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TEAM CHINESE BANDITOZONE PAYLOAD CRITICAL DESIGN REPORT (CDR)

Zach BaumHarry Gao Ryan MoonSean Walsh

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TABLE OF CONTENTS Mission Goal Objectives Requirements Electrical Design Software Design Thermal Design Mechanical Design Payload Construction Plan Mission Operations Master Schedule Master Budget

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MISSION GOAL

Create a profile of ozone concentration with respect to altitude from ground level to 100,000ft.

Ozone sensor reading for 2012 UND/UNF HASP payload

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SCIENCE OBJECTIVES

Map peak of ozone concentration in upper atmosphere.

Create ozone concentration profile with respect to altitude.

Map out any fluctuations within ozone profile.

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TECHNICAL OBJECTIVES

The payload must measure ozone concentration

The onboard program will be able to: Take temperature readings

within close proximity to ozone sensor

Maintain proper operating temperature for all necessary components

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SCIENCE REQUIREMENTS

The payload must take measurements of ozone concentration every 3 seconds

Team Chinese Bandits must receive time and altitude GPS information for analysis from LaACES management

The payload must measure the peak ozone concentration to within .2ppmv

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TECHNICAL REQUIREMENTS The payload must: Not have a mass greater than 500g Not exceed 3oz/in2 on any surface Have two holes 17in apart through which the payload will interface

with the balloon Costs must remain within the allotted $500 budget for Chinese

Bandits In order for the payload to create an ozone profile of the

atmosphere, the following requirements must be met: Payload must take measurements of ozone concentration

throughout the flight Payload must be recovered for post-flight analysis Altitude must be known to within 65 feet For the accuracy to be known within 65 feet, the following

requirements must be met: Real-time clock must be synced with GPS time during pre-flight Real-time clock must be accurate to within 3 seconds of the

LaACES LASSEN iQ GPS

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SENSORSOZONE SENSORS ITO acts as a variable resistor whose

resistance changes in the presence of ozone Applying a constant current allows us to relate

the change in output voltage to the resistance and ozone concentration as measured by each sensor

Has a small operating temperature range, therefore a thermal controlling system will be needed

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SENSORSOZONE SENSORS Calibration data will be obtained from Dr.

Patel The equation can be used to relate the

resistance of each sensor to the ozone concentration Y = sensor resistance, X = concentration of

ozone, m = slope of the calibration curve, b= y-intercept of curve

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SENSORSTHERMISTOR KC003T-ND thermistor

Property Value

Operating Temperature Range

-50°C - 150°C

R0 (Resistance at 25°C) 10 kΩ

Temperature Coefficient (@ 25°C)

-4.40%/°C

Accuracy (@ 25°C) +/- 1°C

Resistance at 20°C 12.5 kΩ

Resistance at 30°C 8.055 kΩ

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HEATER KHLV-101/5 Kapton Heater 1in. X 1in. Provides up to 5W of heat with 28V max

voltage Property Value

Resistance 150 Ω

Current draw 80 mA

Power draw 0.936 W

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SENSOR INTERFACINGOZONE SENSOR

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OZONE SENSOR INTERFACING Zero temp-

coefficient circuit for the constant current sourceResistor

value (Ω)LM234 current output (mA)

0 2.510 2.5100 2.5600 2.51000 2.51400 2.51500 2.51600 2.52000 2.52400 2.52800 2.53200 2.243600 1.48

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THERMISTOR INTERFACE Different constant current, op amp

Output voltage Thermistor resistance3V 12.5KΩ.2V 6.5KΩ

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CONTROL ELECTRONICSBASIC STAMP PIN LAYOUTPin no. Pin Function Pin no. Pin Function1 Serial Out 13 I/O (EEPROM)2 Serial In 14 RTC (EEPROM)3 ATN 15 Reset RTC4 Vss 16 DATA (RTC)5 Data Output

(ADC0838)17 I/O (RTC)

6 RTC (ADC0838) 18 Data Output (ADC0834)

7 CS (ADC0838) 19 RTC (ADC0834)8 NA 20 CS (ADC0834)9 LED Output 21 VDD 10 LED Output 22 RES11 LED Output 23 Vss12 LED Output 24 VIN

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CONTROL ELECTRONICSADC0838 PIN LAYOUT

