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Carthage College, NASA
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Test Equipment Data Package (T EDP)
Microgravity University Systems Engineering Educational Discovery
Carthage College
Physics Department
2001 Alford Park Drive
Kenosha, WI 53140-1994
Fluid Volume Measurement Using
Non-Invasive PZ T Technology
Team Contact: Kimberly Schultz kschultz3@carthage.edu (262) 203-6611
Faculty Advisor: Kevin Crosby kcrosby@carthage.edu (262) 551-5855
Team:
Anderson, KelliAnn Freshman Physics kanderson6@carthage.edu (715) 418-9295
Bakkum, Amber Junior Physics/Math abakkum@carthage.edu (224) 730-0432
Finnvik, Stephanie Junior Physics* sfinnvik@carthage.edu (612) 710-8354
Gross, Erin Senior Physics* egross@carthage.edu (608) 219-1499
Grove, Cecilia Senior Physics cgrove@carthage.edu (563) 370-8867
Mathe, Steven Sophomore Chemistry* smathe@carthage.edu (847) 401-9745
Schultz, Kimberly Junior Physics* kschultz3@carthage.edu (262) 203-6611
Weiland, Danielle Freshman Chemistry/Physics dweiland@carthage.edu (262) 496-6083
*Students are pursuing a dual degree in Engineering along with their listed major
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2.0 Change History Log
Version Effective Date Description of Changes
1 2/23/2011 Initial release
2 3/14/2011
3.0 Assembly Weight corrected
24.3 and 24.8 Revised to match a handle-less design
8.1.8 Design change of glove box noted
8.2.8 Tie Wraps added
Appendix B deleted and placed into separate document
3 3/16/2011 8.1.8 Secondary containment pictures added
4 3/23/2011
8.1.8 Glove box details added
Stress Analysis Section 2.0: Minimum Margins of Safety
updated
Stress Analysis Section 6.0: Table 6.1 updated
Stress Analysis Section 7.1: Laptop and power amplifier
calculations corrected
Stress Analysis Section 7.2: All calculations corrected
Stress Analysis Section 7.3: Rig attachment calculations
corrected
Stress Analysis Section 7.5: Floor load calculation
Corrected
5 4/4/2011
Stress Analysis Section 6.0: Table 6.1 updated
Stress Analysis Section 7.1: Power amplifier calculations
corrected
Stress Analysis Section 7.3: Rig attachment calculations
corrected
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Carthage College, NASA
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3.0 Quick Reference Page
Boeing 727-200 Quick Reference Data Sheet
Principal Investigator: Kimberly Schultz
Contact Information: kschultz3@carthage.edu (262) 203-6611
Experiment Title: Fluid Volume Measurement Using Non-Invasive PZT Technology
Flight Date(s): March 31 April 9, 2011
Overall Assembly Weight: 145.87lbs
Assembly Dimensions (L x W x H): 44in x 30in x 30in
Equipment Orientation Requests: We request that our rig be placed with the long axis
of the rig along the length of the plane in such a way that the control panels are towards
the aft of the aircraft.
Proposed Floor Mounting Strategy (Bolts/Studs or Straps): Bolts
Gas Cylinder Requests (Type and Quantity): None
Overboard Vent Requests (Yes or No): No
Power Requirement (Current and Voltage Required): 5.02A (Peak)/ 115V AC
Free Float Experiment: No
Flyer Names for Each Proposed Flight Day:
First Day: Kimberly Schultz
Amber Bakkum
Rudolph Werlink
Second Day: Stephanie Finnvik
Cecilia Grove
Kevin M. Crosby
Alternate: Erin Gross
Camera Pole and/or Video Support: We request the use of a NASA videographer to
record the outreach portion of the flight. One camera pole is requested for the use of a
camera and video camera. These two devices can be placed on the same pole and will be
used for outreach purposes.
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10.3 Stored Energy .......................................................................................................................... 29
10.4 Kill Switch ................................................................................................................................. 30
10.5 Loss of Power ........................................................................................................................... 30
11.0 Pressure Vessel/System ............................................................................................ 30
11.1 Negative Pressure .................................................................................................................. 31
11.2 Positive Pressure ................................................................................................................... 31
11.3 Catastrophic Depressurization ......................................................................................... 31
11.4 Pressure Components .......................................................................................................... 32
11.5 Non-Commercially Produced Components and Subsystems ................................. 32
12.0 Laser Certification ....................................................................................................... 34
13.0 Parabola Details and Crew Assistance Required .............................................. 34
14.0 Free Float Requirements ........................................................................................... 34
15.0 Institutional Review Board ...................................................................................... 34
16.0 Hazard Analysis ............................................................................................................ 35
16.1 RGO Hazard Analysis ............................................................................................................ 35
16.2 Hazard Identification Checklist ........................................................................................ 35
17.0 Tool Requirements ...................................................................................................... 39
18.0 Educational Outreach ................................................................................................. 39
18.1 Planned Outreach and Dissemination Program ......................................................... 39
18.1.1 Science Fair ...................................................................................................................................... 39
18.1.2 Science Nights ................................................................................................................................. 39
18.1.3 Family Fun Night ........................................................................................................................... 39
18.1.4 School Visits ..................................................................................................................................... 40
18.2 Outreach Experiments ......................................................................................................... 40
18.2.1 Momentum Conservation .......................................................................................................... 40
18.2.2 Buoyancy ........................................................................................................................................... 40
18.2.3 Human Interactions with Zero Gravity ................................................................................ 40
19.0 Photo Requirements ................................................................................................... 41
20.0 Aircraft Loading ............................................................................................................ 41
21.0 Ground Support Requirements ............................................................................... 41
22.0 Hazardous Materials ................................................................................................... 41
23.0 Material Safety Data Sheets (MSDS) ...................................................................... 41
24.0 Procedures ..................................................................................................................... 41
24.1 Equipment Shipment to Ellington Field ......................................................................... 41
24.2 Ground Operations ................................................................................................................ 42
24.3 Loading/Stowing .................................................................................................................... 42
24.4 Pre-Flight .................................................................................................................................. 42
24.5 Take-Off/Landing .................................................................................................................. 42
24.6 In-Flight ..................................................................................................................................... 42
24.6.1 In-‐Flight Setup ................................................................................................................................ 42
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24.6.2 Parabolic Maneuvers ................................................................................................................... 43
24.6.3 In-‐Flight Experiment Shut-‐Down ............................................................................................ 44
24.7 Post-Flight ................................................................................................................................ 44
24.8 Off-Loading ............................................................................................................................... 44
25.9 Emergency/Contingency ..................................................................................................... 44
25.0 Bibliography .................................................................................................................. 46
Appendix A: Acronyms ......................................................................................................... 47
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5.0 Flight Manifest
The Carthage College Team will be participating in the flight week of March 31
to April 9, 2011. Our faculty advisor and one flight crew member have flown previously.
Flight Crew:
First Day
Amber Bakkum
Kimberly Schultz
Rudy Werlink
Second Day
Cecilia Grove
Stephanie Finnvik
Kevin M. Crosby
Alternate:
Erin Gross
Additional Flight Personnel (Journalist for Racine Journal Times):
Elizabeth Young
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6.0 Experiment Background
Due to the high cost of spacecraft propellant, it is essential to monitor propellant volume
at all times during a mission. Therefore, an accurate method of gauging propellant
volume is a mission critical design requirement for most spacecraft programs. Several
methods are currently used at various mission stages, though none is without significant
performance and cost limitations. In a microgravity environment, level sensor-based
gauging can be performed during a period of engine thrust that settles the propellant in a
known acceleration field. Additionally, propellant systems that utilize an external
pressurant to ensure consistent flow can be gauged using temperature, pressure
measurements, and the appropriate equation of state. The latter method is appropriate for
smaller propellant systems, but is not a practical option for large propellant tanks because
of the large required volume of pressurant. In the current project, we investigate the
efficacy of a new gauging technique, previously untested in microgravity.
