Environmental Conditions | Lightning Suppression | Volts | 90 | 90 | IEEE C.62.31-2006; IEEE C.62.62-2010 | |
| TP04 | Temperature Test | ER11 | B | CR11 | Resist Environmental Conditions | Operational Temperature Range | deg C | (-10:30) | (-32:40) | N/A | |
| TP05 | Adverse Weather Test | ER12 | B | CR11 | Resist Environmental Conditions | Adverse weather mode | Method | Manual Trigger | System Detection | N/A | |
| TP06 | Data Transfer Test | ER14 | B | CR4, CR13 | Data Security | Data transfer to Zurich server | Frequency | Daily | Every 15 minutes | ||
| TP06 | Data Transfer Test | ER16 | C | CR4, CR9 | Data Security | Auto backup to ASRAS Server | Pass/Fail | No auto-backup | Auto-backup to ASRAS server | ||
| TP06 | Data Transfer Test | ER18 | C | CR9 | Data Security | Swappable Data Drives | Method | Manual | Local server available, no need for swapping | N/A | |
| TP07 | Auto Shutdown Test | ER15 | B | CR4, CR5, CR9, CR11 | Reliability+Data security | Auto-shutdown during power outage | Pass/Fail | Auto Shutdown only | Auto shutdown and auto startup when power is restored | ||
| TP08 | Tracking Test | ER17 | C | CR6 | Research | Track top 40 emitters in the night sky | Number of emitters | Any | 40 | N/A | |
| TP08 | Tracking Test | ER21 | A | CR5 | Ease-of-use | Track Sun autonomously | Square degrees | 12.5651 | 0.7854 | N/A | |
| TP09 | Stack Light Test | Stack Light Engineering guide | ER19 | D | CR15, CR16 | Safety/Reliability | Operation Indicator Light | Method | Charged by main power | Charged by solar power | IEC 60073 |
| TP10 | Visible Spectrum Scope Test | ER20 | D | CR7 | Ease-of-use | Visible spectrum scope | Pass/Fail | Visible snapshot pulled from web | Visible spectrum of the sun displayed in GUI | N/A |
Preliminary Test Plans Summary
TP01 Auto-Calibration Test Plan
- Setup Callisto to collect data and the Arduino to control the RF switch
- Switch input to 50 ohm stub
- Switch input to white noise generator
- Switch input to ambient dipole
- Switch input to dish line
- Make sure inputs were switched properly
- Compare gathered data to expected values
TP02 Enclosure Test
- Enclosure test to confirm IP66 and NEMA Rating rating
- IP66: Must be completely dust tight, watertight even in direct jets. IEC 60529
- NEMA 4 compliance: undamaged by formation of ice on external structure. NEMA 250-2014
- Manufacturer claims enclosures are IP66 and NEMA 4/12/13 compliant
- Remove all internal electronic equipment from enclosure
- Assemble enclosures with tubing for conduit (shell unit)
- Replace exterior connectors with sacrificial connectors
- Line all seams with Liquid Contact Indicator tape
- Line location of sensitive electronics with LCI
- Subject to spray per IEC 60529
- Leave outdoors to allow ice formation/Put in snow
- Allow ice to thaw, exterior water to dry (wipe off as necessary
- Check LCI for water contact in all areas
TP03 Lightning Arrestor Test
- Setup circuitry to deliver over 90 volts to the lightning arrestor
- Produce the trip condition for the arrestor (90 volt input)
- Observe the fuse to be sure that it broke connection
- Repeat for DC and AC voltages in the range of 0 to 3 GHz
TP04 Temperature Test
- Test Internal temperature to rise no higher than 75 degrees
- No way to test for solar radiation on worst case scenario day, confirm thermal model instead
- Internal temperature sensor will be utilized
- Processor temperature sensor will be utilized
- Exterior temperature sensor/thermometer to get ambient temperature
- Run CPU intensive benchmark on computer indoors to generate heat, to determine internal heat generation for steady state. Record processor, interior and ambient temperatures.
- Place unit in direct sunlight away from wind with device off, record steady state interior and exterior temperature
- Run CPU intensive benchmark in direct sunlight away from wind, record steady state processor, interior and exterior temperature.
- If model and results agree within 5%, validate model.
