Comprehensive description of the capstone senior design course at the Department of Aerospace Engineering of the University of Colorado

1. Aerospace Engineering Sciences
Capstone
Senior Design Projects
ASEN 4018/4028
How they prepare students for the workforce
Jean N. Koster
University of Colorado
Boulder, Colorado
14 February 2009

2. REAL WORLD STATUS 2008
• 20% Of the Workforce Is Eligible To Retire
Today
• One-third Of the Workforce Eligible To
Retire In 5 Years
• One-half Of the Workforce Eligible To
Retire In 10 Years
Greg Enders, LMCO, 2008 2

3. Capstone - Senior Projects
• Two-semester 4+4 credit hour course.
– Typically 8 teams with 7-10 members
– Senior Projects I (ASEN 4018) focuses on the synthesis of undergraduate
knowledge and the design process,.
– Senior Projects II (ASEN 4028) focuses on the fabrication, integration, and
verification of the designs produced in ASEN 4018.
• Requirements-based Systems Engineering.
• Synthesis and application of the fundamental core sciences,
mathematics, and engineering theory.
• Design, Fabrication & Testing, Verification and Validation of
a complex component or system
– CDIO: Conceive, Design, Implement, Operate
• Project Advisory Board (PAB) of 9 Faculty and 2 Staff
members advise student teams
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4. AES Senior Projects Structure
Course
Machinist
Coordinator
Matt Rhode
Electronics
Trudy Schwartz
2 PAB 2 PAB 2 PAB 2 PAB
2 PAB 2 PAB
2 PAB 2 PAB
Advisors Advisors Advisors Advisors
Advisors Advisors
Advisors Advisors
TEAM 2 TEAM 3 TEAM 4 TEAM 5 TEAM 6 TEAM 7 TEAM 8
TEAM 1
Customer Customer Customer Customer Customer Customer Customer
Customer
Maximum 8 Teams
2 3 4 5 6 7 8
1
7-10 7-10 7-10 7-10 7-10 7-10 7-10
7-10
Students Students Students Students Students Students Students
Students
Project Advisor Board (PAB) – Total 9 faculty (1 course credit) and 2 staff
1 Course Coordinator (Jean Koster, 2008)
8 Faculty Team Advisors; advising 2 different teams each
Each advisor duo is different
Staff advisors: Matt Rhode and Trudy Schwartz
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5. Typical Senior Projects Team Structure
Self-directed teams operate like small entrepreneurial businesses
2 PAB
Customer Advisors
Project Systems
Manager Engineer
CFO Manufacturing Safety
Engineer Engineer
Common Subsystems:
Mechanical
Electrical
Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4
Software
Lead Engineer Lead Engineer Lead Engineer Lead Engineer
Aerodynamics
Structures
Thermal
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6. Course Milestones
Foundation:
Customer Project Proposal and Requirements Document (CPRD)
Progress Evaluation Process and Deliverables:
1. Project Definition Document (PDD)
2. Conceptual Design Document (CDD)
3. Preliminary Design Review (PDR)
4. Critical Design Review (CDR)
5. Fall Final Report (FFR)
6. Spring Manufacturing Interim Reviews (IR1, IR2)
7. AIAA Student Regional Conference Paper
8. Spring Project Review (SPR)
9. Project Final Report (PFR)
10. ITLL Public Expo
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7. Course Schedule
Team Formation
CPRD,
PDD
CDD
CDR
PDR
Editing
FFR
Break
Fall
W01 W02 W03 W04 W05 W06 W06 W08 W09 W10 W11 W12 W13 W14 W15 W16 W17
Detailed Design
Preliminary Design
Last Machining Day
ITLL EXPO
IR #2
IR #1
SPR
Editing
PFR
Break
Spring
W01 W02 W03 W04 W05 W06 W06 W08 W09 W10 W11 W12 W13 W14 W15 W16 W17
Manufacturing Integration and Test
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8. Educational Support
The Department provides weekly supporting lectures and specialty
workshops during the Fall semester (ASEN 4018). Attendance at lectures is
required for all; attendance at workshops is required for select positions.
Lectures: Workshops:
• •
Project Selection System Engineers
• •
Conceptual design Program Managers
• •
Defining Requirements Team working
• •
Systems Engineering Fabrication (9)
• •
Mission Failures Measurements
• •
Project Management Electronics
• •
Running Meetings Power Systems
• •
Patent Law, IP Composite Fabrication
• •
Ethical Decision-Making Safety
• •
Entrepreneurship Fire 8

