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4.1 Design Book MCU Specs:
Rigid-Body Rotational Dynamics (Tank Spin System):
Tank Specs:
Material → 304L Stainless Steel
Length → 15 cm
Radius → 4 cm
Thickness → 0.5 cm
Mass → 1.143 kg
Configuration:
Thin-walled cylindrical tank approximation
Instrumented with internal thermocouples
Sealed end-cap with wiring feedthrough
Moment of Inertia (Izz):
Izz = mR²
Izz = (1.143 kg)(0.04 m)²
Izz = 0.001829 kg·m²
Drive Torque:
τ = 0.840 N·m
Angular Acceleration:
τ = Iα → α = τ / I
α ≈ 459.4 rad/s²
Spin Rate Requirement:
2–3 RPM
ω ≈ 12.57 – 18.85 rad/s
Spin-Up Time:
t = ω / α
t ≈ 27 – 41 ms
Power Estimate:
P ≈ 6.5 W
Motor / Servo Notes:
Torque–speed curve limits max RPM
Servo must provide ≥ 0.84 N·m stall torque
Continuous power ≥ 6.5 W
Design Task:
Evaluate 4 candidate servos from electrical spreadsheet →
Compare torque, speed, power, and mass to select optimal model.
Sensor Inventory
The sensor suite must be finalized for CoDR and justified, including:
IMU (gyroscopes and accelerometers
Redundant rate sensing
Tank temperature sensor array
Pump RPM and motor current sensing
Pressure and vent-state sensing
For each sensor, Controls shall specify:
Update rate
Accuracy and noise
Drift characteristics
Survivability under spin
Electrical interface
| Failure Mode | Detection | Isolation / Safe Mode | Recovery |
|---|---|---|---|
| Sensor bias / dropout | Redundancy, out-of-range checks, rate checks, residuals | Flag sensor invalidity, use backup, and reduce authoriuty | Sensor reset → offset compensation where valid |
| Unexpected torque | Model vs measured residuals | Switch to damping mode, inhibit impulses | Let residuals decay and re-estimate states |
| Spin-axis misalignment | Orientation vs expected dynamics | Reduce authority, re-acquisition | Re-estimate axis and update control parameters |
| Partial power loss | Voltage / Current thresholds | Disable non-essential processes and maintain survival | Gradually restore functions as power stabilizes |
FDIR = Continuously:
Observe system state
Compare to model/expectations
Flag anomalies
Enter a safe mode
Attempt recovery
Only return to nominal when consistent