TP05 Adverse Weather Test
Test System ability to detect adverse weather conditions and take precautions- Obtain shop air hose fitted with nozzle
- Measure shop air with cup anemometer
- Set adverse weather mode to trigger at half of shop air speed
- Put system to operation
- Blow shop air to trigger “adverse weather”
- Trigger all clear
- Confirm system resumed operation successfully
TP06 Data Transfer Test
Test system ability to transfer data to Zurich Switzerland.- Configure Callisto data transfer with remote test server
- Copy sample FIT files into Data directory
- Start Callisto data transfer software
- Verify transfers are automatically started
- Disconnect internet while transfers are active and unfinished
- Verify error condition is recorded by Callisto data transfer software
- Reconnect internet
- Verify transfers are automatically restarted and completed
- Verify FIT files moved from Data folder to Archive folder
- Compare files stored in Archive with those on the server
- Plug external data transfer SSD into computer system
- Verify archived FIT files are automatically transferred to external SSD
TP07 Auto Shutdown Test
Test System ability to experience a power loss, both momentary and permanent. System should stay online for 5 minutes to prevent momentary power loss from causing system shutdown- Set system operation to normal
- Unplug power temporarily, plug back in
- If system did not shut down, unplug power, wait 5 minutes, replug
- If system did not shut down, unplug power, wait 10 minutes. System should shut down
- Plug system back in. System should resume operation. Confirm this.
Unplug system until shutdown is triggered. Replug system in during shutdown. System should reboot as it detects power restoration After system resumes proper operation, plug, and unplug the power periodically. After a certain number of periods, the system should shut down regardless of power supply state. Continue cycling to ensure system does not power on until system stops power cycling for 5 minutes
TP08 Tracking Test
This test must be performed after system has been successfully installed on site.- Set system to operate for 3 days with no datum reset (let backlash error accumulate)
- Determine system drift in both azimuth and pitch (separately). Extrapolate error over a year
- Set system to operate for 3 days with datum reset only in azimuth
- Determine system drift in both azimuth and pitch (separately). Extrapolate error over a year
- Set system to operate for 3 days with datum reset only in pitch
- Determine system drift in both azimuth and pitch (separately). Extrapolate error over a year
- Set system to operate for 3 days with both datum resets
- Determine system drift in both azimuth and pitch (separately). Extrapolate error over a year
TP09 Stack Light Test
This test is to ensure that 3v UART is able to communicate over the distance we need it to. The Desired travel distance is about 10 feet. This test will require the Arduino Mega, an MSP430, a length of wire, and a test code that will send and receive data using UART.- Connect the Mega and MSP430 using the RX and TX lines.
- Set the Baud rate to 9600.
- Send and receive a series of data to and from the Mega to the MSP430.
- The MSP430 will have and LED indicator if it receives data that it doesn’t expect or doesn’t know how to handle.
- Adjust Baud rate until the MSP430 can receive the correct data.
TP10 Visible Spectrum Scope Test
Visible spectrum scope has to demonstrate ability to get images of sun and integrate with system- Set system to track sun on clear day
- Obtain image of visible sun
Design and Flowcharts
Existing System
Proposed System
LabVIEW FITS file reader system
Source VI and compiled executable
http://www.ni.com/download/labview-run-time-engine-2013/4059/en/
LabVIEW 2013 32-bit runtime is required (free download) to run the executable if LabVIEW 2013 32-bit is not already installed. Source VI is available for recompilation. Debugging must be turned on for successful recompilation
VI will work in any 32-bit library, GFITSIO library ONLY works in 32-bit LabVIEW
Software Design
Overview of project from software perspective. Main software effort will be outlined area; ASCOM API/RadioEyes will be unchanged, and Arduino/Stack Light will be part of EE development.
The HTTP/JSON protocol will allow LabVIEW and other client UIs to access the driver and get system status, list FIT files, configure the system, and enable/disable auto-scheduler.
Proposed system backend startup sequence.
Proposed autoschedule sequence. Assumes auto scheduler service will be implemented in modified Callisto. Dish control is locked during autoschedule so RadioEyes cannot interfere with operation. ASCOM driver can report "error" to RadioEyes if someone attempts to use the system during autonomous operation. Autoschedule can be disabled from an HTTP client.
New, changed, and removed commands for the Arduino UART interface. SetSystemStatus is used for stack light control.
