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camp2023-57093-eng-Bits_and_Bytes_in_Microgravity_opus.srt
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[MUSIC]
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[MUSIC]
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Okay, we probably all had our fair share of experiments, right?
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Maybe technical experience with some device, maybe some cooking experience,
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or other substances, whatever.
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Dying nodes, always experimental.
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And yeah, but all those experiments have taken place in standard atmosphere, of course.
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And maybe with no acceleration, just being there on Earth.
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But what if you could change that?
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Okay, you know, our next speakers, Martin and Jean-Claude,
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working as computer scientists and mechanical electrical engineers
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at the German Aerospace Center, DLR.
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They will show us how to undertake experiments under microgravity conditions,
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or with the extreme acceleration of hypersonic rockets.
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Please give a warm welcome to Martin and Jean-Claude.
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[APPLAUSE]
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Thank you very much.
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Thank you very much.
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Hi, I'm Martin.
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This is Jean-Claude.
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Hi.
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And yeah, we'd like to present to you bits and bytes in microgravity insights
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into the hard and software of sounding rockets.
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Yeah, so let's start a little bit about the DLR in general.
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So the German Aerospace Center, DLR, is a research facility in Germany,
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one of the biggest with approximately 10,000 employees across 58 institutes
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and facilities at 30 sites, as you can see here in the picture on the right side.
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And we work in one institute in DLR.
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And in one department there called Moraba,
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which is basically in English a mobile rocket base.
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And this is, yeah, the base for the rocket base is in Oberfaffenhofen near Munich,
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which is on the bottom right on the map.
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And currently we are on the bottom top, as you can see.
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Yeah, this is DLR in general.
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But what is Moraba doing?
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So basically what we are doing is we develop, build, and fly customized sounding rockets.
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This means we customize sounding rockets for institutional research within DLR,
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for example, material science, but also for industrial partners.
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And we customize rockets for their experiments and their payloads.
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And in addition, we also do some balloon experiments.
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So, and this especially means that we build rocket vehicles,
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payload support systems, and ground support systems.
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Some facts about Moraba.
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So since like 50 to 55 years, we had 550 plus launches with 30 different vehicles.
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The heaviest of them weighed about seven metric tons.
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And they started from about 20 launch sites on Earth.
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So everywhere on Earth basically.
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And yeah, we cover research fields from astronomy, aeronomy, microgravity, hypersonics.
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And there's also student programs for student education.
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So if you are a student, you can also build rockets and fly them at Moraba,
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or together with Moraba actually.
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And we also do technical demonstrations.
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And yeah, of course, security and defense-related research is also involved.
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So the first question here is, and this is basically the outline of the presentation,
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is what is required to fly a sounding rocket or to operate a sounding rocket?
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And it all starts with mission management and range coordination.
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And then we go over to electrical and mechanical manufacturing,
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as well as assembly integration and test.
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And from there on, we have a full rocket.
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And we can talk about the launch campaign itself.
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And then of course, we have post-flight analysis for scientists and for ourselves, right?
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So much for the outline.
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So when we start a new campaign or a new mission, basically,
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we first talk with our stakeholders and partners about the mission profile in general.
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And basically, we cover two, actually three types of flight profiles.
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And you can see in the picture on the right, this is on the first...
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Firstly, it's hypersonic flight.
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So you can see it's a rather shallow flight there,
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because basically there, the interest is in speed and the effects.
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And then we have somewhere in between the student program,
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which is similar to the actual atmospheric physics and microgravity research,
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which is basically the top trajectory, which is really high.
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And there we have microgravity basically for about six minutes.
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These are the two types, hypersonic flight and microgravity flights with rockets.
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So once we've talked with our partners about the mission profile in general
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and what we wanted to cover, what we wanted to do,
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we can go to the vehicle selection.
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So there's a whole set of vehicles.
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That's basically a combination of different motors or solid rocket motors mostly.
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And then of course, the payload, which is a little bit different every time.
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When we fly a rocket.
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So from left to right, you basically have small apogee, small rocket,
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and to the right you have an orbital rocket,
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which is in general able to fly into orbit with a small payload.