Pin no. Function Pin no. Function1 CH0 11 Analog

Ground2 CH1 12 VREF

3 CH2 13 Shift Enable4 CH3 14 DO5 CH4 15 SARS6 CH5 16 CLK7 CH6 17 DI8 CH7 18 CS9 COM 19 V+

10 Digital Ground

20 VCC

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CONTROL ELECTRONICSCIRCUIT INTERFACINGSensor Board (16 card edge connector)

16 wire Ribbon Cable

Conditioning Board (8x2 pin Header)

16 S1 1 S114 S2 2 S212 S3 3 S310 S4 4 S48 S8 5 S86 S7 6 S74 S6 7 S63 Common 8 C2 S5 9 S5*Other pins not used

*Other pins not used

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CONTROL ELECTRONICSCIRCUIT INTERFACINGConditioning Board (13x1 pin header)

26 wire Ribbon Cable

BalloonSat (13x2 pin header)

1 Vcc (5V in) 1 Vcc (5V in)2 Vref (3V ref.) 3 Vref (3V ref.)3 ADC0

(Thermistor I/O)

5 ADC0 (Thermistor I/O)

4 Not used 7 Not used5 Not used 9 Not used6 Not used 11 Not used7 P0 (I/O ITO) 13 P0 (I/O ITO)8 P1 (RTC

ADC0838) 15 P1 (RTC

ADC0838)9 P2 (CS

ADC0838) 17 P2 (CS

ADC0838)10 P3 (3V Vref.) 19 P3 (3V Vref.)*Other pins not used

All Even pins Ground*Other pins not used

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POWER SUPPLY AND DISTRIBUTION

Two power sources: one 9V, one 12V

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HEATER AND RELAY CONFIGURATION Will Use a 2N3904 transistor as a relay BASICStamp will send 3V to base pin to

saturate it, allowing the 12V load to flow through the transistor and power heater

10KΩ resistor placed before the base pin will limit the base current that can flow into the transistor

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POWER BUDGETPower Budget

Consumer Consumption Rate

Voltage Energy

Ozone Sensors

1 mA * 8 sensors = 80

mA

Variable (depende

nt on sensor, 3V

max)

400 mAh

Thermistor .01 mA 3 V .05 mAh

Heater 80 mA 12 V 400 mAh

Balloon Sat 53 mA 9 V 265 mAh

Total 213.01 mA 1065.05 mAh

Power Supply 1

Power Supply 2

Needed capacity

665.05 mAh

400 mAh

Required Voltage

9 V 12 V

AA Lithium Ion

Voltage (per battery)

1.5 V

Capacity(per battery)

3000 mAh

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THERMAL DESIGNLaACES Thermal Flight Isun 1377.0 W/m2

Earth-Space Parameters

UNITS Latitude 31 degrees

Stefan-Boltzmann5.67E-

08W/m2

K4 T-float 210 K

Isun (solar constant) 1377 W/m2 Albedo 0.5 T-space 4 K Day of year 141 dayFlight altitude 30500 m Hour of day 14 hrEarth orbit eccentricity 0.01672 Declination angle 19.91164 degT-earth 273 K Inclination angle 29.14873 deg

R-earth638000

0 m IR Fluxmin 160 W/m2

Payload Parameters Internal Heat 2.96 WView factor payload-earth 0.451 Effective Isolar 1360.54 W/m2

View factor payload-space 0.700

Effective Isphere 339.12 W/m2

Sphere radius 0.103 mENERGY BALANCE calculations

bladder thickness 0.000 m Qsun 15.824 Wkevlar shell thickness 0.000 m Qalbedo 13.861 Wbladder conductivity 0.026 W/mK Qpower 2.960 W

kevlar shell conductivity 0.040 W/mK Q-IR 2.046 W

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THERMAL DESIGNInsulation Parameters Total input: 34.690 W

insulation absorptivity 0.350 hrad,earth 1.862 W/m2 K

insulation thickness 0.019 m hrad,space 0.769 W/m2 Kinsulation emissivity 0.850 constant1 0.248 W/K

insulation conductivity 0.027W/mK constant2 0.103 W/K

Area Calculations constant3 0.053 W/K

Total sphere projected area

3.33E-02 m2 Qrad-to-earth 2.295 W

Total sphere surface area

1.33E-01 m2 Qrad-to-space 28.542 W

Qconv-at-float 3.853 W

Total output: 34.690 W Ti outer 9.2 degC Ti inner 22.5 degC Tk inner 22.5 degC Tb inner 22.5 degC

