P18571: Sunspot Radio Telescope III
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Detailed Design

Table of Contents

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

public/Detailed Design Documents/IdealFunction.PNG

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

Subsystem Item Qty Unit Cost Total Cost Vendor Website
Re-wire CONN TERM BLOCK T/H 2POS 3.5MM 20 $0.43 $8.28 Digikey https://www.digikey.com/products/en?keywords=%20277-1721-ND%20
Re-wire DIODE SCHOTTKY 100V 5A DO201AD 6 $0.97 $5.82 Digikey https://www.digikey.com/product-detail/en/on-semiconductor/SB5100/SB5100FSCT-ND/3042708
Re-wire CABLE 8COND 18AWG NAT SHLD 50' 1 $48.13 $48.13 Digikey https://www.digikey.com/product-detail/en/general-cable-carol-brand/E2208S.41.86/E2208S-50-ND/5509052
Re-wire CABLE 4COND 18AWG SHLD 100' 1 $92.54 $92.54 Digikey https://www.digikey.com/product-detail/en/alpha-wire/M13244-SL005/M13244-SL005-ND/3838973
Re-wire Routing PCB 1 $20.00 $20.00 OSH Park https://oshpark.com/
Re-wire CONN RECEPT 10POS DUAL 10 $0.46 $4.29 Digikey https://www.digikey.com/products/en?keywords=%20WM3704-ND%20
Re-wire CONN HEADER 10POS 4.2MM VERT TIN 10 $1.54 $13.99 Digikey https://www.digikey.com/products/en?keywords=%20WM3804-ND%20
Re-wire CONN RECEPT 4POS DUAL 10 $0.31 $2.97 Digikey https://www.digikey.com/products/en?keywords=%20WM3701-ND%20
Re-wire CONN HEADER 4POS 4.2MM VERT TIN 10 $0.77 $6.80 Digikey https://www.digikey.com/products/en?keywords=%20WM3801-ND%20
Re-wire BNC, MALE W/20 AWG WIRES 5 $10.62 $53.10 Digikey https://www.digikey.com/products/en?keywords=%20314-1189-ND%20
RF Glass Mount All-Band Scanner Antenna 1 $14.45 $14.45 Home Depot 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 https://www.adafruit.com/product/1733
Robustness SWITCH PUSH SPST-NC 6A 240V 1 $24.48 $24.48 Digikey https://www.digikey.com/products/en?keywords=%20679-3757-ND%20

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

Test Plans Table

Preliminary Test Plans Summary

TP01 Auto-Calibration Test Plan

  1. Setup Callisto to collect data and the Arduino to control the RF switch
  2. Switch input to 50 ohm stub
  3. Switch input to white noise generator
  4. Switch input to ambient dipole
  5. Switch input to dish line
  6. Make sure inputs were switched properly
  7. Compare gathered data to expected values

TP02 Enclosure Test

  1. Remove all internal electronic equipment from enclosure
  2. Assemble enclosures with tubing for conduit (shell unit)
  3. Replace exterior connectors with sacrificial connectors
  4. Line all seams with Liquid Contact Indicator tape
  5. Line location of sensitive electronics with LCI
  6. Subject to spray per IEC 60529
  7. Leave outdoors to allow ice formation/Put in snow
  8. Allow ice to thaw, exterior water to dry (wipe off as necessary
  9. Check LCI for water contact in all areas

TP03 Lightning Arrestor Test

  1. Setup circuitry to deliver over 90 volts to the lightning arrestor
  2. Produce the trip condition for the arrestor (90 volt input)
  3. Observe the fuse to be sure that it broke connection
  4. Repeat for DC and AC voltages in the range of 0 to 3 GHz

TP04 Temperature Test

  1. Internal temperature sensor will be utilized
  2. Processor temperature sensor will be utilized
  3. Exterior temperature sensor/thermometer to get ambient temperature
  4. Run CPU intensive benchmark on computer indoors to generate heat, to determine internal heat generation for steady state. Record processor, interior and ambient temperatures.
  5. Place unit in direct sunlight away from wind with device off, record steady state interior and exterior temperature
  6. Run CPU intensive benchmark in direct sunlight away from wind, record steady state processor, interior and exterior temperature.
  7. If model and results agree within 5%, validate model.