The purpose of this experiment is to determine the volume of contained liquid in an
experimental tank while on the zero-g flights. This will be done by employing the use of
non-invasive piezoelectric transducer (PZT) technology to both generate and detect
vibrations in a water-filled experimental tank. Our project advisor, Rudolph Werlink
(NASA KSC), has proposed that this method be tested under microgravity conditions to
assess its suitability for zero gravity fluid volume measurement. If successful, this
approach will provide a simple way to efficiently and continuously determine propellant
volume during a space flight mission without compromising the integrity of the tank or
adding the complication of settling burns and pressurizing systems to mission profiles.
This experiment has not been previously conducted on a microgravity flight.
7.0 Experiment Description
Our rig consists of two tanks, associated hydraulic components and a data acquisition
system (DAQ). Each steel tank holds a maximum of two gallons of fluid. One of the
tanks, the primary tank, will be partially filled with water, while the other serves as a
reservoir tank.
A piezoelectric transducer (PZT) actuator will be affixed to the primary tank, along with
three PZT sensors. The PZT actuator will convert a continuous broad-spectrum white
noise signal, generated by a signal generator, into mechanical pulses that vibrate the tank.
Three PZT sensors attached to the tank convert the vibrations of the tank to low voltage
electrical signals, which are recorded by the data acquisition system as output signals.
One of these sensors will be located near the actuator to sample the actuator output
signal, or input frequencies. The remaining two sensors will be located on the opposing
side of the tank to detect the resulting vibrations, or output frequencies, of the tank.
The hydraulic system is used to change the fill fraction of the tank during flight. A
solenoid valve connected to the bottom of the primary tank regulates flow through a low
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volume flow totalizer. This is followed by a pump, which is connected to the reservoir
tank. During the fluid transfer from the primary tank to the reservoir tank, pop release
valves will be manually opened to prevent the occurrence of a pressure difference
between the tanks and the surrounding environment. The maximum volume of water that
will be present in the test equipment at any given time is 1.4 gallons. All hydraulic
components are contained within a sealed, leak-proof secondary containment vessel.
Data generation and collection proceeds as follows: a signal generator relays the white
noise waveform to a power amplifier, which drives the PZT actuator. Low voltage
analog signals generated by the PZT sensors after being compressed by the input signal
are converted into digital signals by the DAQ and recorded for later analysis by a
LabVIEW-based virtual instrument. Flight crew will manually control the initiation and
termination of data collection during each parabola using a software interface consisting
on. Data files for each PZT sensor are automatically named
according to parabola, date, and time and are filed upon the termination of each parabola.
7.1 Experiment Schedule
The anticipated flight schedule for our experiment is outlined in Table 7.3.1. While 30
parabolas will be requested, our plan has been written anticipating 27 usable parabolas
per day. If more usable parabolas are present on either day, further data will be collected.
Any parabolas that remain on the second flight day after data collection for all fill
fractions has been completed will be used for outreach activities.
Parabola Number Fill Fraction (%)
Day 1
1 6 70
7 12 65
13 18 60
19 24 55
25 27 50
Day 2
1 3 50
4 9 45
10 15 40
16 21 35
22 27 30
Table [7.3.1]: Anticipated Experiment Schedule
7.2 Experimental Analysis
Post-flight analysis of our data will be performed with the aid of LabVIEW 8.0 software
and the Sound and Vibration toolkit, both produced by National Instruments, Inc. This
software will be capable of performing real-time fast Fourier transforms (FFTs) on the
signals detected by the PZT sensors. For each sensor, a frequency response function
(FRF) will be calculated by taking the ratio of each output FFTs to the input FFT. The
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goal of the analysis is to use the FRF to determine the fluid volume inside the tank. The
fill-fraction is independently established by using a flow totalizer that records flow rates
and totals between the primary and reservoir tanks.
8.0 Equipment Description
The flight rig consists of a secondary containment vessel housing two tanks and
associated hydraulics, and an electronics deck housing a laptop computer, power
amplifier, interface balun, DAQ and power supplies for various components. In this
section, we describe the components and interfaces associated with each assembly.
Specifications of the flight equipment can be found in Table 8.0.1. All equipment is
flight rig layout is shown in Fig. 8.3.1.
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Description Section
Dimensions
(in)
Weight
(lbs) Type
Tank 8.1.1
6.00 x 7.50 x
19.0
5.00 (x2) Experimental
Pressure Gauge 8.1.2 4.5 x 2.5 x 2.5 0.5 Experimental
Water 8.1.3 323.4in3
11.70 Experimental
Fluid Transfer Hose 8.1.4 3/8 x 3/8 x 48 <0.1 Experimental
Solenoid Valve 8.1.5
1.56 x 1.95 x
3.12
0.6 Experimental
Flow Totalizer 8.1.6 0.55 Experimental
Fluid Pump 8.1.7
6.00 x 4.00 x
4.00
5.00 Experimental
Secondary
Containment
8.1.8
15.0 x 18.0 x
26.0
24.48 Experimental
Tank Caps 8.1.9.1 <0.1 Experimental
Dual MNPT 8.1.9.2 <0.1 Experimental
1/4in MNPT to Barb 8.1.9.3 <0.1 Experimental
1/2in MNPT to Barb 8.1.9.4 <0.1 Experimental
FNPT to Barb 8.1.9.5 <0.1 Experimental
Pop Valve 8.1.9.6 <0.1 Experimental
Laptop 8.2.1 15.0 x 7.0 x 1.0 5.0 Experimental
Power Amplifier 8.2.2
15.0 x 7.00 x
3.00
5.80 Experimental
PZT Actuator 8.2.3.1
4.06 x 2.52 x
0.01
<0.1 Experimental
PZT Sensor 8.2.3.2
4.41 x 1.58 x
0.01
<0.1 Experimental
USB Chassis 8.2.4
6.26 x 3.47 x
2.32
2.31 Experimental
Electronics Plate 8.2.7
28.5 x 11.5 x
0.25
2.28 (x2) Experimental
Power Strip 8.2.8
10.0 x 2.00 x
1.50
0.60 Experimental
Balun 8.2.9
8.86 x 4.72 x
2.76
1.56 Experimental
Table [8.0.1]: Equipment Components
8.1 Hydraulics and Pressure
The hydraulics and pressure system subassembly consists of all components and
interfaces that hold or transfer fluid. The components of this subassembly are housed in
the secondary containment vessel. A diagram of the fluid flow is given in Fig. 8.1.1.
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More information about hydraulic interfaces is given in section 8.1.2. Table 8.1.1
contains for the figure components.
Figure [8.1.1] Hydraulics Interface Diagram
Schematic
Reference
Number Component
1 Tank
2 Solenoid Valve
3 Flow Totalizer
4 Pump
5 1/4in MNPT to Barb
6 Hose
7 1/2in MNPT to Barb
8 MNPT to Barb
9 Pop Valve
10 Pressure Gauge
Table [8.1.1] Component Key
8.1.1 Tanks
The stainless steel tanks used in our experiment are distributed by Viair, Inc. The tank
with the PZT attachments will serve as the primary tank while a second tank will serve as
a reservoir for drained fluid. Each tank possesses six 1/4in FNPT ports that will be used
to attach the other components; their locations are shown in Fig. 8.1.1.1 along with the
schematic drawing of the tank. Each tank can hold up to 2gal of fluid and has a wall
-welded to the side of
each tank. They are made of the same stainless steel as the tanks and possess two 1/4in
holes, which will be used to secure the tanks to the structure of the rig.