Tavg interior air 24.7 degC

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MECHANICAL DESIGN

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WEIGHT BUDGETComponen

tQuantit

yMass Uncertain

tyCalculate

d/Measure

dBalloonSa

t1 68.9g +/- 0.05g Measured

Lithium AA

Batteries (9V total

unit)

6 88.3g +/- 0.1g Measured

Lithium AA

Batteries (12V total

unit)

8 117.9g +/- 0.1g Measured

FOAMULAR Casing

1 57.5g +/- 2 g Calculated

ITO sensor 1 13g +/- 0.1g Measured

Total 345.6g +/- 2 g

Component Approximate Mass

Operational Amplifier

57g

Sensor Interface

15g

Electrical Wiring

15g

Heater and Thermistor

10g

Glue, Paint,

Structural Component

s

10g

Total 112g

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PRE-FLIGHT SOFTWARE

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PRE-FLIGHT SOFTWARE: INITIALIZATION STAGE

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PRE-FLIGHT SOFTWARE: TESTING STAGE

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FLIGHT SOFTWARE

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FLIGHT SOFTWARE SUBROUTINES

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FLIGHT SOFTWARE SUBROUTINES CONT.

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POST FLIGHT SOFTWAREByte Offset

Data Description

0 Hour Timestamps the Data1 Minute2 Second3 ITO1 Reads ozone

concentration4 ITO25 ITO36 ITO47 ITO58 ITO69 ITO710 ITO811 Thermistor Reads temperature

of ITO Array

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PAYLOAD CONSTRUCTION PLAN

HARDWARE FABRICATION AND TESTING Full system testing will be conducted after

each subsystem is tested and proven Payload design will be updates after testing A delay in any subsystem will cause

combined testing to be delayed

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INTEGRATION PLAN After each subsystem is tested, individual

systems will be connected together to ensure interfaces work properly

Electrical/software interfacing has been tested and proven

Tests on interfacing electrical, mechanical, and thermal will ensure proper operation temperature can be maintained

Testing will be done on all systems in a simulated flight to complete payload integration

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FLIGHT SOFTWARE IMPLEMENTATION AND VERIFICATION Flight software was tested with electrical

prototypes to ensure it was functioning correctly

Pre-Flight will be loaded the day before flight to clear EEPROM and sync GPS time to RTC

A computer located on site will be used to run programs and retrieve data

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FLIGHT CERTIFICATION TESTING Tests will be conducted to ensure payload

can survive flight Temperatures of -70°C to 30°C Pressure of .163mBar to 1000mBar Impact upon landing A shock test and a thermal/vacuum test will

be conducted

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SYSTEM TESTING PROCEDURE Payload needs to survive 8.94 m/s

H = 4.08m or 13.38 ft. Procedure checklist

Power up payload Run preflight software Run flight software Drop from13.4 feet onto the floor Run post-flight software Verify that all onboard electronics are operating

properly

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VACUUM TEST PROCEDURES Power up payload Run preflight software Run flight software Place payload in Vacuum Testing Chamber Make sure that vacuum chamber is sealed and

pressure gauge is turned on Simulate flight environment in vacuum testing

chamber. This include having a temperature range -70 to

30C This include pressure of .163 mBar- 1000 mBar

Run post-flight software Analyze and verify data

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SYSTEM TESTING RESULTS Preliminary tests done

to test if sensors will work

Spark gap created in box to create ozone

ITO warmed to operating temperature and placed in box until 480 seconds

1 39 77 1151531912292673053433814194574955335710.0

100.0

200.0

300.0

400.0

500.0

600.0Resistance vs Time

Resistance

Seconds After Beginning Test

Chan

ge in

Res

istan

ce o

f orig

inal

val

ue o

f 1.4

kΩITO warmed to 25°C

ITO placed in box

ITO removed from box

After speaking with Dr. Patel, long reaction times may be due to not enough ozone to fully react, or not enough airflow across the sensor

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PRE-LAUNCH REQUIREMENTS AND OPERATIONS:CALIBRATIONS

Two Instruments that require calibration Thermistor

Calibrate for low temperature of 20°C Calibrate for high temperature range of 35°C

