auburn university student launch project tiger launch
TRANSCRIPT
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Project Nova
211 Davis Hall
AUBURN, AL 36849
PROPOSAL
SEPTEMBER 20, 2017
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Table of Contents
General Information ..........................................................................................................................................................12
Section 1.1: Team Information .........................................................................................................................................................12
Section 1.2: Adult Educators ............................................................................................................................................................12
Section 1.3: Safety Officer ...............................................................................................................................................................14
Section 1.4: Team Leader .................................................................................................................................................................15
Section 1.5: Project Organization .....................................................................................................................................................15
Section 1.6: NAR/TRA Sections ......................................................................................................................................................19
Facilities/Equipment ..........................................................................................................................................................19
Section 2.1: Facility Listing ..............................................................................................................................................................19
Aerospace Computational Lab....................................................................................................................................19
Aerodynamics Laboratory ..........................................................................................................................................20
Advanced Laser Diagnostics Laboratory ....................................................................................................................21
Composites and UAV Laboratory ..............................................................................................................................21
Computational Fluid Dynamics Laboratory ...............................................................................................................22
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Design and Manufacturing Laboratory .......................................................................................................................23
Flow Visualization Laboratory ...................................................................................................................................24
GKN Aerospace Tallassee, Alabama ..........................................................................................................................24
Machine Tool Laboratory and the Aerospace Wood Shop.........................................................................................25
Structures Laboratory ...............................................................................................................................................25
Safety ...................................................................................................................................................................................27
Section 3.1: Personnel and Responsibilities .....................................................................................................................................27
Section 3.2: Hazard Analyses ...........................................................................................................................................................28
Section 3.3: Checklists......................................................................................................................................................................32
Section 3.4: Team Briefings and Checks ..........................................................................................................................................32
Section 3.5: Energetic Device Handling ...........................................................................................................................................33
Section 3.6: Law Compliance ...........................................................................................................................................................34
Section 3.7: NAR/TRA Safety Codes ..............................................................................................................................................38
Section 3.8: Caution Statements .......................................................................................................................................................44
Section 3.9: Team Safety Statement .................................................................................................................................................45
Section 3.10: Ongoing Training .........................................................................................................................................................46
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Section 3.11: Risk Assessments .........................................................................................................................................................46
Technical Design ................................................................................................................................................................47
Section 4.1: General Vehicle Design ................................................................................................................................................47
Projected Altitude .......................................................................................................................................................54
Motor Selection...........................................................................................................................................................55
Section 4.2: Recovery System Design ..............................................................................................................................................58
Recovery Structural Elements ....................................................................................................................................58
Materials .....................................................................................................................................................................59
Ejection System ..........................................................................................................................................................60
Parachutes ...................................................................................................................................................................63
Parachute Manufacturing ............................................................................................................................................66
Drift .............................................................................................................................................................................67
Altimeters....................................................................................................................................................................68
Section 4.3: Testing ..........................................................................................................................................................................71
Vehicle Body ..............................................................................................................................................................71
Systems and Electrical ................................................................................................................................................72
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Computational Fluid Dynamics (CFD) ......................................................................................................................73
Rover ...........................................................................................................................................................................73
Recovery .....................................................................................................................................................................74
Section 4.4: Proposed Payloads ........................................................................................................................................................75
Section 4.5: Technical Requirements ...............................................................................................................................................75
Vehicle Requirements .................................................................................................................................................75
Recovery System Requirements .................................................................................................................................88
Payload Requirements ................................................................................................................................................94
Section 4.6: Major Technical Challenges .........................................................................................................................................95
Payloads ..............................................................................................................................................................................96
Section 5.1: Rover ............................................................................................................................................................................96
Overview .....................................................................................................................................................................96
Design .........................................................................................................................................................................96
Electronics ..................................................................................................................................................................99
Section 5.2: Altitude Control Module ............................................................................................................................................100
Overview ...................................................................................................................................................................100
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Structure ....................................................................................................................................................................100
Electronics and Extensibility ....................................................................................................................................101
Educational Engagement.................................................................................................................................................101
Section 6.1: Drake Middle School 7th Grade Rocket Week ...........................................................................................................102
Rocket Week Plan of Action ....................................................................................................................................103
Rocket Week Launch Day ........................................................................................................................................104
Rocket Week Learning Objectives ...........................................................................................................................105
Gauging Success .......................................................................................................................................................106
Section 6.2: Samuel Ginn College of Engineering E-Day .............................................................................................................106
Section 6.3: Boy Scouts of America: Space Exploration Badge ....................................................................................................107
Boy Scouts of America: Requirements .....................................................................................................................108