9. Deliverables 1 (PDD)
Customer Requirements → Project Definition (PDD)
–Background, Goal, Objectives, Functional Block Diagram,
Concept of Operations
–Top level Project Requirements (0.PRJ.xx)
–Top level System Requirements (0.SYS.xx)
–Minimum Requirements for Success
–Deliverables Defined
–Technical and Financial Risks
–Team Formation and Team Expertise
–Resources Defined
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10. Deliverables 2 (CDD)
Project Definition → Conceptual Design (CDD)
– Team skills and positions
– System Architecture (3 design options)
– Requirements (3-5 most important reqs., rank)
– Feasibility (for top ranked architecture option)
– Testing and Verification requirements for key systems
– Assess key risks and mitigation options
– Assess team qualifications
– Respond to criticism received on PDD
– Resources availability update
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11. Examples: Choosing System Architecture
•Wheeled •Snake
•Spider •Roller
•UAV •Tracked
System concept baseline study – selected wheeled architecture
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ASEN 4018

12. Deliverables 3 (PDR)
Conceptual Design → Preliminary Design (PDR)
– Development and assessment of system design options; arguments for
chosen architecture
• Flow-down from functional needs to identified requirements
– System Design-To specifications. Development and assessment of
subsystem design options and design-to specifications
• Preliminary itemization of required performance parameters
– Project Feasibility Analysis and Risk Analysis
• Define high risk sub-system for prototyping
• Back-of-the-envelope, Matlab, preliminary analysis or test
• Define optional “off-ramps”
– Project Management Plan (preliminary)
• Myers-Briggs analysis
– Advisers may submit Request for Action (RFA) to teams.
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13. Oral Presentations: PDR, CDR, IR1+2, SFR
• Presentation to 11 PAB members and entire body of student
• Customers are invited to attend. Separate presentation to
customer recommended.
• Presentations: 50 minutes: 25 min presentation and 25 min Q&A
• Every student must present at least once each semester

14. Example: System Breakdown Structure
Project: MARVLIS - 2007
6’’ Dimension, 10 min Endurance, Image Capture/Transmission with location,
Launch Capability
Structures Electronics Launcher
Aerodynamics Aerodynamics Propulsion
Airfoil Airframe Propeller Camera Spring
Telescoping
Planform Materials Motor/Gearbox Receiver
Leg
Launch
Tail/Stabilizers Batteries GPS
Electronics
Control Speed
MAV Interface
Surfaces Controller
Servos
Legend
System Subsystem Sub-
Requirements s Subsystems
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February 14, 2009 MARVLIS

15. Example: Design-To Specifications
ReMuS 2008
Mother Rover Design-To Specifications
1. Baseline weight of 100 lbf.
2. Baseline dimensions of 3.5 ft. wide x 3.5 ft. long x 2.0 ft. high
3. Base of Mother = 4.25 in. from ground level
4. Mounted camera must see Children at all times
Child Rover Design-To Specifications
1. Baseline weight of 15 lbf.
2. Baseline dimensions of 10 in. wide x 10 in. long x 8 in. high
Ramp Design-To Specifications
1.Length of ramp is greater than length of
Child rover
2.Ramp is 3x wider than Child rover
3.Ramp is placed on front or back of Mother
rover only
4.Ramp will have ¼-in. ground clearance
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(representative model only)
Preliminary Design Review

