AFRL Enclosure Project

The project's objective was to design a resilient and secure enclosure that maintains the functionality of sensitive aerospace electronics amidst the Mojave Desert's severe climate variations and the vibrational impact of nearby rocket engine tests.

The ESP32 microcontroller was the brains of our operation, tasked with real-time environmental monitoring. Its programming controlled a relay-based cooling system, activated or deactivated by a hysteresis algorithm to maintain temperatures within precise thresholds.

A magnetic reed sensor was employed to monitor the door status, alerting the system to potential compromises in the enclosure's seal. To counteract signal attenuation caused by the metallic enclosure, a high-gain 4dBi antenna was utilized, ensuring reliable communication.

Power management was critical, especially considering the remote nature of the location. A 6600 mAh battery provided backup power, while a voltage divider circuit carefully reduced the USB power input from 5V to a GPIO-friendly 3.3V for accurate source detection. Grounding was achieved by connecting the enclosure to the earth ground of a 12V 30A power supply, mitigating potential electrical noise and ensuring data integrity.

The system's communication capabilities were showcased through a web interface that provided real-time data and system status, complemented by an alert system that sent out notifications via email. This setup was crucial for the team to receive timely updates and respond to conditions such as power source changes or temperature fluctuations.

Here is a sample alert email, illustrating the system's capability to automatically communicate critical status changes, keeping the Air Force's team updated and the electronics secure.