Robustness
Grounding:
- Ensure internal systems are all connected to a common ground
- Make the ground the external case
- Ensure case has a proper earth ground connection
- Proper grounding also helps with surge protection (lightning)
- Further research to be done on grounding standards
- Main concern is specific grounding practices for the RF systems
Wiring:
- Ensure that all wiring will be secure and won't come loose or brake when handled or moved.
- All the connections coming to and from the arduous will be routed to a PCB that then goes to it's destination.
- The use of a routing PCB will allow for more secure connection through the use of screw terminals.
- Current wire gauge is insufficient for the travel distance of the signals.
Stack Light Design:
- Use of the MSP430G2553.
- UART Communication with Arduino Mega.
- UART will most likely be able to travel the distance between the Mega and MSP430
- TP09 will ensure that UART will work.
- Use of RGB LEDs.
- Possible Rechargeable battery and Small Solar Panel.
- Having a stand alone power source for the stack light will allow for indication even if the main system is offline.
- Low overall priority, schematic and PCB will be created during winter break.
Feedhorn Antenna: The feedhorn for the dish was broken by the previous team and needs to be replaced.
Terk LOGTVO Log-Periodic TV Antenna that was previously on the dish
We have several candidates for a possible replacement, and they will have live tests over the break to obtain live data. They will be measured on a network analyzer when we return.
Ambient Dipole: Three possible antennae were looked at for the ambient source. Two recieved from the customer, and a third bought by the team.
One is a small antenna, another with adjustable length
that was measured at both minimum and maximum length, and
the third is a radio scanner antenna.
Three sets of data were retrieved for each antenna with the network analyzer.
- Impedance measurement (Smith Chart)
- Gain (Log Magnitude)
- Standing Wave Ratio (SWR)
Below are the three plots for the small antenna. Center Frequency: 365 MHz, Minimum SWR: 2.33:1
Adjustable dipole at minimum length. Center Frequency: 710 MHz, Minimum SWR: 3.06:1
Adjustable dipole at maximum length. Center Frequency: 530 MHz, Minimum SWR: 3.06:1
Car Radio Scanner Antenna. Center Frequency: 705 MHz, Minimum SWR: 1.1:1
The standing-wave ratio is the parameter of most interest, as it gives the best indication of the antenna's operation. SWR is a measure of how much a transmitted signal is reflected by a load (in this case load = antenna), and the desired ratio is 1:1, no reflection. The scanner antenna has the best response over the widest range of frequencies.
Risk Assessment
| ID | Category | Risk Item | Effect | Cause | Likelihood | Severity | Importance | Action to Minimize Risk | Owner |
|---|---|---|---|---|---|---|---|---|---|
| R1 | Technical | Improper feedhorn installation | Feedhorn may have loose mounting or be unable to be assembled. | Manufacturing Faults | 1 | 3 | 3 | "Use proper machining procedures" | ME |
| R2 | Technical | Unreliable internet connection to Zurich | May not be able to transmit all data overnight. | Environmental conditions including thunderstorms. | 2 | 1 | 2 | "Provide data backup until Zurich server confirms reception" | CE |
| R3 | Technical | Dish may be too heavy for motors/actuators | Tracking functionality is lost, manual repairs required | Ice buildup, power depletion, errors in measurements | 1 | 2 | 2 | Motors oversized for current load | CE |
| R4 | Technical | File transfer system error | Zurich server receives incomplete data | Power lost or connectivity issues. | 1 | 2 | 2 | "Provide data backup until Zurich server confirms reception" | CE |
| R5 | Technical | Auto-calibration error | Incorrect data analysis, manual repairs required | Drift of control systems over time | 2 | 3 | 6 | 2 callistos in parallel, one for cal one one for data | CE |
| R6 | Technical | TeamViewer software error | Remote operation made difficult or impossible | Loss of connectivity, random glitch | 1 | 1 | 1 | Ensure system doesnt rely on TeamViewer/Active user input | CE |
| R7 | Technical | UPS battery dies | System loses power and is no longer operational. | Mains power is lost and UPS battery is exhausted. | 1 | 2 | 2 | Put system into safe shutdown state before battery is exhausted | EE |