16. Example: Aerodynamics Risk
Justifications:
• Wings too small
Insufficient
Improperly
directional
– Cannot take off in 75 ft, use batteries
sized tail
stability
too fast
– Mitigation: Prototyping
Improperly
• Improperly sized tail
Wings too
sized control
Consequence
small
– Plane is unstable & uncontrollable
surfaces
– Mitigation: Margin & prototyping
• Improperly sized control surfaces
– Aircraft is uncontrollable
– Mitigation: Extra analysis & margin
• Insufficient directional stability
– Aircraft stability is unknown and not
considered
– Mitigation: Adding a vertical fin &
Possibility
deflecting single rudder in turn, use drag
to turn
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17. Deliverable 4 (CDR)
• System Architecture is fully documented at CDR
• All subsystems are checked for feasibility and are given a “go”
• Sub-system decomposition and integration is understood
– Mechanical, electrical, and software elements are analyzed
– All blue-prints are ready to enter the fabrication process
• Interfaces between sub-systems are working well
– Integration of sub-systems into units is understood
• Manufacturing and System Integration Plan
• The Testing and Verification Plan is finalized
– Test concepts of operation are documented
• Project Management Plan (PMP) is finalized
• The System Engineer signed off on the proposed design
• Manufacturing of components starts after successful completion of
CDR.
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B. S. Blanchard, W.J. Fabrycky, Systems Engineering and Analysis, Prentice Hall,2006.

18. System
Example: System Design Architecture
MADS 2008/9
1. Primary Vehicle (PV)
• On-board PIC controls the Deployment
Mechanism (DM) through Command and
Data Handling (CDH)
• Pilot controls the control surfaces
2. Deployment Mechanism (DM)
• Consists of mounting point for the SV and
linear actuator for pin-movement
• Attached to the PV with bracketing system
3. Sub-Vehicle (SV)
• CUPIC autopilot controls the control
surfaces and motor settings through CDH
• Payload is supplied with its own power
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Critical Design Review

19. Deployment
MDE
Design Detail at CDR (MADS) Mechanism
Deployment Mechanism Design-To Specs
• The SVs shall be deployed on demand.
• The DM shall weigh no more than 13 g
• The DM shall be mounted on a rod (the bracket) capable of
withstanding the expected loads.
Deployment Mechanism Design Prototype & Testing Results
• Actuator pulls a pin • Under vibrations from 0 Hz to 150 Hz, successful
• Pin removes attachment to SV deployment 121/124 trials
• DM weighs 9g • Confidence of 95 % in vibrations
• DM mounted to an aluminum beam • During simulated aerodynamic loading, successful
deployment 20/20 trials
• Confidence of 99 % in aerodynamic loading
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Critical Design Review

20. Example: Matlab Model
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ASEN 4018

21. Example: Verification & Prototyping
Tail Boom Test Load versus Displacement
0
Experimental
-1
Theoretical
-2
-3
Displacement (in)
-4
-5
-6
3.65quot; At Estimated
-7
Max Load
-8
Failure at
23lbs
-9
8.75quot;
-10
0 5 10 15 20 25
Load (lbs)
Conclusion: Need thicker boom due to deflection at max load.
Based on experimental data: OD = .312” for 1.5” deflection (+1.3oz)
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ASEN 4018

22. Deliverable 5 (FFR)
The Fall Final report is a comprehensive documentation of the design process.
The data package includes:
Mechanical Drawings, Electrical Schematics, Software specifications
Table of Content
7. Project Feasibility, Prototyping,
1. Project Objectives and
and Risk Assessment
Requirements
8. Mechanical Design Elements
2. System Architecture
3. Development and Assessment of 9. Electrical Design Elements
System Design Alternatives
10. Software Design Elements
4. System Design-To Specifications
11. Integration Plan
5. Development and Assessment of
Subsystem Design Alternatives 12. Verification and Test Plan
6. Subsystem Design-To
13. Project Management Plan
Specifications
14. Appendices

23. Deliverable 6 (IR1 & IR2)
The two informal Interim Reviews have the goal to inform
the entire PAB about fabrication and testing progress
• current manufacturing progress
• progress in software development
• progress with electronics modules
• any design modifications
• analysis of any “off-ramp” subsystems which require new
system engineering analysis
• changes in verification and test plan
• preliminary testing results and analysis,
• any changes in management plan and team organization
• lessons learned and any issues that have occurred

24. Deliverable 7 (AIAA-paper)
• All teams are required to prepare a paper on their
project according to published AIAA guidelines for
the Region V Regional Student Conference in Spring
• Paper must be prepared according to the published
AIAA Author Kit
• Papers are graded according to quality as perceived
by faculty advisers and any AIAA criteria
• Actual submission to AIAA will be recommended by
team advisers
• Teams will participate in the Team Competition