ITO Sensor Do not have necessary equipment to calibrate Will be provided by Dr. Patel of the University of

North Florida

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PRE-LAUNCH REQUIREMENTS AND OPERATIONS:CALIBRATION PROCEDURES

Thermistor Fill glass with cold water in a heat metal

container Place thermometer and thermistor Record the sensor reading using the voltmeter

and flight software for temperature from 20°C to 35°C

ITO Will be provided by Dr. Patel

ITO Circuit Thermistor Circuit

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PRE-LAUNCH CHECKLISTEvent Time Time

NeededMaterials Needed

Verify all systems are flight ready

2 days before flight

20 minutes

The full Chinese Bandits payload, multimeter

Run Pre-Flight Software

12 hours before flight

15 min. The full Chinese Bandits payload, one computer with BASIC Stamp Editor software, one 9-pin serial

cableSet time of BalloonSAT

clock

12 hours before flight

15 min. The full Chinese Bandits payload, one computer with BASIC Stamp Editor software, one 9-pin serial cable, the LaACES GPS unit with

computer hookupsReplace battery

packs with fresh, tested

packs

12 hours before flight

5 min. Fresh, tested 9 and 12 volt battery packs

Load Flight Software onto the BalloonSat

12 hours before flight

5 min. The full Chinese Bandits payload, one computer with BASIC Stamp Editor software, one 9-pin serial

cableConnect battery packs, close and seal payload lid

1 hour before flight

5 min. Tape

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FLIGHT REQUIREMENTS, OPERATIONS AND RECOVERY Batteries will provide the BalloonSat and

sensors with enough power for the duration of the flight

EEProm will have enough memory to take measurements for the duration of the flight

Must find and recover EEProm during recovery; Extra BallonSats will be brought in order to retrieve the data from the EEProm

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DATA ACQUISITION AND ANALYSIS PLAN: GROUND SOFTWARE The following procedure will

be used to complete Ground Software andexport flight data.

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DATA ACQUISITION AND ANALYSIS PLAN:DATA ANALYSIS PLAN ADC values will be converted into ozone

measurements in PPM(Parts Per Million) Thermistor values will be converted to

degrees in Celsius Sync GPS value with time to get altitude data

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DATA ACQUISITION AND ANALYSIS PLAN:DATA ANALYSIS PLAN (CONTINUED) The following graphs will be made from flight

data to help with the analysis process Ozone vs. altitude Ozone vs. time Temperature vs. time Ozone vs. temperature

Expected uncertainties for thermistor will be 1 percent while the uncertainties for the ozone sensor will be 0.2ppm

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PROJECT MANAGEMENTWBS

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PROJECT MANAGEMENTWBS

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PROJECT MANAGEMENTWBS

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STAFF ORGANIZATION AND RESPONSIBILITIES

Category Team Member

Project Manager Zach Baum

Software Developer and Lead

Harry Gao

Mechanical Lead Sean WalshElectrical Lead Harry Gao

Calibrations Harry GaoIntegration Zach Baum

Version Control and Editing

Ryan Moon

System Testing Sean Walsh

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MASTER BUDGETEXPENDITURE PLAN

Quantity Part no. Description Unit Price Total PriceParts For Testing (1)

1 ADC088S102CIMT/NOPB-ND

8 channel ADC

$3.09 $3.09

1 LM234Z-6/NOPB-ND

Constant Current Source

$1.27 $1.27

1 AT24C512C-SSHM-B-ND

64KB EEPROM $1.76 $1.76

2N7002K-T1-E3CT-ND

Transistor for relay

$0.38 $0.38

KHLV-101/5 Heater $31.00 $31.00 Shipping

Total$18.99

Parts For Testing (2)

1 TIP112TU-ND

Transistor for relay

$0.66 $0.66

1 24LC512-I/P-ND

64KB EEPROM $1.96 $1.96

1 ADC0834CCN/NOPB-ND

4 Channel ADC

$3.11 $3.11

1 LM234Z-6/NOPB-ND

Constant Current Source

$1.27 $1.27

1 ADC0838CCN/NOPB-ND

8 channel ADC

$2.97 $8.91

1 ITO Sensor for Testing

Ozone Sensor Borrowed $0.00

Shipping Total

$14.94

Total $86.33

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MASTER BUDGETEXPENDITURE PLAN

