University of Colorado Department of Aerospace Engineering Sciences ASEN 4028 Project Final Report (PFR) May 3rd, 2021 Weight Analysis for Surveillance Pods (WASP) 0 Information 0.1 Project Customer Name: Gary Hutton Name: AJ Olson Email: [email protected] Email: [email protected] Name: Jon Matula Name: Becky Vander Hoeven Email: [email protected] Email: [email protected] Name: Stephen McLaughlin Email: [email protected] 0.2 Project Advisor Name: Francisco Lopez-Jimenez Email: [email protected] 0.3 Team Members Name: Maddie Dube Name: Adam Elsayed Email: [email protected] Email: [email protected] Phone: 406-799-6489 Phone: 303-815-2304 Name: Samuel Felice Name: Foster Greer Email: [email protected] Email: [email protected] Phone: 512-284-2569 Phone: 303-912-0353 Name: Ansh Jerath Name: Aidan Kirby Email: [email protected] Email: [email protected] Phone: 720-320-0620 Phone: 720-530-8774 Name: Emma Markovich Name: Bailey Roker Email: [email protected] Email: [email protected] Phone: 303-587-1367 Phone: 925-784-5100 Name: Parker Simmons Name: Matthew Zola Email: [email protected] Email: [email protected] Phone: 218-391-5160 Phone: 971-409-5787 1 Contents 0 Information 1 0.1 Project Customer . 1 0.2 Project Advisor . 1 0.3 Team Members . 1 1 Project Purpose 11 1.1 Problem Statement . 11 1.2 Mission Statement . 11 1.3 Related Work . 11 2 Project Objectives and Functional Requirements 12 2.1 Specific Objectives & Levels of Success . 12 2.2 Concept of Operations . 13 2.3 System-Level Functional Block Diagram . 13 2.4 Project Deliverables . 14 2.5 High-Level Functional Requirements . 14 3 Final Design 15 3.1 Requirements Flowdown . 15 3.2 Final Design Overview . 20 3.2.1 Weight and CG Equation Development . 21 3.2.2 Equation Updates Post-Manufacturing . 23 3.2.3 Structures and Mechanical Design . 24 3.2.4 Electronics . 30 3.2.5 Software . 34 3.2.6 Safety . 38 4 Manufacturing 40 4.1 Manufacturing Scope . 40 4.2 Structural Manufacturing . 40 4.3 Electrical Manufacturing . 42 4.4 Software Development . 43 4.5 Integration . 43 4.6 Manufacturing Lessons Learned . 45 5 Verification and Validation 46 5.1 Design Verification . 46 5.1.1 Testing Scope . 46 5.1.2 Load Cell Characterization Test . 47 5.1.3 Lug Mount Tensile Test (LMTT) . 49 5.1.4 E&S Functionality Test . 52 5.1.5 Structural Integrity Test . 53 5.1.6 Measurement Accuracy Test . 57 5.2 System Accreditation . 63 5.3 Summary of Additional Checks . 64 6 Risk Assessment and Mitigation 65 6.1 Risk Identification . 65 6.2 Technical Risk Matrices . 65 6.3 Logistical Risk Matrix . 66 6.4 Safety Risk Matrix . 66 6.5 Financial Risk Matrix . 66 6.6 Risk Tracking and Mitigation . 67 2 6.7 Risk Outcomes and Impacts . 67 7 Project Planning 67 7.1 Organizational Chart . 67 7.2 Work Breakdown Structure . 69 7.3 Work Plan . 70 7.4 Manufacturing Plan . 71 7.5 Cost Plan . 72 7.6 Test Plan . 73 8 Lessons Learned 74 8.1 Technical: Your Final Design is not your Final Product . 74 8.2 Technical: "All Models are Wrong, Some Models are Useful" . 74 8.3 Financial: Raw Materials are Like Stocks . 75 8.4 Schedule: Sometimes, 100% Margin Still is not Enough . 75 9 Individual Contributions 76 9.1 Maddie Dube . 76 9.2 Adam Elsayed . 76 9.3 Samuel Felice . 76 9.4 Foster Greer . 76 9.5 Ansh Jerath . 77 9.6 Aidan Kirby . 77 9.7 Emma Markovich . 77 9.8 Bailey Roker . 78 9.9 Parker Simmons . 78 9.10 Matthew Zola . 78 9.11 Baseline Design Overview . 120 9.12 Appendix C: Risk Descriptions and Mitigation . 128 9.13 Risk Identification . 128 9.13.1 Technical Risks . 128 9.13.2 Logistical Risks . 135 9.13.3 Safety Risks . 136 9.13.4 Financial Risks . 137 3 List of Figures 1 ISR Pod Coordinate Frame . 13 2 Concept of Operations . 13 3 Functional Block Diagram for WASP . 14 4 Critical Project Elements . 20 5 Load Cell Setup on Testbed . 21 6 Pod in Flat Configuration (for Equation Derivation) . 22 7 Pod in Tilted Configuration (for Equation Derivation) . 22 8 Load Cell Alignment Geometry - X . 23 9 Load Cell Alignment Geometry - Y . 23 10 Z-Offset Parameter . 23 11 Isometric View of the WASP Structure as of SFR . 24 12 Lug Mounts Attached to the Testbed . ..