RockOn! Structure Build

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RockOn! Structure Build
RockOn! 2008
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Step 11 Staking AVR Wires

• Stake the soldering location of the AVR wires on
  the AVR PCB as shown.

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Structures Overview

• Open your structures kit and verify its contents.
• ESD protection should be utilized during the
  entire building process!
• Make sure anyone handling the hardware is
  protected from ESD damage.
• If any issues arise raise your hand for
  assistance.

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Structural Kit Overview Nuts and Bolts
Red M3.0x35 (4)
Black M3.0x25 (4)
Nylon spacers (24)
Light Green M2.5x10 (3)
M3.0 nuts (16)
M2.5 nuts( 3)
Red M2.0x10 (2)
M2.0 nuts (2)
Purple M3.0x10 (2)
Light Blue M3.0x10 (4)
Light Green M3.0x10 (2)
Bolts and nut are 11 scale
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Structural Kit Overview Brackets
L Battery bracket (1)
Battery bracket (1)
G-Switch bracket (1)
Z Accelerometer bracket (1)
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Structural Kit Overview Adding Electrical Tape
Leaving the holes free, add electrical tape to
the Z accelerometer on the three-hole piece.
Z Accelerometer bracket
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Structural Kit Overview Parts from other kits
Red LED with connector (1)
G-switch (1)
Blue RBF Wire (several feet)
Green LED (1)
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Structural Kit Overview Parts from other kits
Red LED with connector (1)
G-switch (1)
Blue RBF Wire (several feet)
Green LED (1)
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Structural Kit Overview Parts from other kits
Geiger Board (1)
AVR Board (1)
Z Accelerometer Board (1)
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Structural Kit Overview Tools
Small Wrench
Needle Nose Pliers
Screwdriver Set
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Structural Kit Mounting Plate
Geiger Board (red)
AVR (black)
Z Acc (green)
G-Switch (purple)
Batteries (blue)
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Lets Start Building!
RockOn! 2008
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Structural Kit Completed Plate
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Step 1 AVR Mounting

• Find the M3.0x25 Black bolts for the AVR.
• Mount the AVR in the orientation shown on the
  following slide using nylon spacers.
• The nylon spacers will be above and below the
  board as shown.
• AVR holes are colored black on the mounting
  plate.
• Hand tighten with an M3.0 nut followed by a final
  ½ turn using the wrench and screwdriver.

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Step 1 AVR Mounting
Note the orientation of the AVR
x4 for all holes on the AVR
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Step 1 AVR Mounting Before
Geiger Board
AVR
Z Acc
G-Switch
Batteries
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Step 1 AVR Mounting After
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Step 1 AVR Mounting After close-up
Top Down View
Side View
Bottom-Up View
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Step 2 Z Accelerometer Mounting

• Find the M3.0x10 green bolts for the Z
  accelerometer bracket.
• Mount the Z accelerometer bracket as shown.
• Make sure the electrical tape is oriented on the
  correct side of the Z accelerometer bracket.
• Z accelerometer holes are colored green on the
  mounting plate.
• Hand tighten with an M3.0 nut followed by a final
  ½ turn using the wrench and screwdriver.

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Step 2 Z Accelerometer Mounting Before
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Step 2 Z Accelerometer Mounting
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Step 2 Z Accelerometer Mounting after
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Step 2 Z Accelerometer Mounting after close-up
Bottom View
Top View
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Step 3 Z Accelerometer Mounting

• Find the M2.5x10 Light Green bolts for the Z
  accelerometer.
• Mount the Z accelerometer as shown.
• Hand tighten with an M2.5 nut followed by a final
  ½ turn using the pliers and screwdriver.
• Use three nylon washers between the bracket
  and PCB of the accelerometer.
• Hand tighten with an M3.0 nut followed by a final
  ½ turn using the wrench and screwdriver.

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Step 3 Z Accelerometer Mounting before
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Step 3 Z Accelerometer Mounting



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Step 3 Z Accelerometer Mounting after
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Step 3 Z Accelerometer Mounting after close-up
Behind View
Front View
Caution! These are the leads in question.
Top Down View (note the washers used for spacing)
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Step 4 Z Accelerometer Connection

• Connect the four pin header to the Z main
  location on the AVR as shown.
• Make sure you connect Red to and Black to
  -.