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Fig. [8.1.1.1]: Tank
8.1.2 Pressure Gauge
ports to monitor the pressure differentials between the primary tank and the secondary
containment. A picture of the gauge can be seen in Fig. 8.1.2.1. Although this
component is only designed to measure pressure differences up to 5psi, it can withstand a
maximum pressure of 1500psi.
Fig. [8.1.2.1]: Pressure Gauge
8.1.3 Water
Our propellant simulant is water. The total volume of water in the system will be 1.4gal,
split between the two tanks.
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8.1.4 Fluid Transfer Hose
The hose used for transferring water throughout the hydraulic system is made of Nylon
11. It will provide sufficient bending to allow both the primary and reservoir tanks to
connect in an uninhibited, nonlinear path. The hose has an ID of 3/8in and an OD of
1/2in.
8.1.5 Solenoid Valve
A solenoid valve is used to control the flow of water from the primary tank to the
reservoir tank. It is a 24VAC device that will remain closed until powered on. The
connectors are 1/4in FNPTs and allow fluid to flow at a rate ranging from 0 to 4.7 gallons
per minute. This device is operable under pressures of up to 175psi, is listed by UL and
certified by the CSA. The SV will be securely attached to the floor of secondary
containment using industrial Velcro.
8.1.6 Flow Totalizer
A flow totalizer will be used to monitor the volume of fluid that is being transferred from
the primary tank to the reservoir. The totalizer has a digital display that will show the
flow rate and volume of the liquid passing through it. This component utilizes a PVC
body with a stainless steel seal, operates at pressures up to 225psi and has an accuracy of
± 3%. The ports are 1/2in FNPTs. It will be secured to secondary containment using
Velcro.
8.1.7 Fluid Pump
In order to transfer fluid from the primary tank to the reservoir, a water pump (Fig.
8.1.7.1) will be used. It is a 120VAC aquarium pump. This pump is able to move a
maximum of 160 gallons of water a minute (at a 1 foot pressure head). The input of the
pump requires a 3/8in MNPT to 3/8in hose barb. The output requires a barb to 1/2in
MNPT fitting. This device will be securely attached to the secondary containment vessel
using Velcro. Hose connections will be thread-sealed and leak proof.
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Fig. [8.1.7.1]: Fluid Pump
8.1.8 Secondary Containment
Due to the use of greater than 6oz of liquid in the experiment, all of the hydraulic
components are housed within a leak-proof secondary containment, illustrated in Fig.
8.1.8.1. This containment gives added security in the case of a leak or tank failure. To
better observe the experiment, secondary containment is clear, made of 1/4in Lexan
sealed with IPS Weldon 3. The top of the secondary containment vessel has a removable
plate to allow access to the components within. See Figures 8.1.8.2-4 for diagrams of the
top face of the secondary containment and the locking mechanism for the removable
door. The door can be removed by unlatching the locks on top and pulling on the
handles; it will not be removed during flight. During flight, a glove box will be used to
open the pressure release valves of each tank when transferring fluid. Each pop-valve
has a six inch long nylon fishing line tied to the manual release lever. Those strings are
attached to a rubber membrane mounted on the top face of the secondary containment
vessel. Operators will be able to manually activate the pressure release valves by pulling
on the rubber membrane which, in turn, pulls the lever on the valve with the nylon string.
The secondary containment also has a pop valve designed to relieve a pressure difference
of 5psi. The valve we have chosen has an air flow rate of 8cfm. The secondary
containment vessel will be leak-tested with 1.5 gallons of water in each orientation of the
vessel to ensure its integrity.
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Figure [8.1.8.1]: Secondary Containment Diagram
Figure [8.1.8.2]: Overhead View of the Top Face of Secondary Containment
Figure [8.1.8.3]: Side and Top Views of Latching Mechanism
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Figure [8.1.8.4]: Key to Figs 8.1.8.2 and 8.1.8.3
8.1.9 Interfaces
The hydraulic interfaces are the pieces of hardware that connect the different components
to each other. More specifications on hydraulic interfaces can be found in Table 8.1.1
and the following sections.
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Fig. [8.1.9.1]: Hydraulic Interfaces
A) Cap B) Dual MNPT C) MNPT to Barb D) FNPT to Barb E) Pop Valve
8.1.9.1 Caps
Type 304 stainless steel caps are used to plug the unused tank ports. They are 1/4in
MNPTs and are rated to withstand a pressure difference of 150psi. An illustration of a
cap can be seen in Fig. 8.1.9.1 A. Caps will be thread-sealed to tank.
8.1.9.2 Dual MNPT
The 1/4in dual MNPT connector is designed to couple the tank with the pressure gauge.
It is constructed using type 316 stainless steel and can work under pressures of up to
7500psi. An illustration of the connector is shown in Fig. 8.1.9.1 B.
8.1.9.3 1/4in MNPT to Barb
The zinc-plated steel 1/4in MNPT to 3/8in ID barb interfaces provide a water-tight
transition from hosing to several hydraulic components. It is pressure rated to 150psi.
An illustration of this connector is shown in Fig. 8.1.9.1 C.
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8.1.9.4 1/2in MNPT to Barb
MNPT to barb interfaces with a pipe diameter of 1/2in will also be used. They are the
same as their 1/4in counterparts in all respects except diameter. These connectors will
be used to couple the hose to both ends of the flow totalizer.
8.1.9.5 FNPT to Barb
The brass 1/2in FNPT to 3/8in ID barb provides the same water-tight transition between
3/8in ID hosing and hydraulic components as the MNPT to barb connectors. This
interface can withstand pressures of up to 145psi and will be used on the input and output
ports of the water pump. An illustration of this interface is shown in Fig. 8.1.9.1 D.
8.1.9.6 Pop Valve
In case pressure builds up within the tanks or secondary containment, a series of pop
pressure. Secondary containment and each tank will have one attached pop valve. They
are made of brass and bronze, have brass seals and contain a type 316 stainless steel
spring, as well as a 1/4in MNPT to allow connection directly to each tank. Each valve
can be activated either manually, when needed during flight maneuvers, or automatically,
at a pressure difference of 5psi or greater. An illustration of this component is shown in
Fig. 8.1.9.1 E.
8.2 Electronics System
The electrical subassembly consists of the components that are powered by the aircraft.
A layout of the electronic chains may be found in Fig. 8.2.1. For electrical specifications
and analysis refer to section 10.
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F ig. [8.2.1] : Three Primary Electrical Sub-assemblies and Their Interfaces;
A) Driver Chain B) Receiver Chain C) Solenoid Valve Chain;
Component Interfaces are indicated by I[n] which are identified in
Table [8.2.2]
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Wire # I1 I2 I3 I4 I5 I6-8 I9-11 I12 I13
Kind
USB
2.0
TP
BNC
Connector
BNC
Connector
TP TP
BNC
Connector
TP TP
Gauge N/A 22 coax coax 22 22 coax 22 22
Max.
Current
N/A 1.0mA 1.0mA 1.6A 1.6A ~0 ~0 1A 0.83A
From
Laptop SG Balun PA Balun
PZT
Sensors
Balun Relay
Trans-
former
To
USB
Chassis
Balun PA Balun
PZT
Actuator
Balun DAQ SV SV
Table [8.2.2]: Interface Summary
8.2.1 Laptop
A Toshiba Satellite laptop will be used to control the data collection, generation and
organization throughout the experiment. A steel bracket will secure the laptop to the
upper electronics deck of the rig.
