High altitude payload design
Overview: During my placement year, I led a comprehensive project to design, build, and validate a high-altitude payload intended for stratospheric balloon flights reaching 30 km altitude. This challenging environment presents unique thermal and mechanical risks, especially given the atmospheric density and the consequent reduction in convective cooling. The payload’s primary purpose was to safeguard sensitive electronics from impact and extreme cold, while maintaining operational temperatures for critical computing components during prolonged flight profiles.
Design Approach: Addressing the thermal challenges, I initially researched various cooling techniques tailored for conditions at high altitude, drawing from existing ballooning systems and aerospace engineering principles. Based on this exploration, I devised multiple conceptual solutions and employed ANSYS to develop preliminary models, comparing their performance through simulations. Although these models could not perfectly replicate the exact conditions at 30 km, they proved invaluable for evaluating the relative effectiveness of each cooling strategy.
Following the selection of an optimal cooling design, I implemented physical testing to verify the solution’s performance. Employing Cambridge Consultants’ environmental chambers, capable of reaching -40°C, combined with a vacuum chamber to simulate the upper atmosphere, allowed us to recreate the extreme conditions at 30 km. I constructed a detailed test plan considering variables such as flight duration, temperature, pressure changes, and thermal gradients, ensuring the tests closely mimicked operational scenarios. The full system was then tested during two flight campaigns in April and May, with the second payload successfully recovered containing comprehensive data, including temperature profiles showcasing the cooling system’s effectiveness.
Key Results and Validation: The flight data demonstrated that the cooling system maintained CPU temperature well below critical thresholds, confirming that the thermal management approach prevented hardware throttling. An image from the flight at 24 km altitude over Bedford vividly captures the payload with a commercial airliner below, illustrating the stratospheric environment in which the system operated. The successful thermal regulation was a pivotal achievement, validating the design for potential deployment in real scientific missions.
Key Results and Validation: The project culminated in a presentation delivered to the entire company, where I articulated our journey from concept to flight. I crafted clear visual narratives and tailored explanations, mindful of the diverse technical backgrounds in the audience. Post-project, I authored detailed documentation including procedures, parts lists, and recommendations for future enhancements to ensure smooth knowledge transfer. This systematic communication was instrumental in enabling ongoing development and operational continuity.
