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BIG BLUE Satellite
Program
A High Altitude Inflatable -Winged Aircraft
Baseline Balloon
Inflatable Launch
Glider Unmanned
Experiment
BIG BLUE Satellite
Program
Core Team• Student team leaders
– Justin Kearns, Overall Team and Mechanical Engineering Technical Lead
– Mike Carter, Project Manager
– Aaron Welch, Electrical Engineering Technical Lead
• Advisors– Dr. Suzanne Weaver Smith, Principal Investigator and System Integration
– Dr. Jamey Jacob, Aeronautics
– Dr. William Smith, Communications and Power
– Dr. James Lumpp, Flight Control and Power
• Sponsors– National Space Grant Consortium via Kentucky Space Grant Consortium
– NASA EPSCOR
– ILC Dover, Inc.
– UK VP of Research
BIG BLUE Satellite
Program
The General Plan
• Phase 1 and 2: 1.5 hour ascent at a constant rate • Phase 2 begins prior to balloon release
• Phase 3: 2.5 hour descent
BIG BLUE Satellite
Program
Motivations• Low density (low Re) aircraft
- High altitude defense- Marscraft
• To overcome this challenge: larger wing span• Problem: costly to launch such large structures• Solution: Inflatable wings
BIG BLUE Satellite
Program
ILC Dover • Design and development of softgoods products for both
government and industry
• Experienced NASA contractor
– spacesuit design
– flexible space structures
BIG BLUE Satellite
Program
CU Balloon Launch
• Edge of Space Sciences (EOSS)
– a Colorado based non-profit
organization that explores frontiers in
amateur radio and high altitude
ballooning
BIG BLUE Satellite
Program
Project Time-Line • October 2002 - core team formed, grant awarded, ILC Dover, Inc. visit
• November 2002 - balloon launch in Colorado
• December 2002 - wing design completed, control system design completed and tested
• January 2003 - NASA Langley, Wallops Island, UAT & NASA Marshall visits
• February 2003 - Final verification tests
• March 2003 - Critical Design Review, 1st Flight Readiness Review, 1st BIG BLUE Satellite launch
• May 2003 – 2nd Flight Readiness Review, 2nd BIG BLUE Satellite launch
• August 2003 - flight data reduction and analysis
BIG BLUE Satellite
Program
Balloon Launch Basics
• Density and pressure drop
exponentially
– 30 km: alt=sl/60, Palt=Psl/100
• Temperature drops linearly in
the troposphere, then stabilizes
in the stratosphere until
increasing again
BIG BLUE Satellite
Program
High Altitude Conditions
BIG BLUE Satellite
Program
Team Organization
Wing Design Flight Control I Flight Control II Wing Deployment
Data AcquisitionRF/Digital
CommunicationsPower Autopilot Electronics
Structural / Integration
Launch / Recovery Outreach Risk Mitigation
BIG BLUE Satellite
Program
Wing Design (X-foil)
• Aerodynamic analysis
– X-Foil software
– Conduct analysis under:
• Low Reynolds number
– 50,000 ~ 200,000
• Various angles of attack
– Lift and Drag coefficients
obtained determine performance
– Pressure distribution may then be
established
BIG BLUE Satellite
Program
Wing Design (Airfoil Selection)
• Five different airfoils were
selected based on efficiency
of airfoils under low-
Reynolds number conditions
and analyzed using X-foil.
(dae11, dae31, e387, e398 and
s7012).
• After these were examined by
ILC Dover, airfoil e398 was
selected based on
manufacturability.