8.2.2 Power Amplifier
The PA is used to amplify the white noise signal from the SG to provide the voltage
necessary for the function of the PZT actuator. The PA operates using a standard 115V
60Hz service. It amplifies the signal from the SG to 100V RMS. It will be attached and
secured to the rig with steel brackets. Refer to Fig. 8.2.2 for a picture of the PA.
Figure [8.2.2]: Power Amplifier
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8.2.3 PZT Actuator
One PZT, attached to the outside wall of the primary tank, will be used as an actuator,
creating mechanical energy from electrical energy. The signal from the SG will be
converted into vibrational pulses that perturb the primary tank.
8.2.4 PZT Sensor
The opposite of the actuator, the three PZT sensors convert mechanical energy into
electrical energy. The vibrations of the tank are detected by each PZT and converted into
an analog signal, recorded separately for each sensor for later analysis. One sensor is
placed right next to the actuator to pick up the initial input signal before it has an
opportunity to become distorted inside the tank. The remaining two sensors are placed
on the opposing side of the tank of the actuator and first sensor. All PZT sensors and the
actuator are manufactured by Smart Material, Corp.
8.2.5 USB Chassis
The USB chassis, as seen in Fig. 8.2.5.1 houses the DAQ, the relay and signal generator.
All three of these components can be connected to and controlled by the computer via a
USB interface. A mounting kit supplied by the manufacturer, National Instruments, will
be used to bolt the chassis to the rig frame.
Fig. [8.2.5.1]: Empty USB Chassis
8.2.5.1 Relay
The relay is a four channel electric switch that is part of the cDAQ chassis. When
activated via the single-touch user interface on the laptop, it will allow power to flow to
the SV. The relay is a Single Pole Single Throw (SPST) type with a resistance of
per channel.
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8.2.5.2 DAQ
The DAQ is a module that receives the analog signals from the PZT sensors and converts
the signals into digital values for processing. We use a four channel DAQ. The DAQ is
one of the modular components comprising the cDAQ chassis.
8.2.5.3 Signal Generator
The SG generates the analog signal sent to the PZT actuator to agitate the tank. It is a
four-channel generator with each channel having input for the load and ground. It is
powered by the cDAQ and its power usage is around 500mW. The SG is a modular
component of the cDAQ chassis.
8.2.6 Solenoid Valve
The SV regulates fluid flow from the model tank to the reservoir tank. It will be powered
by 24VAC from a power converter plugged into the power strip. When activated by the
relay, the SV opens and allows fluid to flow; it blocks the water from draining when not
activated.
8.2.7 Electronics Plate
Two plates will be mounted at the front end of the rig to provide a designated location to
mount all the electronic components of the experiment. They are constructed from
corrugated aluminum with bolt holes drilled to attach the electrical components.
8.2.8 Power Strip
For this experiment, we will use a standard UL-rated utility power strip that will connect
to the aircraft electrical system via an extension cord. The power strip contains the
master kill switch for all electrical components. It is a COTS device with a 15A circuit
breaker and a built-in surge protector. It will be secured to the rig structure using Velcro
and tie wraps.
8.2.9 Balun
An eight channel passive BNC balun from UTP Video will be used to convert the
between electrical wire and BNC connectors. A picture of the balun can be found in Fig.
8.2.9.1. The device requires no power to run. This component will also be bolted to the
structure of the rig with a bracket.
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Fig. [8.2.9.1]: Balun
8.3 Equipment Layout
The rig for the proposed experiment is constructed from extru -
components. The rig itself is 44in long, 30in wide and 30in tall. Relevant pictures of the
rig can be found in Fig. 8.3.1.
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Figure [8.3.1]: Equipment Layout
8.4 Free Float
This experiment does not require any components to be able to float freely.
9.0 Structural Verification
Refer to the Carthage College Stress Analysis, submitted separately, for an extended
structural analysis.
10.0 Electrical Analysis
The electrical system consists of three main subassemblies: one for signal generation and
PZT actuation, another for signal acquisition and processing and one for control of the
mechanical solenoid valve. They are labeled driver chain, receiver chain and fluid flow
chain, respectively. Each of the three functions is controlled through a software interface
running on a laptop computer. The three primary components, the DAQ, the SG and the
relay, are integrated into a component chassis, the cDAQ, with a common USB data
connection to the laptop. Each of the modules of the cDAQ is physically mated to the
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chassis by spring locks and RS-232 port connections. Additionally, a water pump is
electrically separate from the subassemblies.
10.1 Schematic
All electrical components share a common ground with the aircraft power source. A
master power strip will plug into a 115V, 60Hz and 20A service from the aircraft that
will work as the master kill switch for the electrical components. The strip is a COTS
device with a 15A circuit breaker and a built-in surge protector. Fig. 10.1.1 details the
power service from the aircraft. Each outlet, labeled 1-5 in Fig 10.1.1, on the power strip
does not draw more than the stated allotment of current. See Tables 10.2.1-5 for specifics
and voltage draw.
An overview of the electrical sub-assemblies and their interfaces is illustrated in Fig.
10.1.2. In Fig. 10.1.2, Bx, where x is a number, relates to a port on a BNC to Terminal
Block balun to convert the connections between components. This balun is passive and
does not produce or require electric power.
The peak operating current of the rig is 5.02A at 115VAC. The nominal operating
current is 3.6A as the pump and solenoid valve do not continuously draw current during
flight. The breaker rating on the power strip is 15A, so our current draw will not exceed
the rated value.
Figure [10.1.1] Generalized Rig Electrical Schematic
PowerStrip
115VACOut
Kill
Switch
Aircraft
115VAC
2 cDAQ
Laptop1
Power Amp3
Solenoid Valve4
Pump5
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Laptop USB
Chassis
Signal
Generator
B1
Power
Amplifier
B2
PZT
Actuator
I1 I2
I3
I4 I5
A.
B.
C.
Figure [10.1.2] Interface Diagram, A) Driver Chain
B) Receiver Chain C) Solenoid Valve Chain
Wire # I1 I2 I3 I4 I5 I6-8 I9-11 I12 I13
Kind
USB
2.0
TP
BNC
Connector
BNC
Connector
TP TP
BNC
Connector
TP TP
Gauge N/A 22 coax coax 22 22 coax 22 22
Max.
Current
N/A 1.0mA 1.0mA 1.6A 1.6A ~0 ~0 1A 0.83A
From
Laptop SG Balun PA Balun
PZT
Sensors
Balun Relay
Trans-
former
To
USB
Chassis
Balun PA Balun
PZT
Actuator
Balun DAQ SV SV
Table [10.1] Interface Details
Laptop
USB
Chassis
Data
Acquisition
System
B3-‐5
PZT Sensor
PZT Sensor
PZT Sensor
I1
I9
I8
I7
I6
I11
I10
Laptop
USB
Chassis Relay
Solenoid
Valve
I1 I12
Pump
I13
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10.1.1 Driver Chain
The driver chain consists of the electronic components that produce and transmit an
acoustic waveform into the tank. The driver chain begins with the laptop. A continuous,
arbitrary white noise signal ranging from 0 to 5 kHz will be converted from a MATLAB
code on the laptop to an analog signal by the signal generator (SG). The power amplifier
(PA) will amplify the signal to a voltage of 100V and will relay the signal to the PZT
actuator. The actuator then converts the electrical signal into vibrational pulses that
travel through the tank and its contents. The SG and the DAQ are housed in and powered
by the cDAQ USB chassis. The PA is powered by the plug-in on the power strip. The
actuator is driven by the PA.
10.1.2 Receiver Chain
The receiver chain is responsible for detecting acoustic vibrations from the tank,
transforming them into low-voltage signals, and logging the signal. The DAQ is housed
and powered by the cDAQ chassis and converts the signals from the PZT sensors into
digital format for later analysis.
