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Structures & Mechanical / Incorporating Injection Molding
« Last post by Cosmoneer on April 27, 2017, 03:24:02 PM »
Hi all!

Now that we have obtained a small scale injection machine, we wanted to list some of the areas of improvement or areas we wanted to reduce complexity/cost while adding to the integrity of the Cosmoneer.

Targeted Areas of Improvement
  • Front PCB attachment points/methods
  • Receiver Coil & support
  • Rear PCB attachment points
  • Counterweight attachment point

Easy Injection Convertible Parts
  • Support Feet
  • Front Legs
  • Thread Spool
  • Coil Cover

Large Injector needed
  • Upper & Lower Support Arms
  • Main Stand Support Plate
  • Dash/Gyro Support
  • Inner Hanger

Any ideas or suggestions you have on these items?  Leave a post!
Command & Data Handling (microController) / Re: Command and Control
« Last post by digital_gods on April 23, 2017, 11:41:34 PM »
I found a breif tutorial for configuring COSMOS and Arduino to play together.
I'm trying to get Ball Aerospace Cosmos ( telemetry software to work on Win10 64-bit without much luck. A couple of the components don't get installed not will the demo load. This week I'm setting up a Win 7 VM to test on. Can someone else see if it will install on their copy of Win 10?

I visited NASA's new SSBK website and read section #5 on GNC.  Interestingly, Control Moment Gyros were not mentioned anywhere in that section.  Since CMGs are not good at high accuracy pointing (yet), I can only speculate that they were omitted since they are typically not chosen for space missions where accurate pointing is required.

This knowledgebase will be in constant flux, so I expect this to change in the future.
Communications (Serial IrDa) / When you really want to do RF
« Last post by Cosmoneer on April 12, 2017, 04:05:33 PM »
So, you want to do RF instead of Infrared?  You could try a microstrip YAGI antenna and have directional WiFi.
Yes, the Serial IrDa *CAN* be connected to an FTDI cable!

We tested it out and used the Arduino Serial Monitor interface to send/receive data to a Cosmoneer.  We've since updated the IrDa spec sheet to include simple wiring instructions (shown below).

FTDI          to            IrDa
GND  - - - - - - - - - - >  GND
VCC  - - - - - - - - - - >  +5v
TXD  - - - - - - - - - - >  TX
RXD  < - - - - - - - - - -  RX

Note: Jumper from ENABLE to +5v (suggest using a 3.3k, 4.7k or 10k resistor)
Guides & Plans / Mission Planning
« Last post by Cosmoneer on April 05, 2017, 05:20:55 PM »
We often overlook the complexities associated with planning a mission in space, especially an interplanetary mission.  So many factors affect one another, where do you start?

  • How close is Earth to the planet we want to visit?
  • How long will it take to develop the systems (scientific, navigational, propulsion, software, etc) we'll fly on the spacecraft?
  • Where do we find the people and the skills to tackle all the problems we'll encounter building it?
  • Who will pay for it?
  • What launch vehicle can we use?  Will it be custom built, or an existing solution?
  • What is the maximum weight we can send?
  • What sacrifices can we make due to weight/size constraints, yet still accomplish our mission?
  • What happens if we miss our launch window?
  • Who will talk to our spacecraft and receive it's signals when it is in space?

This is just a small list of the many items that affect a mission from the beginning.

Some of the points we want to focus on are mission constraints such as weight, size and hardware...
General Discussion / Re: Assembly Issues
« Last post by digital_gods on April 05, 2017, 12:54:07 AM »
I appreciate the offer of sending out replacement parts.  Don't worry about sending me anything. I'm a machinist and we are miracle workers. I made them work. I'm just giving you feedback to improve the Cosmoneer.

Command & Data Handling (microController) / Re: Command and Control
« Last post by digital_gods on April 05, 2017, 12:31:18 AM »
I found a breif tutorial for configuring COSMOS and Arduino to play together.
General Discussion / Re: Assembly Issues
« Last post by Cosmoneer on April 04, 2017, 01:17:01 PM »

In regards to Issue #2, I believe we may be able to use shrink-wrap as you suggested, while looping the wires out through holes in the wrap and back in so they exit in approximately the same location.  This will eliminate the strain on the solder joints while also protecting the exposed circuitry.

General Discussion / Re: Assembly Issues
« Last post by Cosmoneer on April 04, 2017, 03:20:29 AM »
Thanks Digital for the feedback!  Your patience is appreciated while we hammer out kinks in the initial kits we are producing.

I'll quote your post and address each item individually.

1. Add labels to the photos so the builder know what they are looking at.

This is a great suggestion and something that we'll work in in the next couple of weeks.

2. Magnetic power circuit on the craft need a shrink wrap to give support to the small wires. I had to resolder both.

I am extremely sorry you ran into this issue.  It was recently encountered with other users who assembled the kits for the first time as well.  We are reviewing options to mitigate this issue so it doesn't happen in the future.

3. On attaching the coil to the project boards, you instructed to use jumpers. They would not fit in the holes of the ABS. Switch to super glue or screws.

This was one of the most difficult steps to follow and is being replaced with screws.  The 3D models will also be updated to support the screws selected.  If you'd like, we can mail you the updated parts once they are tested and approved.

4. The holes for the cut acrylic and 3D printed parts did not line up. Check quality issues.

I am very sorry for this issue.  Our process is being updated to prevent this in the future.  In the meantime, what color was your dash panel so I can send a replacement to you.

5. The FDMI to USB card does not plug in easily because the 3.3 or 5 volt jumper. Maybe jumper cabling?

With a new revision of the Cosmoneer PCB planned for the near future, perhaps your suggestion to incorporate a USB interface onboard (similar to the Arduino Nano) might be the way to go.

6. The port for the servo and speed controller not clearly labeled on the directions of what goes where and orientation of the plug.

Thank you for pointing this out.  I believe this issue falls in-line with point #1 above.

Were you able to figure it out via the instructable?  The second picture in step 19 would have helped (had it included labels as you suggested.)  The connectors in that picture (until we get them updated) from left to right are:    Wireless power connector, Servo wire and Superburst wire (which then feeds through to the ESC.)  The signal wires are always to the outside of the mainboard.

The bottom center picture in step 20 shows the orientation of the Superburst board, which has the wire coming from the mainboard (mentioned above) to the Superburst board.  Shown in the orientation pictured, the white wire (or yellow, depending on your kit) is at the topmost edge of the Superburst board.  The black wire is towards the middle of the Superburst board.

The ESC plugs into the other side of the Superburst board, with the yellow wire being on the top-most edge of the Superburst board.  In the future, these boards will have silkscreen on both sides that indicate " - + S " for ground, power and signal to aid in connecting them correctly.  The mainboard will have the same as well.

7. The little inserts to join both halves of the crescent hanger was not going in by hand. It was a job for superglue.

These parts are being redesigned for easier assembly and for injection molding, which should eliminate the fit problem you encountered with the 3D printed parts.  Once we replace these with injected parts we'd love to send you replacements.

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