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Structures Overview

• Open your structures kit and verify its contents.
• ESD protection should be utilized during the
  entire building process!
• Make sure anyone handling the hardware is
  protected from ESD damage.
• If any issues arise raise your hand for
  assistance.

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Step 5 Geiger Counter Mounting

• Using hot glue, stake down the red wire leading
  off the Geiger counter to the Geiger PCB near the
  bend in the wire.

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Step 5 Geiger Counter Mounting

• Make sure the red Geiger wire is staked down
  before you mount the Geiger counter.
• Using four nylon spacers and the Red M3.0x35
  bolts mount the Geiger Board to the plate as
  shown.
• Hand tighten with an M3.0 nut followed by a final
  ½ turn using the wrench and screwdriver.

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Step 5 Geiger Counter Mounting
Side View
Bottom View
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Step 6 Geiger Counter Connection

• Connect the three pin header on the Geiger
  counter to the breadboard on the AVR as shown.
  Connect black to the black wire, red to the red
  wire as depicted.

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Step 6 G Switch Bracket Mounting

• Find the G Switch bracket and mount to the plate
  as shown.
• The mounting bolts are two M3.0x10 colored
  purple.
• The holes to be mounted are closest the bend in
  the L bracket.
• Finger tighten with an M3.0 nut followed by a
  final ½ turn using the wrench and screwdriver.

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Step 6 G Switch Bracket Mounting after
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Step 6 G Switch Bracket Mounting after close-up
Bottom View
Top View
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Step 7 G Switch Mounting

• Find the G Switch and mount to the G Switch
  bracket.
• The mounting bolts are two M2.0x10 colored red.
• Finger tighten the bolts with M2.0 nuts plus an
  additional ½ turn using the pliers and
  screwdriver.

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Step 7 G Switch Mounting
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Step 7 G Switch Mounting After
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Step 7 G Switch Mounting After Close-up
Front View
Back View
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Step 7 G Switch Mounting

• Connect the G Switch header to the AVR board
  location labeled G-switch.

• Since there is no polarity to this shorting
  mechanism, the orientation of the wires does not
  matter.

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Step 7 G Switch Mounting After
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Step 8 Battery Bracket Mounting

• Acquire Flight Batteries in your structures kit.
• Find both battery brackets and mount to the plate
  as shown.
• Mount all brackets using m 3.0x10 bolts colored
  light blue.
• Hand tighten with an M3.0 nut followed by a final
  ½ turn using the wrench.
• Mount the L bracket first pushing the batteries
  flush with it on the plate.

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Step 8 Battery Bracket Mounting Before
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Step 8 Battery Bracket Mounting
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Step 8 Battery Bracket Mounting After

• Orient the battery connectors to lead the
  extending wires to the left.

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Step 8 Battery Bracket Mounting After close-up
Top View Note flushness of batteries
with L bracket
Bottom View
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Step 8 Battery Connection

• Connect the header from the batteries to the
  Power location on the PCB.
• The header should be right next to the RDY and
  ON locations within the PCB.
• Note the Red lead from the battery should
  connect to the indication on the PCB.

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Staking and Mounting
RockOn! 2008
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Step 1 Mounting the AVR

• Slide some nylon threading underneath the AVR
  socket and tie down to the socket as shown.
• The nylon should be tightly secured to the chip.
  Have a partner (who is also ESD protected) help
  you tie a tight knot.

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Step 1 Mounting the AVR

• Slide some nylon threading underneath the AVR
  socket and tie down to the socket as shown.
• The nylon should be tightly secured to the chip.
  Have a partner (who is also ESD protected) help
  you tie a tight knot.

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Step 1 Mounting the AVR
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Step 2 Tying sensor wiring plate overview
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Step 2 Bundling Wires

• Each set of wires on the board should be bundled
  two or three times.
• Use the nylon threading to bundle the wires
  together as shown.
• Use a square knot to tie the nylon threading and
  trim the excess leaving an inch remaining.
• USE CAUTION!! Dont snip your wiring while doing
  this!!!