25. Senior Design Student Paper Awards
AIAA Region V Student Paper Conferences
2008
• First Place, Team Division (KRAKEN team)
• Second Place, Team Division (MARVLIS team)
2007
• First Place, Team Division (SOARS team)
• Best Student Paper, JANNAF Conference, MaCH-SR1 team
2002
• First Place, Undergraduate Division (Otto Krauss – MaCH-SR1 team)
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26. Deliverable 8 (SFR)
The Spring Final Review (SFR) marks the
culmination of the senior design project.
The oral presentation includes:
– Project Objectives and Requirement
– System Architecture and Component design
– Fabrication and Integration
– Experimental Test Results; Verification and Validation
– Project Management
– Lessons Learned
– Project Conclusion and Summary

27. Deliverable 9 (PFR)
The Project Final Report is a comprehensive documentation of results
including design, integration, verification and validation, for both semesters
1. Project Objectives and 8. Mechanical Design
Requirements Elements
2. System Architecture 9. Electrical Design
Elements
3. Development and
Assessment of System Design 10. Software Design
Alternatives Elements
4. System Design-To 11. Integration Plan
Specifications 12. Verification and
5. Development and Validation
Assessment of Subsystem 13. Fabrication and
Design Alternatives Integration
6. Subsystem Design-To 14. Project Management Plan
Specifications 15. Lessons Learned
7. Project Feasibility and Risk 16. Appendices
Assessment

28. Deliverable 10: ITLL Poster Presentation
The major component of this assignment is for teams to
communicate the project goals and accomplishments to a
broad audience of non-specialists and K-12 students
Poster elements:
• Project Objectives and Requirements
• Development of Design Alternatives
• Final Design
• Project Drawings, Schematics and Diagrams
• Project Hardware
• Experimental Test Results
• Project Management

29. Example: ITLL Poster Presentation
http://www.colorado.edu/ASEN/SrProjects
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30. Conclusion
The Capstone Senior Design course as implemented would
not have been possible without the undergraduate
Curriculum 2000 reform, which integrated the
Conceive – Design – Implement - Operate (CDIO)
elements into the entire undergraduate curriculum

31. History of Recent Projects - 1
To create an experimental apparatus that can
BIRDIE Biologically-Inspired low
trace out a given wing motion similar to a
Reynolds number Dynamic
hummingbird in hovering flight
Imagery Experiment
Provide a spinning satellite with a de-rotated
DIABLO De-rotated Imager of the
imaging system
Aurora Borealis in Low-
Earth Orbit
To design, fabricate, integrate and verify a RC
D-SUAVE Deployable Small UAV
controlled UAV capable of being remotely
Explorer
deployed from the ARES aircraft and flying a
specific flight pattern
To provide the Colorado Space Grant
PRV Peregrine Return Vehicle
Consortium with a reusable vehicle that can
return student built science payloads to a
selected target
Design, build and test an autonomous aerial
SOARS Self Organizing Aerial
system (UAS) capable of imaging multiple
Reconnaissance System
targets within a 1 km circle as quickly as
possible with 99% probability of object detection
(according to Johnson criteria)
Supersonic wind tunnel (Mach number 1.5 – 2.5)
SWIFT Supersonic Wind and
and flow visualization system operable by
Imaging Flow Tunnel
undergraduate students

32. History of Recent Projects - 2
Design and build a prototype for locomotion
VITL Vehicle for Icy Terrain
system of a vehicle exploring a Europa-like surface
Locomotion
capable of traversing 1 km of icy terrain in 7 days
with characteristic obstacles
Conceive, design, fabricate, integrate, test, and
BREW Bolt-on Racecar
verify a device that allows the measurement of the
Enhancing Wing
downforce and drag of any rear wing for present
and future CU FSAE cars
Conceptualize, design, fabricate, test, and verify
CALAMAR-E Cavity Actuated Low-
synthetic jet actuators for a highly maneuverable,
speed Actively
low speed under water vehicle
Maneuverable Aquatic
Rover Experiment
Produce a wing that demonstrates roll control
Flap and Aileron
without mechanical linkages by integration of
Replacement System
smart materials as actuators
Conceive, design, fabricate, integrate, and verify a
MaCH-SR1 Multi-disciplinary
self-sufficient hybrid rocket engine
Conceive, design, fabricate, and test a deployable
MARS Meteorological Aerial
dual-mode sonde system that will provide multi-
Research Sonde
unit communications ability capable of sustained
flight times and controlled flight