10.1.3 Hydraulics Chain
The hydraulics chain is the sequence of components from the primary tank drain through
the reservoir tank. The hydraulics chain consists of the solenoid valve at the primary
tank, the flow totalizer, the transfer pump and the reservoir tank. The solenoid valve is
controlled by a relay mounted to the cDAQ chassis and is powered by a 24 VAC supply.
The transfer pump is powered by 115VAC electrical service. The flow totalizer is
powered by internal batteries.
10.2 Load Tables
The following load tables, in Tables 10.2.1, 10.2.2, 10.2.3, detail the current usage for
each electrical load in use during flight. With each load component operating at
maximum power, the peak rig load is 5.02A. The nominal operating load is 3.6A.
Power Source Details Load Analysis
Power Cord 1 (From Fig. 10.1.1) Laptop-4.86A
Voltage: 115VAC, 60Hz
Max Outlet Current: 20A Total Current Draw: 1.5A
Max Voltage Use: 115V
Table [10.2.1] Load Table for Power Cord 1
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Power Source Details Load Analysis
Power Cord 2 (From Fig. 10.1.1) cDAQ USB Chassis: 0.5A
Voltage: 115VAC, 60Hz Signal Generator: 1mA per channel (1 channel in use)
DAQ: 2.0mA
Relay: 1.5mA
Max Outlet Current: 20A Total Current Draw: 503mA
Max Voltage Use: 30V
Table [10.2.2] Load Table for Power Cord 2
Power Source Details Load Analysis
Power Cord 3 (From Fig. 10.1.1) Power Amp: 1.6A
Voltage: 115VAC, 60Hz
Max Outlet Current: 20A Total Current Draw: 1.6A
Max Voltage Use: 110V
Table [10.2.3] Load Table for Power Cord 3
Power Source Details Load Analysis
Power Cord 4 (From Fig. 10.1.1) 24VAC Solenoid Power: 0.83A
Voltage: 115VAC, 60Hz Solenoid Valve: 0.38A
Max Outlet Current: 20A Total Current Draw: 1.21A
Max Voltage Use: 24V
Table [10.2.4] Load Table for Power Cord 4
Power Source Details Load Analysis
Power Cord 5 (From Fig. 10.1.1) Pump: 0.22A
Voltage: 115VAC, 60Hz
Max Outlet Current: 20A Total Current Draw: 1.7A
Max Voltage Use: 115V
Table [10.2.5] Load Table for Power Cord 5
10.3 Stored Energy
This experiment does not contain components that might store a large electrical charge.
The only stored energy devices are the company-supplied batteries used in the laptop.
All components that store energy are COTS and have not been modified. The laptop has
internal Lithium Ion (Li-Ion) batteries and capacitors that will not be accessed during the
experiment. The MSDS sheets for the batteries are included in Section 23.1.
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10.4 Kill Switch
Should an electrical crisis occur, an emergency kill switch will cut all power to the rig.
The power strip has an on/off switch that will serve as the kill switch for our experiment.
By , electrical power will instantly be cut off to all
components in the system. A team member will easily be able to distinguish whether the
power is flowing or not by an LED light inside the switch. The power strip switch will
be easily accessible on the rig and within reach of the team members. The laptop will
continue to function with battery power until manually turned off.
10.5 Loss of Power
If there is a loss of power, the laptop is the only component that will remain running until
drive as well as onto an external flash drive. All other components will cease operation
until aircraft power is restored.
11.0 Pressure Vessel/System
The purpose of the pressure vessel system is to ensure the pressure equality between
closed systems and prevent test equipment failure due to pressure differences. All
aspects of the experiment are conducted at ambient pressure. A pressure difference
between the tank and cabin will only be induced in the event of a cabin depressurization.
Pop valves will automatically release air from the tanks and the secondary containment
vessel at a pressure difference of 5psi in the event of a cabin depressurization in order to
rapidly equalize the pressure. If needed, the pop valves can be released manually. For a
system schematic see Fig. 11.0.1 and corresponding Table 11.4.1 with interface
descriptions.
Figure [11.0.1]: Hydraulic System Schematic. Numbered interfaces 5-8 are described in
Table 11.4.1.
Water present in our primary tank will be drained from 70% to 30% of tank capacity in
increments of 5% over the course of the two flight days. Tank capacity is 2gal, making
the maximum fluid volume present in our experiment 1.4gal, or 70% of the maximum
tank volume. Water will be pumped from the primary tank into a reservoir tank during
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fill changes. Both tanks and all interface components will be contained within a
secondary containment vessel to mitigate leakage into the aircraft cabin in case of
primary or reservoir tank failure.
No experiment-induced pressurization shall occur because a pressure equalization system
is in place. In the event of a failure to activate the pop valves, the primary tank would be
subject to nominal negative pressure during fill changes. Mitigation of negative tank
pressures is discussed in Section 11.1. Should the pop valves fail to equalize pressure, the
reservoir tank would be subject to a slight positive pressure during fill changes. In the
case of catastrophic depressurization giving a maximum differential pressure of
11.35psi the tanks will have a margin of safety greater than 10 as is detailed in Section
11.3.
11.1 Negative Pressure
Negative pressure can occur only in the primary tank while the fluid drain pump is in use.
To equalize pressure during the draining process, a pop valve has been installed into the
primary tank. This pop valve will be manually released during the draining process so
that no negative pressure occurs. These pop valves allow air to flow in or out at a rate of
8cfm. This rate is consistent with maintaining pressure equalization even when the pump
operates at its maximum rate of 6.0gpm.
11.2 Positive Pressure
The addition of water into the reservoir tank during the draining process induces positive
pressure in the tank. This positive pressure is released through a pop valve in the
reservoir tank, which will also be manually released during the draining process.
The tank will be filled and closed at ground pressure in Houston, TX 14.64psi [1]. As
the plane rises, the atmospheric pressure will drop. Cabin pressure is specified to remain
between 10.91 and 12.22psi [2]. This will create a nominal positive pressure in the
primary and secondary containments, ranging between 2.42 and 3.73psi. This pressure
difference will have negligible effects on the structure of the rig itself or the operation of
the experiment. The pop valves will be manually released once in the air to equalize any
pressure differences caused by the ascent.
11.3 Catastrophic Depressurization
In the worst-case scenario a catastrophic depressurization at 36,000ft an ambient
atmospheric pressure of 3.29psi will be present outside the secondary containment vessel
of our experiment. Should this occur, both tanks and the secondary containment vessel
will be subject to a positive pressure of 11.35psi. Pop valves on the tanks and secondary
containment vessel are set to automatically release air at a positive pressure of 5psi or
greater. A pressure difference of 5psi will have negligible effects on the structure of the
rig or operation of the experiment. The MAWPs for each component exceed 5psi. Even
given a differential pressure of 11.35psi and the failure of automatic release by the pop
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valves, the tanks still have a margin of safety of 12. See Table 11.4.1 for the specific
margins of safety for all components exposed to possible differential pressure. The
MAWP and the maximum operational pressure are used to generate the margin of safety
as defined in Eq. 11.3.1.