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Step 2 Bundling Wires AVR Overview
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Step 2 Bundling Wires Plate Overview
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Step 3 Mounting Battery wires

• Orient the battery wiring as shown and stake to
  the AVR bolt indicated.
• Wrap nylon thread around the bolt as shown and
  tie around the bundle of battery wires.
• The wires are now secure to the plate.

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Step 3 Mounting Battery wires
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Step 3 Mounting Battery wires
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Step 3 Mounting Battery wires plate overview
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Step 4 Mounting G-switch wires

• Orient the G-switch wiring for mounting to the
  AVR bolt indicated.
• Wrap nylon thread around the gold battery bracket
  as shown and tie around the bundle of G-switch
  wires.
• Wrap nylon thread around the bolt as shown and
  tie around the bundle of G-switch wires.
• The wires are now secure to the plate.

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Step 4 Mounting G-switch wires
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Step 4 Mounting G-switch wires
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Step 5 Mounting Geiger wires

• Orient the Geiger wiring for mounting to the
  Geiger bolt indicated.
• Wrap nylon thread around the Geiger bolt as shown
  and tie around the bundle of Geiger wires.
• The wires are now secure to the plate.

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Step 5 Mounting Geiger wires Geiger PCB
overview
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Step 5 Mounting Geiger wires Geiger PCB
overview
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Step 5 Mounting Geiger wires plate overview
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Indicator LED and RBF Wiring
RockOn! 2008
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Step 6 LED Mounting General

• Make sure the Green LED is attached to the ON
  header with the correct polarized orientation.
• Additionally, make sure the connector for the Red
  LED is attached to the RDY header in the
  correct orientation.
• Extend all three sets of wires underneath the
  plate using the notch nearest the AVR as shown.

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Step 6 LED Mounting General

• Use copious amounts of hot glue without being
  overly excessive.
• Keep the tip of the hot glue gun from touching
  hardware, only molten glue should touch the
  hardware.

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Step 6 LED Mounting General

• There are two orientations of LED mounting for
  the structures build.
• If your plate serial number is odd (ending in 01,
  03, 05) orient the LEDs in the first orientation
  given. This is opposite the Geiger Counter.
• If your plate serial number is even (ending in
  02, 04) orient the LEDs in the second orientation
  given. This is underneath the Geiger Counter.

Example of an even plate serial number
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Step 6 LED Mounting General

• Extend the wiring underneath the plate and match
  the red x mounting location as shown.
• Mount the blue RBF wiring and stake near the
  middle of the appropriate notch on your plate.
• Make sure the lip of the red LED connector is
  flush with the edge of the plate.
• The front of the green LED should be even with
  the edge of the notch when mounting.
• Consult the following pictures of each
  orientation with any questions.

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LED Mounting Odd Serial Number
RockOn! 2008
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Step 6 LED Mounting Odd Serial Number

• The red LED connector goes on top of the red x as
  shown. Orient the lip down and flush with the
  edge of the plate.
• Also note the positive red wire is oriented
  inwards for this orientation.

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Step 6 LED Mounting Odd Serial Number

• Have a partner hold the LED and RBF wiring in
  place.
• Now hot glue the wiring in place in the same
  manner the photo shows.
• Be careful not to burn your partners hand!

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Step 6 LED Mounting plate overview
Bottom View
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LED Mounting Even Serial Number
RockOn! 2008
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Step 6 LED Mounting Even Serial Number

• The red LED connector goes on top of the red x as
  shown. Orient the lip down and flush with the
  edge of the plate.
• Also note the positive red wire is oriented
  outwards
• Also notice the green LED is flush with the notch
  edge, but under the plate.

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Step 6 LED Mounting Second Orientation

• Have a partner hold the LED and RBF wiring as
  shown.
• Now hot glue the wiring in place in the same
  manner the photo shows.

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Staking Components
RockOn! 2008
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Step 7 Staking bottom nuts

• Add hot glue to the nuts on the bottom of the
  plate.
• Stake all nuts on the bottom of the plate using
  hot glue as shown in the following two pictures.