| R8 | Technical | RadioEyes/LabView incompatibility | Additional time required for integration solution | No documented API support | 2 | 2 | 4 | Plan B (parallel solution/other), converse with developer | CE |
| R9 | Technical | Feedhorn selection may carry unexpected collaterals (integration) | RX levels may become inefficient for extraction from raw signal | Mismatching impedance and frequency response | 2 | 2 | 4 | Perform extensive testing on feed/dish assembly | EE |
| R10 | Technical | Software Error | Data may be corrupted or incorrect; Zurich may not recieve data at all | Improper program setup / unforeseen program error | 1 | 2 | 2 | "Perform extensive software testing and provide data backup" | CE |
| R11 | Technical | Interference between subsystems | May cause errors or discrepencies in subsystem operation | Improper magnetic shielding on power lines near vulnerable systems | 1 | 2 | 2 | "Isolate magnetic interference, or place wiring more carefully" | EE |
| R12 | Technical | Improper power management | One or more subsystems failing due to internal power loss | Power delivery components insufficient to meet power needs | 1 | 3 | 3 | Perform extensive power system calculations | EE |
| R13 | Technical | Internal subsystem overheating | Damage to one or more subsystems | Inadequate cooling systems or lack of temperature sensor | 1 | 3 | 3 | Test Plan for thermal model validation | ME |
| R14 | Technical | UPS overheat | Damage to battery system | Temperature sensitive battery in harsh enviornment | 0 | 3 | 0 | Will install UPS indoors | ME |
| R15 | Resource | Insufficient budget to meet all project requirements | May need to take performance hits to accomodate cheaper budget | Limited funds (~$500) | 1 | 1 | 1 | "Design and build where possible" | All |
| R16 | Resource | Destruction of Suntracker project hardware | Loss of uniquely designed hardware, project delays | Incorrect assumptions about input levels and tolerances | 1 | 3 | 3 | Observe best practices | All |
| R17 | Resource | Inadequate space to assemble and test | Team may not be able to build project | Dish components too big for design space | 1 | 3 | 3 | Ensure that proper space or devices are reserved well in advance, only attempt finaly assy onsite | All |
| R18 | Resource | Theft of system components | Irreplaceable components may be lost | Improper storage of materials | 1 | 3 | 3 | Lock physical project materials in a locker/keep at home | All |
| R19 | Resource | Insufficient backup data storage | Zurich or ASRAS server may fail to recieve data | Insufficient or nonexistant backup data storage | 0 | 2 | 0 | Amount of data needed to exceed data capacity exceeds lifetime of system | CE |
| R20 | "Environmental/Social" | Remote log-in to unit may pose security threat | System may be tampered with by unauthorized user | Malicious actor obtaining password/login information | 1 | 3 | 3 | "Ensure strict security in regard to username/ password information" | All |
| R21 | Technical | IP66 may not be as advertized | Water Damage | Leak, improper sealing | 1 | 3 | 3 | Test current enclosure, use waterproof sealing | ME |
| R22 | Technical | Software sends too many emails consecutively | Flooded Mailbox | Periodic Failure alerts | 2 | 2 | 4 | Batch alerts together, rate limit messages | CE |
| R23 | Technical | Smarthost service unavailable | System unable to send email alerts | Service is unavailable | 1 | 2 | 2 | Alternate alert mechanism (stacklight) | EE |
| R24 | Technical | Wind Damage | System components break | High winds, low structural integrity | 1 | 3 | 3 | Perform comprehensive stress analysis, reinforce structure | ME |
| R25 | Technical | System achieves resonance from wind | System components break | Winds hitting natural frequency of structure | 1 | 3 | 3 | Apply Damping | ME |
| R26 | Technical | Heat Sensor Fails | System overheats | Random Failure | 1 | 2 | 2 | Overkill on cooling solution | ME |
| R27 | Technical | Humidity Sensor Fails | Loss of humidity information, water damage | Random Failure | 1 | 1 | 1 | Enhanced waterproofing solution | ME |
Design Review Materials
DDR PresentationHome | Planning & Execution | Imagine RIT
Problem Definition | Systems Design | Preliminary Detailed Design | Detailed Design
Build & Test Prep | Subsystem Build & Test | Integrated System Build & Test | Customer Handoff & Final Project Documentation
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- Node updated 2017-12-07 13:28 by dlf4798