Equation [11.3.1]: Margin of Safety
11.4 Pressure Components
Schematic
Reference
#
Component
Description
M A WP
(psi)
Relief
Valve
Setting
Built By
Proof Test-
Certified
By
Operational
Pressure
(psi)
MS
1 Tank 150 N/A Viair
no
information
currently
available
11.35 12
2 Solenoid Valve 175 N/A ASCO CSA 11.35 14
3 Flow Totalizer 225 N/A GPI N/A 11.35 19
4 Pump N/A 11.35
5 1/4" MPT to Barb 150 N/A N/A N/A 11.35 12
6 Hose 140 N/A N/A N/A 11.35 11
7 1/2" MPT to Barb 150 N/A N/A N/A 11.35 12
8
FPT to Push-to-
Connect
145 N/A N/A N/A 11.35 12
9 Pop Valve 125 5psi
Aquatrol
Inc
ASME 11.35 10
10 Pressure Gauge 1500 N/A N/A CSA 11.35 131
Table [11.4.1]: Pressure System Components
11.5 Non-Commercially Produced Components and Subsystems
Except for the secondary containment vessel, all primary and subsystem components are
commercially produced. The secondary containment consists of a box made from six
1/4in Lexan sheets as shown in Fig. 11.5.1. Lexan is a brand of polycarbonate resin
thermoplastic and has a tensile pressure rating of 9,000psi.
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Figure [11.5.1]: Secondary Containment
To form the secondary containment vessel, Lexan sheets are welded together with IPS
Weldon 3. The bond strength of IPS Weldon 3, after a 48hour cure, is approximately
2400psi. The weld strength is the area of the surface being attached, SAweld , times the
bond strength, Fbond. With a minimum weld area of 3.75in2
where the 15x26in wall is
attached to the 15x18in wall, the weld strength, Fweld, is found in Eq. 11.5.2.
Equation [11.5.2]: Weld Strength
The weld strength must be stronger than the total outward force on the vessel. The total
outward force, Foutward, on the secondary containment can be calculated by multiplying
the surface area, SAwall, by the stress, outward. With a maximum surface area of 390in2
, a
stress of 11.35psi, and the assumption of rapid cabin depressurization, the total outward
force is calculated in Eq. 11.5.3.
outwardwalloutward FSA
11.35psi 390in2
4427lbF
Equation [11.5.3]: Outward Force
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The Margin of Safety is calculated by dividing the weld strength (maximum allowable
stress) by the outward force (maximum operational force) and subtracting 1. The result
for the MS of the secondary containment vessel is shown in Eq. 11.5.4.
Fweld
Foutward
1 MS
9000lbF
4427lbF
1 1.0
Equation [11.5.4]: Margin of Safety
With an accepted margin of safety of above 0, the secondary containment can withstand
the worst-case scenario of a catastrophic depressurization and failure of the automatic
release on the pop valves [3]. Safety is further enhanced by the presence of the ASME
certified pop valve on the secondary containment vessel. The pop-valve will
automatically bleed air out of the secondary containment vessel in the event of a pressure
difference of 5psi or greater.
12.0 Laser Certification
The experiment does not contain a laser.
13.0 Parabola Details and Crew Assistance Required
The Carthage team requests 30 zero parabolas, one Martian parabola, and 3 lunar gravity
parabolas. The experiment will not be negatively affected during the zero gravity portion
of the flight. In-flight support will not be necessary however crew assistance will be
needed to load and unload the experiment onto the aircraft.
14.0 Free Float Requirements
The device will be secured to the floor throughout the flight. There are no free float
components except for the outreach activities that are further detailed in Section 18.
15.0 Institutional Review Board
The Carthage College experiment does not involve research on human test subjects,
animal test subjects. The experiment does not involve biological materials and thus does
not require approval from the JSC IRB.
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16.0 Hazard Analysis
16.1 RGO Hazard Analysis
Please see Appendix B.
16.2 Hazard Identification Checklist
Following is the NS-STO-CH01, General Hazard Identification Checklist.
HAZARD YES NO CONTROLS/COMMENTS
ACCELERATION
INADVERTENT MOTION X All parts are securely fastened to rig, which in
turn will be bolted to floor of aircraft.
SLOSHING OF LIQUIDS X Volume of liquid at any given time consists of a
maximum of 1.4gal and will be contained within
the primary and reservoir tanks.
TRANSLATE LOOSE OBJECT X All loose components and free-float outreach
objects are fitted with Velcro and placed in
stowed duffel bag.
DECELERATION
IMPACTS (SUDDEN STOPS) X The structural design of the rig is designed to
withstand forces that accompany impacts or a
sudden stop.
FALLS X The structural design of the rig is designed to
withstand forces that accompany a fall.
FALLING OBJECTS X All equipment components are securely
fastened to the structure which is securely
attached to the deck of the plane.
FRANGMENTS OR MISSILES X No part of the rig is prone to fragmentation and
all components are securely attached.
CHEMICAL REACTION (Non-Fire)
DISASSOCIATION X There are no chemicals that could result in
disassociation.
COMBUSTION X There are no chemicals that could result in
combustion.
CORROSION X There are no chemicals that could result in
corrosion.
REPLACEMENT X There are no chemicals that could result in
replacement.
ELECTRICAL
SHOCK X All wires are wrapped and sleeved together. A
kill switch is in easy reach of the operators.
BURNS X All wires are wrapped and sleeved together and
no wires are exposed.
OVERHEATING X Should an over-current or overheating occur, a
component circuit breakers will pop.
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IGNITION OF COMBUSTIBLES X No combustible material is used.
INADVERTENT ACTIVATION X The rig is fitted with a kill switch in easy reach of
the operator should the system be inadvertently
operated. There is no hazard associated with
inadvertent activation.
UNSAFE FAILURE TO OPERATE X Operator will undergo training and a kill switch is
in easy access.
EXPLOSION, ELECTRICAL X No wires are exposed and all wires are sleeved.
A kill switch is in easy access of the operator.
VOLTAGE (>50 VOLTS) X The PZT actuator, PA, and the connections
between them are properly connected, secured,
and insulated.
BATTERIES X Computer battery will be tested pre-flight for
integrity.
GENERATION/STORAGE (COILS,
MAGNETS, CAPACTIORS, ETC.)
X No generation system or non-commercial
storage will be used. Battery storage will be
tested pre-flight.
EXPLOSIVE/EXPLOSIONS
EXPLOSIVE PRESENT X No explosive is used.
EXPLOSIVE GAS X No explosive gas is used.
EXPLOSIVE LIQUID X No explosive liquid is used.
EXPLOSIVE DUST X No explosive dust is used.
FLAMMABILITY AND FIRES
PRESENCE OF FUEL X No fuel is present.
PRESENCE OF STRONG OXIDES X No strong dioxides are present.
FIRE DETECTION X There are no fuels or strong oxides, therefore
fire detection is not necessary.
HEAT & TEMPERATURE
SOURCE OF HEAT, NON-
ELECTRICAL
X No sources of eat or other non-electrical
sources of heat are used.
HOT SURFACE BURNS (>113
O
F,
45
O
C)
X All surfaces will be at room temperature.
VERY COLD SURFACE BURNS
(<39
O
F, 4
O
C)
X All surfaces will be at room temperature.
INCREASED GAS PRESSURE X No part of the rig will be pressurized.
INCREASED FLAMMABILITY X There is no threat of increased flammability if
temperature is increased.
INCREASED VOLATILITY X There is no threat of volatility if temperature is
increased.
TEMPERATURE DIFFERENTIALS
STRESSES
X There are no thermal differentials that could
cause stress on the structure of the rig.
HARDWARE SAFE THERMAL
LIMITS KNOWN
X There is no reasonable possibility of the
experiment deviating sharply from cabin
temperature.
MECHANICAL
SHARP EDGES OR POINTS X All corners and edges of the rig frame will be
covered by foam padding.
ROTATING EQUIPMENT X There is no rotating equipment.
RECIPROCATING EQUIPMENT X There is no reciprocating equipment.
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PINCH POINTS X There are no exposed moving components;
hence, no pinch points are present on the
structure.