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Step 7 Staking bottom nuts
Side View
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Step 7 Staking bottom nuts
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Step 8 Staking the AVR

• Add hot glue across the AVR as shown for extra
  structural security.

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Step 8 Staking the AVR
Side View
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Step 9 Staking connectors

• Ensure all connectors are attached in the correct
  orientation.
• Add generous amounts of hot glue to pot the
  connectors to the AVR PCB.
• Now the wiring is mounted solidly to the AVR PCB.

Example Connector
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Step 9 Staking connectors
Example Connector
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Step 9 Staking connectors
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Step 10 Staking Geiger Wires

• Stake the soldering location of the Geiger wires
  on the Geiger PCB as shown.

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Step 10 Staking Geiger Wires
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Structures Overview

• Open your structures kit and verify its contents.
• ESD protection should be utilized during the
  entire building process!
• Make sure anyone handling the hardware is
  protected from ESD damage.
• If any issues arise raise your hand for
  assistance.

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Step 11 Staking AVR Wires

• Stake the soldering location of the AVR wires on
  the AVR PCB as shown.

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Step 12 Staking Accelerometer Nuts

• Add hot glue to the Accelerometer nuts as shown.
• You may also add hot glue to the wire leads of
  the Z-axis accelerometers if you desire.

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Step 13 Staking Battery Bracket

• Add hot glue to the areas shown on the battery
  bracket and connectors.

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Step 13 Staking G-switch nuts

• Add hot glue to the nuts on the G-switch as
  shown.

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Step 14 Staking G-switch weights
Before Staking
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Step 14 Staking G-switch weights
After Staking back view
After Staking front view
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Final Check
RockOn! 2008
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Bottom of an odd plate
Staking should occur at all of these places!!
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Top of an odd plate

• Staking should occur at all of these places!!!
• Set the completed Plate on the ESD mat and wait
  for further instructions.

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Structural Integration
RockOn! 2008
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Structures Overview

• Open your structures kit and verify its contents.
• ESD protection should be utilized during the
  entire building process!
• Make sure anyone handling the hardware is
  protected from ESD damage.
• If any issues arise raise your hand for
  assistance.

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Overview

• Now that your payload has been built, tested, and
  mounted to a structural plate, it is time to
  assemble a stack of plates and integrate them
  into the RockSat can configuration.

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What Are We Building?
RockOn! 2008
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Structural Kit Overview Parts from other kits
Red LED with connector (1)
G-switch (1)
Blue RBF Wire (several feet)
Green LED (1)
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Step 6 LED Mounting Odd Serial Number

• The red LED connector goes on top of the red x as
  shown. Orient the lip down and flush with the
  edge of the plate.
• Also note the positive red wire is oriented
  inwards for this orientation.

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Final Product 1
Below Stacked configuration in can. (Minus lid)
Above 5 plate stacked configuration.
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Final Product 2
SolidWorks model and actual picture of structural
RockSat can.
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Groups and Hardware
RockOn! 2008
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Group Formation
To Begin - Examine your plate for a serial
number. The leading number indicates which can
your team flies in, and the last two digits
indicate plate number.
Plate Number
Can Number
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Group Formation 2

• Find the other four (4) groups that have the same
  can number and sit together. (5 Plates total)
• The assistants will come around and pass out the
  hardware that each team will need to build the
  RockSat can structure.

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Required Hardware 1

• One (1) Top Bulkhead

• One (1) Bottom Bulkhead

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Required Hardware 2
Wrenches
Hex Key

• Twenty (20) long male-female (MF) stand-offs

• One (1) 9/64 hex key
• Two 5/16 open-end wrenches

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Required Hardware 3
3/8
5/8

• Five (5) male-female (MF) short (cut-off)
  stand-offs

• Five (5) female-female (FF) stand-offs

• Sixteen (16) 3/8 bolts
• Five (5) 5/8 bolts

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Required Hardware 4

• Ten (10) locking washers

• Five (5) 1/2 bolts

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An Update
RockOn! 2008
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Update Note

• Some AVR boards were too close to a support
  stand-off during fit checks.

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Update Note

• To help alleviate the issue, a small chunk was
  nipped from the edge of the board.
• This should resolve the issue.
• If at any time you are unsure if you may be doing
  damage to your board while installing stand-offs,
  please raise your hand.