Parts for Fabrication

24 AA Energizer L91 batteries

Batteries for power supply

$49.95 for 24-pack

$49.95

6 AD822ANZ-ND Op-Amp for ITO’s

$6.28 $37.68

2 AD820 Op-Amp for Thermistor

$4.54 $9.08

18 3299W-104LF-ND

Variable resistor $2.60 $46.80

12 LM234Z-6/NOPB-ND

Constant Current Source

$1.27 $15.24

2 TIP112TU-ND Transistor for relay

$0.66 $1.32

1 KHLV-101/5 Back-up heater $31.00 $31.00 1 24LC512-I/P-

NDBack-up EEPROM

$1.96 $1.96

1 PCB Printed Circuit Board

$177.70 $177.70

1 Flight-ready ITO sensor

Borrowed $0.00

12 445-5327-ND 10microF capacitor

$0.46 $5.52

1 Pack of Real Velcro

$8.14 $8.14

Shipping Total $18.99

Total $416.85 Total Expected

Expenditure $502.18

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MASTER BUDGETMATERIAL ACQUISITION PLANMaterial Qua

ntities

How Acquired

When Needed

When to Order

BalloonSat 1 Supplied by LaACES

Calibration and testing

Already Have

Capacitors, resistors, wires, etc

x Supplied by LaAces

Calibration and testing

Already Have

ADC088S102CIMT/NOPB-ND8 channel ADC

1 Ordered from Digikey

Calibration and testing

Already Have

LM234Z-6/NOPB-NDConstant Current Source

12 Ordered from Digikey

One for Calibration and testing, the rest for fabrication

1 week before fabrication

AT24C512C-SSHM-B-ND64KB EEPROM

2 Ordered from Digikey

One for Calibration and testing, the other for backup

Need 1 more

2N7002K-T1-E3CT-NDTransistor for relay

1 Ordered from Digikey

Calibration and testing

already have

KHLV-101/5Heater

1 Ordered from Omega

Calibration and testing

already have

TIP112TU-NDTransistor for relay

1 Ordered from Digikey

Calibration and testing

already have

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MASTER BUDGETMATERIAL ACQUISITION PLAN24LC512-I/P-ND64KB EEPROM

1 Ordered from Digikey

Calibration and testing

already have

ADC0834CCN/NOPB-ND4 Channel ADC

1 Supplied by LaAces

Calibration and testing

already have

LM234Z-6/NOPB-NDConstant Current Source

1 Ordered from Digikey

Calibration and testing

already have

ADC0838CCN/NOPB-ND8 channel ADC

1 Ordered from Digikey

Calibration and testing

already have

ITO Sensors 1 Borrowed from Dr. Patel

Calibration and testing

already have

AA Energizer L91 batteriesBatteries for power supply

24 Order Online through Amazon

Fabrication Need to order 1 week before fabrication

AD822ANZ-NDTable 22: Material Acquisition Plan

Op-Amp for ITO’s

6 Ordered from Digikey

Fabrication Need to order 1 week before fabrication

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RISK MANAGEMENT AND CONTINGENCY PLANSystem Risk Contingenc

y PlanTrigger Who is

responsibleElectrical Not returning

correct dataCalibration and testing in simulated conditions

Changes in output related to unexpected conditions

Team

Electrical Interface and component problems

Testing components hardware and software before, during, and after assembly

Faulty wiring and components

Harry

Mechanical Inclement weather

Structurally sound and sealed mechanical design and testing

Weather Sean/Ryan

Electrical/Mechanical

Inability to maintain operating temperature

Using a heater and thermistor, testing in simulated flight conditions

Extreme cold Team

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RISK MANAGEMENT AND CONTINGENCY

Electrical Frying EEPROM

Have back-up parts, and use extreme caution pre-flight

Carelessness

Zach

All systems Loss of payload

Prepare failure report

Loss of payload during flight

Team/LaACES staff

All systems Loss of team member

Rest of team would pick up responsibilities

Increased workload

Team

Project Management

Not meeting deadlines

Set early deadlines to allow for mistakes to be fixed

Poor project management

Zach

All systems Over budget Find cheaper and more cost-effective components

Not enough money

Team