WEIGHT TO BE LIFTED (exceeds
40 lbs, or 4 ft. in diameter)
X The rig weighs approximately 145lbs and has
overall dimensions 44 x 30 x 30in. For rig
movement, a minimum of four team members
will assist to ensure the safe distribution of
weight.
STABILITY/TOPPLING
TENDENCY
X The rig will be bolted securely to the floor and all
components are either contained within the
secondary containment or are securely attached
to the rig frame.
EJECTED PARTS/FRAGMENTS X No part of the rig is at risk for fragmentation. All
parts will be firmly attached to the rig frame or
contained within the secondary containment.
INADEQUATE DESIGN X All components in the rig are within safe
operating parameters by high margins of safety
and structural verification.
STORED ENERGY (SPRINGS,
WEIGHTS, FLYWHEEL, ETC.)
X Our rig has no mechanism that stores significant
amounts of energy.
PRESSURE & GASES
DYNAMIC X There are no dynamic pressures.
COMPRESSED GAS X There is no compressed gas.
COMPRESSED AIR TOOL X There is no compressed air tool used.
ACCIDENTAL RELEASE X There is no gas that could inadvertently escape.
BLOWN OBJECTS X Small pressure differentials may be created
during fill fraction changes but automatic and
manual pressure release valves have been
equipped on primary and secondary
containments.
HYDRAULIC WHIPPING X There are no hydraulics being used that could
result in whipping.
STATIC X There are no non-atmospheric static pressures.
CONTAINER RUPTURE X The primary tanks and secondary containment
are fit with pressure release valves that release
at a difference of 5psi and can also be released
manually. The COTS tanks are pressure tested
and certified for operation up to 150psi.
PRESSURE DIFFERENTIAL X No part is pressurized but both primary and
secondary containments are outfitted with
pressure release valves that automatically
release at a difference of 5psi and can also be
released manually.
NEGATIVE PRESSURE EFFECTS X Negative pressure may occur when the drain
pump is in use. Pressure release valves have
been outfitted in the primary tank to relieve the
pressure change.
LEAK OF MATERIAL WHICH IS:
FLAMMABLE X No flammable materials are in use.
TOXIC X No toxic materials are in use.
CORROSIVE X No corrosive materials are in use.
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RADIATION
IONIZING RADIATION X There is no threat of ionizing radiation.
ULTRAVIOLET LIGHT X There is no ultraviolet light created.
HIGH INTENSITY VISIBLE LIGHT X There is no high intensity visible light created.
INFRARED RADIATION X There is no infrared radiation created.
MICROWAVE RADIATION X There is no microwave radiation created.
LASER X There are no lasers used.
TOXIC
GAS OR LIQUID X There are no toxic gases or liquid used or
created.
ASPHYXIANT X There are no asphyxiants used.
IRRITANT X There are no irritants used.
SYSTEMIC POISON X There are no systemic poisons used.
CARCINOGEN X There are no carcinogens used.
OTHER ADVERSE PROPERTY X There are no other known adverse properties.
COMBINATION PRODUCT X There are no reactions that will take place to
form combination products.
COMBUSTION PRODUCT X No combustion will take place.
POTENTITAION X There is no threat of potentiation.
SYNERGISM X Nothing used is at risk for synergism.
VIBRATION
VIBRATION TOOL X There are no vibration tools used.
HIGH NOISE LEVEL SOURCE X There are no high noise level sources used.
METAL FATIGUE CAUSATION X All metal structural components have been
designed to have generous margins of safety.
FLOW OR JET VIBRATION X No jets are used.
SUPERSONIC X There is no potential for components to achieve
supersonic speeds.
MISCELANEOUS
CONTAMINATION X No material used can contaminate the aircraft.
LUBRICITY X Nothing used will cause a slick surface if spilled.
VIOLENT ODOR X There is nothing odorous used.
TRAINING X Each team member will be fully trained in the
proper way to operate the rig. Each member
will also be trained on the various types of
difficulties that could be encountered that the
proper ways to handle each scenario. Team
members will also be cross-trained to carry out
each role in the event of crew-member
incapacitation.
HYPOXIA X No risk of hypoxia is associated with the
experiment.
STRUCTURAL FAILURE X All structural components have a margin of
safety greater than zero.
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17.0 Tool Requirements
Our experiment is self-contained and no tools are required during operation. Any tools
needed for assembly and final adjustments of the experiment will be those of the Reduced
Gravity Office.
18.0 Educational Outreach
Educational outreach is essential for the promotion of STEM fields and NASA programs.
Through outreach activities, excitement for science and engineering and motivation to
work hard are instilled within young audiences in a fun and engaging manner. The
Carthage Team plans on organizing and setting up many outreach activities and events to
allow the participation and engagement of the K-12 audience, particularly in the Kenosha
area. Each Carthage team member has outreach experience; these experiences include
original demonstrations and volunteering at local community science events. Since each
many outlets to venues and audiences in the local community are available.
18.1 Planned Outreach and Dissemination Program
18.1.1 Science Fair
Team members have already assisted in judging a science fair at Gateway Technical
College (Kenosha, WI) for students from Lakeview Technology Academy. This gave
team members an opportunity to directly influence individual high school students and
introduce the SEED program to them.
18.1.2 Science Nights
Through Christine Pratt, the Kenosha Unified School District Science Coordinator, the
team will assist in planning and organizing science nights at elementary schools for the
students and their parents. The team will be able to share their experiences with NASA
and inspire them to learn more about space science and related STEM fields.
18.1.3 Family Fun Night
Carthage College regularly hosts Family Fun Nights for younger students in the
community, as well as their families. These are of no cost to the visitor and provide a
ve
the students and get them to actively think about the principles behind each demo. The
The idea is that an asteroid is going to hit the children's school and the
students need to learn about the laws of physics and outer space to prevent the disaster.
Through this theme, students will practiced problem solving and apply basic physics
concepts in a fun way.
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18.1.4 School Visits
Each team member will visit his or her respective high school after departing Ellington
Field. The team will also visit multiple schools located in Kenosha County including
Harvey Elementary, Kenosha School of Technology Enhanced Elementary, Stocker
Elementary, Somers Elementary, Bullen Middle, Lance Middle, Mahone Middle, Indian
Trail Academy High and Tremper High School. During these visits, the team will
perform age-appropriate demonstrations, show flight footage, and get K-12 students
interested in science and the STEM programs.
18.2 Outreach Experiments
The Carthage flight team will conduct short, safe experiments while on board the aircraft.
These experiments demonstrate basic physics concepts and will be shown to various age
groups during our planned outreach presentations. The items, when not in use, will be
stored in a closed bag which will be attached to our rig or stowed in the aircraft storage
boxes.
18.2.1 Momentum Conservation
A team member will firmly hold on to a Shake Weight and turn it on. For each
moveme
direction to conserve momentum. This demonstration will be recorded on a video camera
and be shown in schools to demonstrate momentum conservation in an exciting, novel
way.
Fig. [18.2.2]: Shake Weight
18.2.2 Buoyancy
Before flight, a balloon will be filled with helium and attached to the rig by a string. A
balloon throughout the remainder of the flight. The team will show the video of the
balloon during school visits to talk about the density of helium, buoyancy and their
relationship to gravity.
18.2.3 Human Interactions with Zero Gravity
During flight, one team member will wear a helmet camera and do somersaults in zero
gravity with assistance from an RGO crewmember. The camera will be securely fastened
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to the experimenter while he or she is spun around. This will provide perspective during
the acrobatic maneuvers. The footage will be shown during school visits. Video cameras
will also record footage of the experimenters during each zero-g parabola. During the
outreach presentations, the team members can exhibit how zero gravity affects humans
and their movement.