BIG BLUE Satellite
Program
Wing Design (ANSYS)
• Finite element analysis– ANSYS 6.1 software
– “Bumpy” airfoil coordinates were
provided by ILC
– Pressure distributions obtained from
X-Foil were applied on the top and
bottom surfaces
– Wing material modeled as cured
– Static and Modal analyses were
performed
– Objective was to determine the
maximum stress to define the number
of composite layers
BIG BLUE Satellite
Program
Wing Design (Prototype)
• UK Rapid-Prototyping lab created (using stereo-lithography) the two types of wing test sections for the selected airfoil
BIG BLUE Satellite
Program
Wing Design (Test setup)
• Prototypes will then be tested in the UK low-turbulence wind tunnel
• Tunnel test section: 24” x 24” cross section and 48” length
• 50-hp motor drives 50 m/s with free-stream turbulence levels less than 1/2%
• additional wind-tunnel with smaller test section (8” x 16”) and lower velocity (35 m/s) is also available
BIG BLUE Satellite
Program
Wing Design (Verification)• X-foil verification for other airfoils (e387 and
s7012) was first accomplished using wind
tunnel test data available from UIUC– UIUC conducts low-speed airfoil testing (data found
at http://www.aae.uiuc.edu/mselig/uiuc_lsat.html )
• Wind tunnel tests of our smooth e398 airfoil
will be compared to X-foil data to verify our
testing process
• Wind-tunnel tests of the bumpy airfoil will then
be conducted and compared to the ideal section
• One question to be resolved is loss at the
trailing edge
BIG BLUE Satellite
Program
Flight Control I
• Who? Fall 2002 ME 412 group
• Autonomous Flight Control via
a closed loop feedback control
system
– Information System: GPS and
Gyroscopic Feedback
• Microprocessor Controller to
Control Attitude and Flight
Path
• Low altitude verification tests
via rigid wing glider
BIG BLUE Satellite
Program
Flight Control I
• Autonomous flight capability:
MP1100 control system
– central microprocessor
integrates accelerometers,
gyroscopes, an altimeter, a pitot
tube, and GPS
– components allow capability of
airspeed hold, altitude hold, turn
coordination, and GPS
navigation
BIG BLUE Satellite
Program
Flight Control I
• Control System Components
Control SystemMicroprocessor
GPSGyros &
Accelerometers
Speed(Pitot Tube)
Altimeter
ServoMotors
SpeedController
Motor &Prop
RxReceiver
TxRc Controller
ControlSurfaces
BIG BLUE Satellite
Program
Flight Control I
• MP1100 offers versatile
programming options
– numerous configurations
accessible through onboard flash
memory
• Capable of multi-routine program
loops
• Emergency or failsafe routines
• PID loops and adjustable gains
BIG BLUE Satellite
Program
Flight Control II
• Who? Spring 2003 ME 412 group
• Low altitude Micropilot testing
• Integrating UK Autopilot into BIG BLUE aircraft
• UK Autopilot low altitude testing
• Meet payload constraints (power and weight)
BIG BLUE Satellite
Program
Wing Deployment
• Who? Spring 2003 ME 412 group
• Inflatable tube deployment
simulation
– Analytically predicts tube
deployment sequence
• Plenum design and inflation
method
• Meet payload constraints (power
and weight)
• Thermal vacuum chamber
verification tests
BIG BLUE Satellite
Program
Wing Deployment • Vacuum chamber testing to explore expansion methods
BIG BLUE Satellite
Program
Data Acquisition
• Who? Spring 2003 ME 412 group
• Instrumentation and data acquisition
– Cameras
– Environmental condition measurements
– Flight performance
• Meet payload constraints (power and
weight)
• Equipment calibration
• Ground testing
BIG BLUE Satellite
Program
RF/Digital Communications
• Who? Spring 2003 EE 499 group
• Communication of control signals and
data; APRS/GPS System interface
• Verification tests
– Temperature
– Moisture
• Meet payload constraints (power and
weight)
• Integration and testing
BIG BLUE Satellite
Program
Power
• Who? Spring 2003 EE 499 group
• Verification, temperature tests
• Develop power budget – set constraints for other subsystems
• Integrated effort with inflation and data acquisition
BIG BLUE Satellite
Program
Flight Control Sensors/Programming
• Who? Spring 2003 EE 587 group
• Design, build autopilot based on MicroPilot design– AHRS unit: gyros and sensors for roll, pitch, yaw heading
– Crossbow is a possible purchase
• GPS certification to top speeds above 60k feet
• AHRS, APRS, GPS interface
BIG BLUE Satellite
Program
Structural/Integration
• Who? Spring 2003 ME 380 group
• Planform design• Fuselage
• Wing mounting
• Internal mounting hardware and
orientation, abort parachute
• Manipulate component placement for
optimal C.G.
• Overall tracking of payload weight budget
• Tail control surfaces
• Meet payload constraints
BIG BLUE Satellite
Program
Launch/Recovery
• Volunteer opportunities:
– Critical Design Reviewers
– Flight Readiness / Safety Reviews
– UK BIG BLUE website design
– Tracking interface to “watch” flights
• Lat/Long coordinates
• Altitude data packets
• Live camera feed
– www.findu.com
BIG BLUE Satellite
Program
Risk Mitigation
• Volunteer opportunity
• Risk identification
• Likelihood and severity ranking of risks
• Development of solutions and verification tests in order to alleviate these risks
• Examples:– Premature rigidization of wings
– Batteries die early
– Transceiver malfunctions as a result of low temperatures
BIG BLUE Satellite
Program
Outreach
• Volunteer opportunity:
– BIG BLUE t-shirts
– E-Day demonstrations and
exhibit booth
– Talks to K-12 schools; science
fun days, etc.
BIG BLUE Satellite
Program
Overall Objectives
• Fall 2002
– Flight control verification
• Design and build rigid wing glider
• Test at low altitude
– Inflated wing design completed
• Spring 2003
– Establish remaining subsystem teams
– Design and build high altitude system
– Verification testing
– Balloon launch (late March – early May 2003)
– Data reduction and analysis through August 2003