TP05 Adverse Weather Test

Test System ability to detect adverse weather conditions and take precautions
  1. Obtain shop air hose fitted with nozzle
  2. Measure shop air with cup anemometer
  3. Set adverse weather mode to trigger at half of shop air speed
  4. Put system to operation
  5. Blow shop air to trigger “adverse weather”
  6. Trigger all clear
  7. Confirm system resumed operation successfully

TP06 Data Transfer Test

Test system ability to transfer data to Zurich Switzerland.
  1. Configure Callisto data transfer with remote test server
  2. Copy sample FIT files into Data directory
  3. Start Callisto data transfer software
  4. Verify transfers are automatically started
  5. Disconnect internet while transfers are active and unfinished
  6. Verify error condition is recorded by Callisto data transfer software
  7. Reconnect internet
  8. Verify transfers are automatically restarted and completed
  9. Verify FIT files moved from Data folder to Archive folder
  10. Compare files stored in Archive with those on the server
  11. Plug external data transfer SSD into computer system
  12. 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
  1. Set system operation to normal
  2. Unplug power temporarily, plug back in
  3. If system did not shut down, unplug power, wait 5 minutes, replug
  4. If system did not shut down, unplug power, wait 10 minutes. System should shut down
  5. 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.
  1. Set system to operate for 3 days with no datum reset (let backlash error accumulate)
  2. Determine system drift in both azimuth and pitch (separately). Extrapolate error over a year
  3. Set system to operate for 3 days with datum reset only in azimuth
  4. Determine system drift in both azimuth and pitch (separately). Extrapolate error over a year
  5. Set system to operate for 3 days with datum reset only in pitch
  6. Determine system drift in both azimuth and pitch (separately). Extrapolate error over a year
  7. Set system to operate for 3 days with both datum resets
  8. 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.
  1. Connect the Mega and MSP430 using the RX and TX lines.
  2. Set the Baud rate to 9600.
  3. Send and receive a series of data to and from the Mega to the MSP430.
  4. The MSP430 will have and LED indicator if it receives data that it doesn’t expect or doesn’t know how to handle.
  5. 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
  1. Set system to track sun on clear day
  2. Obtain image of visible sun

Design and Flowcharts

Existing System

public/Systems Level Design Documents/Existing System/RF_System_Diagram.pdf.png

public/Systems Level Design Documents/Existing System/Visio-Computer Box Diagram - Existing.pdf.png

Proposed System

public/Systems Level Design Documents/Proposed System/RF_System_Diagram.pdf.png

public/Systems Level Design Documents/Proposed System/Computer Box Diagram - Proposed.pdf.png

LabVIEW FITS file reader system

public/Detailed Design Documents/Software/Labview/FitsDemo1.PNG

public/Detailed Design Documents/Software/Labview/FitsDemo2.PNG

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

public/Detailed Design Documents/Software/sw_overview.png

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.

public/Detailed Design Documents/Software/sw_seq_startup.png

Proposed system backend startup sequence.

public/Detailed Design Documents/Software/sw_seq_autosched.png

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.

public/Detailed Design Documents/Software/controllerProtocol.png

New, changed, and removed commands for the Arduino UART interface. SetSystemStatus is used for stack light control.

Robustness

Grounding:

Wiring:

public/Detailed Design Documents/Schematics/Wiring_Diagram_Schem2.PNG

Stack Light Design:

Feedhorn Antenna: The feedhorn for the dish was broken by the previous team and needs to be replaced.

public/Detailed Design Documents/Electrical/LOGTVO_1.png

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.

public/Detailed Design Documents/Electrical/possible_new_antenna.jpg

Ambient Dipole: Three possible antennae were looked at for the ambient source. Two recieved from the customer, and a third bought by the team.

public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/small_antenna.jpgpublic/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/adjustable_min.jpgpublic/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/scanner_antenna.jpg 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.

Below are the three plots for the small antenna. Center Frequency: 365 MHz, Minimum SWR: 2.33:1

public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/small_log.pngpublic/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/small_swr.png public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/small_smith.png

Adjustable dipole at minimum length. Center Frequency: 710 MHz, Minimum SWR: 3.06:1

public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/adjust_min_log.pngpublic/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/adjust_min_swr.png public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/adjust_min_smith.png

Adjustable dipole at maximum length. Center Frequency: 530 MHz, Minimum SWR: 3.06:1

public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/adjust_max_log.pngpublic/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/adjust_max_swr.png public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/adjust_max_smith.png

Car Radio Scanner Antenna. Center Frequency: 705 MHz, Minimum SWR: 1.1:1

public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/scanner_log.pngpublic/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/scanner_swr.png public/Detailed Design Documents/Electrical/dipole_measurements_12-3-2017/scanner_smith.png

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
Risk Management

Design Review Materials

DDR Presentation

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