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Update 2025 Rocket Satellite authored by Lennard Rohs's avatar Lennard Rohs
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Student-Projects/2025-Rocket-Satellite.md
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...@@ -6,6 +6,7 @@ title: 2025 Rocket Satellite ...@@ -6,6 +6,7 @@ title: 2025 Rocket Satellite
<details> <details>
<summary>Table Of Contents</summary> <summary>Table Of Contents</summary>
...@@ -226,6 +227,7 @@ The hardware must remain within the budget. ...@@ -226,6 +227,7 @@ The hardware must remain within the budget.
The DLA used a custom Rocket PCB in previous Prjects therfore it was the foundation to be expandaed apon with additional functionality for this Project. The DLA used a custom Rocket PCB in previous Prjects therfore it was the foundation to be expandaed apon with additional functionality for this Project.
WE kept the Xiao ESP32C3 as the Micoprocessor, the 10 DOF Sensor PCB and the SingleCell LiPo Battery. WE kept the Xiao ESP32C3 as the Micoprocessor, the 10 DOF Sensor PCB and the SingleCell LiPo Battery.
**Periphery** **Periphery**
The Periphery to be supported: The Periphery to be supported:
...@@ -236,7 +238,8 @@ The Periphery to be supported: ...@@ -236,7 +238,8 @@ The Periphery to be supported:
- 1 10 DOF Sensor PCB - 1 10 DOF Sensor PCB
- 2 Generic Servos with adatible Voltage - 2 Generic Servos with adatible Voltage
**Power Supply Design**!
**Power Supply Design**
- Design 1: Only Voltage Regulator on ESP32 - Design 1: Only Voltage Regulator on ESP32
![Power Supply Design 1](uploads/9bfd4ab18d8e08cbdd67c810caa9f2d4/DC_1.png) ![Power Supply Design 1](uploads/9bfd4ab18d8e08cbdd67c810caa9f2d4/DC_1.png)
...@@ -252,6 +255,7 @@ While it is simple, not requiring additional Components it only offers 3.3V with ...@@ -252,6 +255,7 @@ While it is simple, not requiring additional Components it only offers 3.3V with
The Second Design Tested was to have a seperate Voltage Supply for the Motors and the rest of the Hardware. The Second Design Tested was to have a seperate Voltage Supply for the Motors and the rest of the Hardware.
This failed hower because the Boost Converter and Esp32 would effectivly act as a Voltage Divider dropping the Voltage registered at the battery Protection circuit of the esp32 below the needed 3.2V, even at very low currents. This failed hower because the Boost Converter and Esp32 would effectivly act as a Voltage Divider dropping the Voltage registered at the battery Protection circuit of the esp32 below the needed 3.2V, even at very low currents.
- Design 3: Boost Converter and seperate BMS - Design 3: Boost Converter and seperate BMS
![DC2_fr_fr_eigentlich_3](uploads/724917f8ae6e85e3931fdf7ccaf16f5c/DC2_fr_fr_eigentlich_3.png) ![DC2_fr_fr_eigentlich_3](uploads/724917f8ae6e85e3931fdf7ccaf16f5c/DC2_fr_fr_eigentlich_3.png)
...@@ -259,6 +263,7 @@ This failed hower because the Boost Converter and Esp32 would effectivly act as ...@@ -259,6 +263,7 @@ This failed hower because the Boost Converter and Esp32 would effectivly act as
The third design tested was utilising a seperate BMS PCB to keep the Battery Voltage at the correct level on for Protection circuit while not beeing limited to the 0.75 A of the ESP32s Voltage regulator. The third design tested was utilising a seperate BMS PCB to keep the Battery Voltage at the correct level on for Protection circuit while not beeing limited to the 0.75 A of the ESP32s Voltage regulator.
While the Design theoretically provided optimal Power for the Motors it had a lot of Components and inefficiencies limiting the actual benefits. While the Design theoretically provided optimal Power for the Motors it had a lot of Components and inefficiencies limiting the actual benefits.