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Once we've selected a vehicle for the mission profile,
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we have to select a proper site for the flight in general.
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And what you can see here is basically all the locations we have launched a rocket from.
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The yellow locations here are the locations that are used frequently.
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These are Kiruna in Sweden and Andernes in Norway, then also Spitsbergen, Norway.
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And there's one site in Brazil and one site in Australia.
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So from here on, we now have a whole plan.
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We now know what we wanted to do.
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And it's time to talk a little bit about how to build the rocket in general.
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And I think that's the first time we switch.
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So the rocket itself is divided into different sections.
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First, we have the launch segment on the left.
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The launch services are responsible for the aerodynamics, for the trajectory,
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and for the decision on which engine we use.
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Then we have the mechanical flight systems.
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They do almost every structural thing,
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like the hull, fins, the nose cone, the bulkheads, the insides, everything we need.
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But they do also the recovery.
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For the parachute, we come back to that later.
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Then we have the data handling.
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That's where we're from.
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Data handling is what it says.
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The experiment sends data from the inside the payload,
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and we transmit it and distribute it on the ground.
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Then we have control and instrumentation.
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Some flights, especially the microgravity flights,
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they have a cold gas thruster system to reduce movement during the micro-gea phase.
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They're responsible for that.
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And then we have the telemetry and tracking station.
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They track the rocket during the flight with an antenna
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and receive the telemetry or send the telecommand if necessary.
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So that's all the departments.
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You can see what a rocket can look like.
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This is the VSB-30 vehicle.
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From left to right, you have the booster, where is S-31,
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and then the second stage, and then you have the payload.
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The three modules on top are the recovery system and the motor adapter.
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Then we have the rate control system and the attitude control system.
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That's where the cold gas thrusters are.
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And then the service module, of course, where everything comes together.
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Since we're from the data handling group, we're responsible for the service module.
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The service module is kind of modular.
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So the experiments say, "We need that data rate, and we'd like to have so many power connections."
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And we say, "Okay, we can do that for you."
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We also have the batteries.
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Then the experiment says, "Okay, we have, for example, 10 megabits of data,
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and we'd like to transmit it to ground, and then we decide how to do it."
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So the experiments are happy.
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This is an explosion view.
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It's a little bit crowded, but just short.
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This is our largest service module we can offer.
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You can decide on the national measurement unit, depending on your trajectory,
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if you need very precision or not.
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Then on the left, we have the e-box.
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This is the brain from the service module.
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There comes everything together.
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And on the right, we have some GPS receivers.
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And on the bottom, the telemetry transmitters or telecommand receivers.
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And all of that, you can see, or most of that is built in-house, mechanics, PCBs,
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wiring harness.
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Yes.
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And talking about the brain from the service module, the e-box,
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has the multifunction card inside where it's basically the CPU,
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where everything runs together.
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And Martin will tell you some details about the MFC2.
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Yeah, talking about the brain of the system,
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having the multifunction card second generation here.
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So this is the MFC2G, as we call it.
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It basically is a processor, a dual-core Blackfin 561 with 500 MHz,
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and also an FPGA Cyclone III.
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You can see that it only has 64 megabytes of SD-ROM and 2 megabytes of DS-ROM.
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So this hardware is about 10 years old.
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And currently, actually this year, or in two or three weeks,
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we started to design the next generation
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computer or module, service module, actually the whole service module.
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This also includes the redesign and new design of these circuit cards.
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But coming back to the current generation,
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currently we can support 16 422 serial ports and RS 424 eight times.
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Then we have two CAN bus.
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We have an Ethernet 10 to 100 base T possibility as a downlink from the experiments.
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Then we have two GSMK modems for the telemetry inside so that we can send the data during flight,
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which is coming basically from the experiments via serial.
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So the next generation basically will use mostly, or this is our idea,
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will use mostly Ethernet, of course, going a little bit more into the modern area here.
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Nevertheless, we also have an FPGA which does a lot of work in the background.
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For example, evaluating flags and stuff so that the CPU does not have to deal with it.
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We also have an SD card on board here, a mass storage device.
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That is basically for backup, meaning if we are not able to receive data,
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via telemetry, for whatever reason, we also have a backup on an SD card from the experiments
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from all the data that is sent to the ground.