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Lets Begin The Integration
RockOn! 2008
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Bottom Plate 01 Step 1
2

• Take one (1) short stand-off and place the male
  end through one of the 5 holes on the plate with
  the serial number ending in 01.
• The threaded end should protrude on the top side
  of the plate.

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Bottom Plate 01 Step 2

• Screw on one (1) FF stand-off to the short MF
  stand-off you added.
• Important Tighten by hand until you cannot turn
  it anymore.

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Bottom Plate 01 Step 3

• Use your wrenches to tighten the stand-off an
  extra quarter turn. (90 or p/2 radians)

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Bottom Plate 01 Step 4

• Repeat the previous steps to add the other four
  (4) MF and FF stand-offs to plate 01 as shown.
• Plate 01 should look similar to the pictures to
  the left.

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Plate 02 Step 1

• Take one (1) long stand-off and place the male
  end through one of the 5 holes on the plate with
  the serial number ending in 02.
• The threaded end should protrude on the bottom
  side of the plate to thread into the FF stand-off
  on plate 01.

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Clocking

• Clocking
• Clocking is a technique where each plate is
  rotated 180 relative to the previous plate.
• Clocking is used here to better balance the
  RockSat cans due to the CG not being exactly at
  the geometric center of the plate.

AVR 05
AVR 04
AVR 03
AVR 02
AVR 01
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Plate 02 Step 2

• Clock or rotate plate 02 180 such that the AVR
  boards are opposite to each other.
• Hand tighten the MF stand-off until you can turn
  it no further.

Clocked 180
MF Stand-Off
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Plate 02 Step 3

• Use your wrenches to tighten the stand-off an
  extra quarter turn. (90 or p/2 radians)

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Plate 02 Step 4

• Repeat the previous steps to mate the MF
  stand-offs into the FF stand-offs on the deck
  below.
• Plates 01 and 02 should look similar to the
  pictures to the left.

4
1
3
5
2
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Plate 03 Step 1

• Take one (1) long stand-off and place the male
  end through one of the 5 holes on the plate with
  the serial number ending in 03.
• The threaded end should protrude on the bottom
  side of the plate to thread into MF stand-off on
  plate 02.

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Plate 03 Step 2

• Clock or rotate plate 03 180 such that the AVR
  boards on plate 02 and 03 are opposite to
  each other.
• Hand tighten the MF stand-off until you can turn
  it no further.

MF Stand-Off
Clocked 180
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Plate 03 Step 3

• Use your wrenches to tighten the stand-off an
  extra quarter turn. (90 or p/2 radians)

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Plate 03 Step 4

• Repeat the previous steps to mate the MF
  stand-offs into the MF stand-offs on the deck
  below.
• Your stack should resemble the picture to the
  left.

2
3
1
5
4
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Plate 04 Step 1

• Take one (1) long stand-off and place the male
  end through one of the 5 holes on the plate with
  the serial number ending in 04.
• The threaded end should protrude on the bottom
  side of the plate to thread into MF stand-off on
  plate 03.

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Plate 04 Step 2

• Clock or rotate plate 04 180 such that the AVR
  boards on plate 04 and 03 are opposite to
  each other.
• Hand tighten the MF stand-off until you can turn
  it no further.

Clocked 180
MF Stand-Off
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Plate 04 Step 3

• Use your wrenches to tighten the stand-off an
  extra quarter turn. (90 or p/2 radians)

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Plate 04 Step 4

• Repeat the previous steps to mate the MF
  stand-offs into the MF stand-offs on the deck
  below.
• Your stack should resemble the picture to the
  left.

3
2
1
4
5
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Plate 05 Step 1

• Take one (1) long stand-off and place the male
  end through one of the 5 holes on the plate with
  the serial number ending in 05.
• The threaded end should protrude on the bottom
  side of the plate to thread into MF stand-off on
  plate 04.

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Plate 05 Step 2

• Clock or rotate plate 05 180 such that the AVR
  boards on plate 05 and 04 are opposite to
  each other.
• Hand tighten the MF stand-off until you can turn
  it no further.