- Design 4: Hybrid Solution - Design 4: Hybrid Solution
![Untitled_Diagram.drawio__3_](uploads/a151ebf583ed98e7146584670af08911/Untitled_Diagram.drawio__3_.png) ![Untitled_Diagram.drawio__3_](uploads/a151ebf583ed98e7146584670af08911/Untitled_Diagram.drawio__3_.png)
...@@ -267,6 +272,7 @@ The fourth Desing tested and ultimatly used in the Rocket was a hybrid design wh ...@@ -267,6 +272,7 @@ The fourth Desing tested and ultimatly used in the Rocket was a hybrid design wh
During testing we noticed that while the mechanical Power correlated to the electical Power provided the maximum Torque of the Moter was purly related to the supplyed Voltage. During testing we noticed that while the mechanical Power correlated to the electical Power provided the maximum Torque of the Moter was purly related to the supplyed Voltage.
The hybrid Design offerd maximum flexibility where the Servo Motor could ether be optimized for Torque by boosting the Voltage or optimized for optimal Power/Efficency using the ESP32 3.3V supply. The hybrid Design offerd maximum flexibility where the Servo Motor could ether be optimized for Torque by boosting the Voltage or optimized for optimal Power/Efficency using the ESP32 3.3V supply.
**Full Design** **Full Design**
![Untitled_Diagram.drawio__2_](uploads/e550f9be40eb19ea4c06742da0a5967e/Untitled_Diagram.drawio__2_.png) ![Untitled_Diagram.drawio__2_](uploads/e550f9be40eb19ea4c06742da0a5967e/Untitled_Diagram.drawio__2_.png)
...@@ -276,6 +282,8 @@ Additionaly the remaining Periphery needed to be connected and the IC2 Communica ...@@ -276,6 +282,8 @@ Additionaly the remaining Periphery needed to be connected and the IC2 Communica
### PCB Design ### PCB Design
The PCB was designed in KiCad and ordered from PCBWay
**Schematic** **Schematic**
![Schematic](uploads/3cee39822335470400a2120d005afc05/Schematicc.png) ![Schematic](uploads/3cee39822335470400a2120d005afc05/Schematicc.png)
...@@ -298,6 +306,21 @@ PCB Final: ...@@ -298,6 +306,21 @@ PCB Final:
![1751919357998__1_](uploads/f4ce46795475e25e376fb19b2424ca67/1751919357998__1_.jpg) ![1751919357998__1_](uploads/f4ce46795475e25e376fb19b2424ca67/1751919357998__1_.jpg)
## Mounting
![Screenshot_2025-07-07_at_11-41-23_Fairing_Tests_Fairing_V2.3]
The PCB was screwed into the Bottom Cargo Section leaving the Periphery accessible with a with hole to equalise the pressure for the barometer.
## Testing
During Testing we found that overcoming the friction of the linear Servo Motors and Hinges was the limiting Factor.
Therfore the optimal reliability of the Servomotors was reached when the voltage was boosted to 4.3V providing maximum Torque without dropping below 3.3V on the ESP32 during stall current.
Additionaly lubrication with silicon greace helped tremendously.
## Launch Day
On Launch Day one of the Servomotors provided significantly lower Torque and was therefore not able to reliably push one side of the Fairing open.
This was ether because we transported the upper section fully assembled with most of the loads aplyed transfered into the motor or due to the greece of the silicon greece drying up which was applied during the extensive testing on the day before.
## Software Design (@stsuyooo) ## Software Design (@stsuyooo)
To keep it simple an illustration of the state machine will be used to explain the software. To see the full code visit the project [repository](https://code.fbi.h-da.de/hda10343/dla/-/tree/Satellite/Satellite?ref_type=heads). To keep it simple an illustration of the state machine will be used to explain the software. To see the full code visit the project [repository](https://code.fbi.h-da.de/hda10343/dla/-/tree/Satellite/Satellite?ref_type=heads).
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