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This is basically the multifunction card here.
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Once we've designed or finished the service module,
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we can go over to the whole testing procedure.
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We have the service module and then we have also the modules from the experimenters.
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Then we have to test all of this on the ground before flight, of course.
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Maybe a little bit to the software, sorry, let me go back again.
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Just about the software here.
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So the Blackfin is usually programmed in C++ and Assembler, of course.
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Then we have the Cyclone processor, which is usually programmed using VHDL for FPGA.
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I just want to mention that here.
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If we then assemble the service module and the experiments are ready,
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and also the mechanical structure is ready, for example, the fins,
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that are also made in-house, we have to test the whole rocket on ground.
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One of the first tests we do is basically the air-bearing test.
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For example, if you have a cold-gas thruster system that controls the rocket in space,
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we have to make sure that our software pushes the rocket into the right direction.
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It's a little bit difficult.
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If you do it wrong in space, yeah, that's too late.
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So we have to check firstly on ground if all the thrusters work in the correct direction.
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This is a little video here that shows that.
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So you can see this is basically lifted by air pressure, the whole structure.
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The rocket is currently flying basically in simulation mode,
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and it's moving within the hull.
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We can check then, okay, it's going into the right direction.
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It's doing what it's supposed to do.
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Then also included in this bench test is testing if everything is connected together,
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if every signal is coming from the experiment to the rocket to the service module.
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If everything goes to the ground, then we also look into the countdown phase.
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So how we're supposed to start up the rocket, when we should turn on the batteries, for example,
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and stuff like that.
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After all of this, we do a final bench test, which is basically
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the certificate it's working intended in the plan.
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Nevertheless, we also do some environmental testing on the rocket.
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Of course, it's a sounding rocket boosted by solid rocket boosters,
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so you have a lot of G on the rocket.
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So we do some shaker tests, which involve sign sweeps on all three axes of the rocket.
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That basically means, if you basically build together the rocket,
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then you have some sensors on it, and then you do a frequency measure
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over some specified frequencies.
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There's a standard for that.
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I'm a computer scientist.
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You know it a little bit better, I guess.
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But basically what you do is you do a sweep, then you shake the rocket,
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and then you can take another spectrum.
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And if it looks different from the first time, you know something is loose inside, maybe a screw.
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And then you have to take it apart and see what is wrong.
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Then we also do a center of gravity check so that the rocket is stable in flight.
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We do moments of inertial measurement and sometimes thermal vacuum testing.
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Well, and if all this works out, we basically have a completed rocket.
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For example, some examples here on the side,
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different vehicles with different payloads, just to see how it could look like.
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Yeah, so this is then the point where we basically have a completed rocket
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in Oberpfaffenhofen, Germany, and then we have to go to the launch site.
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And it's called Mobile Rocket Base, which basically means we take everything we have,
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and that's a lot of stuff, like the whole telemetry station, the launcher rack,
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everything you need to maintain and to fly a rocket, and we take it to the place
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where it's going to be used for the launch.
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And we take it to the place where we want to launch the rocket,
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and we build up the whole mobile infrastructure.
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And this also includes the electrical ground support equipment, or EGSE as we call it.
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And this is basically on this little sketch here, it's the things on the right side.
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So you have the rocket on the left with the service module and the experiments.
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And then you have a serial connector or more than one serial connector or Ethernet
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going to the service module interface rack, which is basically housed next to the rocket.
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And from there we have Ethernet of fiber or Ethernet wire fiber to the data switching center,
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which is basically also a software, again, written currently in C++
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that is distributing all the data.
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So taking the data stream, selecting the data streams, and pushing it to the correct experiments
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or to the scientists and their monitoring stations.
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Because we only push the data through and they have their own monitoring system
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where they can do whatever they like with their data, because that's so different every time.
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But we also have, of course, housekeeping of our own system, like temperatures,
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and what is also involved, like position and stuff like gyroscope, accelerator, you name it.
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And then, of course, we have an Ethernet and fiber also coming into our data switching system.
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So you have the left side to the service module interface rack, which is basically the connection
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while the rocket is on ground.