Clocked 180
MF Stand-Off
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Plate 05 Step 3

• Use your wrenches to tighten the stand-off an
  extra quarter turn. (90 or p/2 radians)

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Plate 05 Step 4

• Repeat the previous steps to mate the MF
  stand-offs into the MF stand-offs on the deck
  below.
• Your stack should resemble the picture to the
  left.

4
5
1
2
3
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Bottom Bulkhead 1

• Carefully turn the stack upside down.
• Place the bottom bulkhead (with the outer bolt
  circle) on the bottom of the stack
• Make sure the notch aligns with the set of blue
  RBF wires as shown.

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Bottom Bulkhead 2
- Take one (1) 1/2 bolt and locking washer and
hand screw it into the center stand-off as shown.
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Bottom Bulkhead 2

• Lightly tighten the 1/2 bolt and lock washer
  with the hex key.
• Important Dont not over tighten the bolt. After
  all bolts are in, they will be torqued to 30
  inlbs.

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Bottom Bulkhead 3
4
3
1
2
5

• - Insert and tighten the remaining four (4) 1/2
  bolts and washers on the bottom bulkhead.
• Note Add the bolts in an alternating fashion
  (like tire lug nuts) as indicated above. Tighten
  until bolts are flush with the plate.

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Bottom Bulk Head 4

• Have two people in the group carefully rotate the
  stack 180 so that it now rests on the bottom
  bulkhead.
• - Your stack should resemble the picture to the
  left.

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Outer Skin 1

• Ensure that the blue wires all pass down the
  channel with the LEDs.
• Also check that no wires or objects are on the
  edge of any of the plate.
• Place the outer skin onto the bottom bulkhead.

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Outer Skin 2

• Align the outer skin to allow the skin and
  bulkhead holes to line up.
• By hand, screw in all eight (8) 3/8 bolts
  through the skin to attach it to the bottom
  bulkhead.

• Important Do not over tighten the bolts. The
  bolts will be torqued to 30 inlbs

Good Alignment
153
Outer Skin 3

• Use the hex key to lightly tighten all eight (8)
  3/8 bolts
• Note Use an alternating pattern (like tire lug
  nuts).
• Caution Do not over tighten the bolts. The bolts
  will be torqued to 30 inlbs once all structural
  bolts are installed.

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Outer Skin 4
- Your structure should now resemble the picture
to the left.
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Outer Skin 5

• Place the top bulkhead on the stack as shown to
  the left.
• Make sure that the notch aligns with the wire
  path way.

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Outer Skin 6

• Align the outer skin to allow the skin and
  bulkhead holes to align.
• By hand, screw in all eight (8) 3/8 bolts into
  the skin to attach it to the top bulkhead.

8 Total
Good Alignment
157
Outer Skin 7

• Use the hex key to lightly tighten all eight (8)
  3/8 bolts
• Note Use an alternating pattern (like tire lug
  nuts).
• Caution Do not over tighten the bolts. The bolts
  will be torqued to 30 inlbs once all structural
  bolts are installed.

158
Outer Skin 8
- Your structure should now resemble the picture
to the left.
159
Top Bulk Head 1

• You might find that your top bulkhead bolts dont
  align perfectly.
• If this is the case, reach in through a window
  and apply a small amount of force to achieve
  alignment.

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Top Bulkhead 2

• Once alignment is achieved, insert one (1) 5/8
  bolt and lock washer into the center hole.
• Lightly tighten the bolt with the hex key.
• Important Leave this bolt loose enough to make
  slight adjustments to the other four (4) bolts.

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Top Bulkhead 3

• By hand, lightly screw in the other four (4) 5/8
  bolts and lock washers.

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Top Bulkhead 4

• Use your hex key to tighten all five (5) 5/8
  bolts and lock washers on the top of the
  bulkhead.

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Top Bulkhead 5

• Your structure should look like this, but with
  more wires coming down the pass-through.
• Note All LEDs and connectors should be visible
  in the wire way.

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Final Product
Congratulations! You have completed
integration of your payload with the RockSat can.
We will now walk through a shorting plug test,
pull the RDY LED, and get all structural bolts
torqued and ready for the hand-off to Wallops
engineers!