33. History of Recent Projects -3
Design, build, test a return vehicle for scientific
HARRV High Altitude Research
payloads released from high altitude balloons
Return Vehicle
to proximity of balloon launch site
Design a model space elevator system to compete
SPEC Space Elevator Climber
in the Spaceward Foundation “Elevator 2010”
competition.
Design, fabricate , and characterize a FanWing
Short TakeOff Wing
device
Conceive, design, fabricate, integrate, test, and
HAVUC Heavy-lift Aerial Vehicle for the
verify an un-inhabitated aerial vehicle (UAV) with a
heavy-lift capability that has an empty weight no
greater than 10 lb; heavy-lift being defined as the
payload contributing a minimum of 60% to the total
takeoff weight
Develop a low-cost, easy to operate, and reliable
SHARC Stable Handling Aerial Radio-
aerial vehicle for testing of sensor payloads
controlled Cargo-testbed
Design, build, fly a high-volume payload
CUBDF Design-Build-Fly
competitive aircraft after AIAA competition
guidelines.

34. History of Recent Projects -4
APTERA Aero-Braking Project To Design, build, and test a deployable device
Effectively Reduce Altitude which will increase aerodynamic drag with the
intent of changing the orbit of the DANDE
satellite from 600km to 350km within 300 days.
Mach-SR1 Multi-disciplinary Hybrid Student design, build, test, integrate feed, injection and
Rocket Project ignition subsystems into a flight configuration for a
hybrid rocket to deliver a 0.5 kg payload to an
altitude of 4,500 m.
KRAKEN Kinematically Roving Design, build, competitively test an unmanned
Autonomously controlled Electro- underwater vehicle equipped with vortex ring
Nautic thrusters
MARVLIS Micro Air Reconnaissance Vehicle Design, fabricate, and test a micro air vehicle
Launch and Imaging System capable of capturing an image and transmitting it
with a time and position stamp
ADAMSS Aerially Deployed Autonomously Design and build a system that can remotely place
Monitored Surface Sensors low-cost disposable sensors, collect science data,
and then retrieve this data all without on-site human
interaction
ARCTIC Arctic Region Climate Tracking The goal is to develop a payload that provides arctic
and Instrumentation Cargo climate data measurements at otherwise
inaccessible earth-fixed locations. The payload will
be constructed for an InSitu Insight A-20 UAV.

35. History of Recent Projects -5
MADS Miniature Aircraft Deployment Goal is to develop a system that can attach to
System the radio-controlled (RC) primary vehicle
capable of in-flight deployment of 4 secondary
vehicles that are capable of self-sustained flight.
ReMuS Re-deployable Multi-rover System The goal of this project is to provide a proof-of-
concept for an interacting multi-robot system.
Two child robots will detach from the mother,
perform tasks and reattach to the mother.
SUAV Solar Unmanned Aerial Vehicle The goal is to modify a high performance
sailplane by the addition of a structurally
integrated photovoltaic System in order to
extend the standard endurance of the aircraft by
250%.
SWARM Systematic Waypoint based Design an autopilot, communication
Autonomous Reconnaissance infrastructure, and coordination algorithm
MAVs compatible with Micro Air Vehicles. Integrate
autonomous launch and flight in swarm with rigid
algorithm control.
VALASARAPTOR Vertical Ascent and Landing Design and build modifications that will outfit an
Aircraft for the Study of existing remote controlled UAV with VTOL and
Atmospherics in Recording hovering capabilities and carry a NOAA
Acoustic Propagation of Terrestrial designed probe.
and Oceanic Radiation

36. CU-AES Senior Design Webpage:
http://www.colorado.edu/ASEN/SrProjects
AES Senior Design Network
http://aesseniordesign.ning.com/
http://www.linkedin.com/groups?gid=159152
Contact:
Jean.Koster@Colorado.edu
+(303)492-6945
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