19.0 Photo Requirements
We request that video footage and still photographs be taken for documentation purposes
that will be used in outreach efforts made by the team after flight. One camera pole is
also requested to support two cameras that will be used for outreach.
20.0 Aircraft Loading
A forklift will be needed to lift the experiment onto the plane. Once onboard the aircraft,
the rig can be moved into place by two people. The rig will be strapped down with the
assistance of the RGO staff.
21.0 Ground Support Requirements
Access to a power source is necessary to test equipment.
22.0 Hazardous Materials
This experiment does not use hazardous materials.
23.0 Material Safety Data Sheets (MSDS)
The MSDS for water is not necessary.
24.0 Procedures
24.1 Equipment Shipment to Ellington Field
The equipment shall be sent to Ellington Field via UPS. The equipment will arrive before
March 30, 2011 to allow time for buildup, inspection, and the Test Readiness Review
(TRR). The only storage requirement requested is for the rig to be stored in a dry place
and in the orientation specified on the shipping crate to ensure the integrity of our
hardware.
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24.2 Ground Operations
Once the crew arrives and after the safety briefing, we will run through our inventory
checklist to ensure that all parts are accounted for. Ground testing shall be conducted to
verify that the rig is still in working order and to practice in-flight procedures. Water
access and a power outlet of 115V will be needed to perform ground testing.
24.3 Loading/Stowing
Due to the weight of the rig, we request a forklift to load the rig onto the aircraft. Once
the rig is aboard the aircraft, four flight crew members shall move the rig to the assigned
location by hand. During take-off and landing, the outreach supplies will be stowed in a
zippered bag that is attached securely to the rig for safety.
24.4 Pre-Flight
Check lists will be used to ensure that the fill caps, water pump, electronics, and solenoid
valve are working correctly and are in the correct states. Before the first flight, the tank
shall be filled with water to the maximum required experimental volume of 70% of the
capacity of the tank (1.4 gal). The secondary containment shall be sealed around the
experiment equipment, and the rig secured to the plane.
24.5 Take-Off/Landing
The rig shall be secured to the plane during take-off and landing. Outreach materials
shall be stowed in a bag at this time. This is the only on-board storage our experiment
requires. There are no power requirements during take-off or landing.
24.6 In-Flight
24.6.1 In-Flight Setup
Before Takeoff
1. The laptop will be stowed in the power off state
2.
After Takeoff
1. Main power will be turned on
2. Laptop will be attached to the rig, turned on, and connected to the cDAQ
3. LabVIEW 8.0 activated and the experiment interface will be loaded
4. External power source for pump will be turned on
5. Pressure release valves will be triggered in both tanks and the secondary containment to
equalize pressure
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24.6.2 Parabolic Maneuvers
Zero Gravity
1.
the parabola and to initializing the fluid pump and pressure regulation
2. One member will be assigned to watching the differential pressure gauge on the
tank to ensure that the differential ullage pressure does not exceed 5 psi
3. One member will be responsible for opening the solenoid valve to drain the tank
at specified intervals during the flight. This is necessary to test all 9 fill fractions
all the way down to 30%
4. Specific roles of members are assigned below:
First Flight Day
I. Kimberly
II. The Alternate or Faculty Advisor will watch the differential pressure
gauge while performing outreach activities
III. Amber will release the solenoid valve in order to achieve these fill
fractions (The solenoid valve will be released every 6 parabolas
assuming that we have about 27 manageable parabolas per day) :
70%
65%
60%
55%
50% (Note: the 50% fill fraction will only be tested for 3 parabolas on
the first day)
IV. Kimberly will also manually open the pressure release valves on the
secondary containment and both tanks. She will then power on the pump
to drain the water into the reservoir tank.
Second Flight Day
I.
II. The Alternate or Faculty Advisor will watch the differential pressure
gauge while performing outreach activities
V. Stephanie will release the solenoid valve in order to achieve these fill
fractions (The solenoid valve will be released every 6 parabolas
assuming that we have about 27 manageable parabolas per day) :
50% (Note: Testing of the remaining 3 parabolas for the 50% fill fraction
will be conducted on the second day)
45%
40%
35%
30%
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VI. Cecilia will also manually open the pressure release valves on the
secondary containment and both tanks. She will then power on the pump
to drain the water into the reservoir tank.
Martian Gravity
The experiment does not require Martian Gravity; therefore outreach activities will take
place during this time.
Lunar Gravity
The experiment does not require Lunar Gravity; therefore outreach activities will take
place during this time.
24.6.3 In-Flight Experiment Shut-Down
1. After all parabolas are complete, all electronics will be turned off. This includes the
laptop, solenoid valve, and pump
2. Laptop will be stowed
24.7 Post-Flight
All equipment will be inspected to ensure all powered features are completely turned off.
The data collected on the first day flight will be inspected and analyzed on LabVIEW 8.0
to determine whether the data followed expected trends. If not, adjustments to the
experimental procedures will be made to ensure data will be taken properly the second
day.
24.8 Off-Loading
Outreach materials will be removed from the rig after the final flight. The rig will be
removed using 4 crew members and a forklift. The forklift will be used to move the rig
to a position where it will be ready to be picked up by UPS. The rig shall be shipped
back to Carthage College in Kenosha, WI.
25.9 Emergency/Contingency
The equipment will be designed so that emergency procedures can be initiated to prevent
furthering a hazardous situation.
Fluid Leak:
1. One person will be assigned to turning the kill-switch to the off position.
2. One person will be assigned to monitoring the other equipment to ensure all electronics are
turned off in this event.
Rapid Cabin Depressurization:
1. Pop valves will be released automatically after a differential pressure of 5 psi is experienced
by the tank.
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2. The crew member monitoring the pressure gauge will check to ensure all pop valves have
been popped.
Fire:
1. All electronics will be turned off by the kill-switch.
Crew member incapacitation:
1. If a crew member becomes incapacitated, critical procedures can be conducted by a single
crew member.
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25.0 Bibliography
1. Turblex Inc. Siernens Company, 2001.
Web. <http://www.turblex.com/altitude/index.cfm>.
2. AOD 33897, Experiment Design Requirements and Guidelines NASA 932 C-9B
3. Fast Facts Reduced Gravity Flight Education Program, Rev B, NASA Johnson
Space Center, September 2010.
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Appendix A: Acronyms
A/D Analog to Digital Converter
ANSI American National Standards Institute
AOD Aircraft Operations Division
ASME American Society of Mechanical Engineers
AWG American Wire Gauge
BX Balun where X is the terminal number
BNC Bayonet Neill-Concelman coaxial cable
cDAQ compactDAQ
COTS Commercial Off the Shelf
CSA Canadian Standards Association
D/A Digital to Analog Converter
DAQ Data Acquisition System
FFT Fast Fourier Transform
FNPT Female National Pipe Tapering Threads
FRF Frequency Response Function
HV High Voltage
ID Inner Diameter
IX Interface X where X is a number
JSC Johnson Space Center
KSC Kennedy Space Center
MNPT Male National Pipe Tapering Threads
MWAP Maximum Allowable Working Pressure
NASA National Aeronautics and Space Administration
NPT National Pipe Tapering Thread
OD Outer Diameter
PA Power Amplifier
PI Principle Investigator
PZT Piezoelectric Transducer
RF Radio Frequency
RGO Reduced Gravity Office
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SE Systems Engineering
SEED Systems Engineering Educational Discovery
SG Signal Generator
SPS Society of Physics Students
SV Solenoid Valve
TB Terminal Block
TEDP Test Equipment Data Package
TP Twisted Pair
USB Universe Serial Bus
VI Visual Interface
WBS Work Breakdown Structure
WSGC Wisconsin Space Grant Consortium