Boy Scouts of America: AUSL Requirements .........................................................................................................109
Boy Scouts of America: Plan of Action....................................................................................................................110
Boy Scouts of America: Goals..................................................................................................................................111
Section 6.4: Girl Scouts of America: Space Badge ........................................................................................................................111
Girl Scouts of the USA: Requirements .....................................................................................................................111
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Girl Scouts of the USA: AUSL Requirements .........................................................................................................114
Girl Scouts of the USA: Plan of Action ....................................................................................................................114
Girl Scouts of the USA: Goals ..................................................................................................................................115
Section 6.5: Auburn Junior High School Engineering Day ............................................................................................................115
Section 6.6: Aeropalooza ................................................................................................................................................................116
Section 6.7: Organization Week .....................................................................................................................................................117
Section 6.8: Auburn University Rocketry Association...................................................................................................................117
Project Plan ......................................................................................................................................................................118
Section 7.1: Timeline ......................................................................................................................................................................118
Section 7.2: Budget .........................................................................................................................................................................119
Section 7.3: Funding Plan ...............................................................................................................................................................124
Section 7.4: Community Support ...................................................................................................................................................125
Dynetics ....................................................................................................................................................................125
GKN Aerospace ........................................................................................................................................................125
Drake Middle School ................................................................................................................................................126
Phoenix Missile Works .............................................................................................................................................126
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Chris’s Rocket Supplies ............................................................................................................................................126
Auburn Engineering ..................................................................................................................................................127
Section 7.5: Project Sustainability ..................................................................................................................................................127
Appendix A. Safety Waiver ...................................................................................................................................................................129
Appendix B. Risk Assessment ...............................................................................................................................................................132
Appendix C. Gannt Chart .....................................................................................................................................................................166
List of Figures
Figure 1.1: Team Organization Chart ....................................................................................................................................................... 16
Figure 2.1: Subsonic Wind Tunnel ........................................................................................................................................................... 20
Figure 2.2: PIV of a Synthetic Jet Flow Field .......................................................................................................................................... 21
Figure 2.3: Water Tunnel .......................................................................................................................................................................... 24
Figure 2.4: GKN Autoclave ...................................................................................................................................................................... 24
Figure 2.5: Hydraulic Loading System ..................................................................................................................................................... 26
Figure 4.1: Vehicle Rendering .................................................................................................................................................................. 47
Figure 4.2: Design Layout ........................................................................................................................................................................ 48
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Figure 4.3: Braided Section Sample ......................................................................................................................................................... 50
Figure 4.4: Fin Image ................................................................................................................................................................................ 52
Figure 4.5: Grid Fin Rendering ................................................................................................................................................................. 54
Figure 4.6: Simulated Altitude .................................................................................................................................................................. 55
Figure 4.7: Motor Thrust Curve ................................................................................................................................................................ 57
Figure 4.8: Jolly Logic Chute Release ...................................................................................................................................................... 61
Figure 4.9: Manufactured Parachute and Chute Release .......................................................................................................................... 62
Figure 4.10: Gore Template ...................................................................................................................................................................... 65
Figure 4.11: Hemisphere Dimensions....................................................................................................................................................... 65
Figure 4.12: Altus Metrum Telemega Altimeter ...................................................................................................................................... 69
Figure 4.13: Altus Metrum Telemetrum Altimeter................................................................................................................................... 69
Figure 5.1: Rover Rendering..................................................................................................................................................................... 96
Figure 5.2: Rover Design ........................................................................................................................... Error! Bookmark not defined.
Figure 5.3: Rover Capsule Front View ..................................................................................................................................................... 98
Figure 5.4: Rover Capsule Cut-away Side View ...................................................................................................................................... 99
Figure 6.1: Photo From DMS 7th Grade Rocket Week, February 2017 ................................................................................................ 104
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Figure 6.2: Photo From Boy Scouts of America Educational Event ...................................................................................................... 107
Figure 6.3: Auburn Junior High School Engineering Day, October 2015.............................................................................................. 116
Figure 6.4: Level 1 Example Rocket Designed in OpenRocket During AURA .................................................................................... 118
Figure 7.1: Spending Comparison .......................................................................................................................................................... 123
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List of Tables
Table 1.1: Team Members ........................................................................................................................................................................ 16
Table 3.1: Severity Levels ........................................................................................................................................................................ 29
Table 3.2: Probability Levels .................................................................................................................................................................... 30
Table 3.3: Risk Assessment Matrix .......................................................................................................................................................... 31
Table 3.4: NRA/TRA Safety Codes.......................................................................................................................................................... 38
Table 4.1: Section Lengths ....................................................................................................................................................................... 48
Table 4.2: Fin Dimensions ........................................................................................................................................................................ 53
Table 4.3: Motor Specifications ................................................................................................................................................................ 56
Table 4.4: Parachute Shape Comparison .................................................................................................................................................. 64
Table 7.1: Vehicle Costs ......................................................................................................................................................................... 119
Table 7.2: Recovery Costs ...................................................................................................................................................................... 120
Table 7.3: Payload Costs......................................................................................................................................................................... 121
Table 7.4: Budget Allocation .................................................................................................................................................................. 122
Table 7.5: Funding Sources .................................................................................................................................................................... 124
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General Information
Section 1.1: Team Information
General Team Information
Team Affiliation Auburn University
Mailing Address 211 Engineering Drive
Auburn, AL 36849
Title of Project Tiger Launch
Date of Proposal September 20, 2017
Experiment Option 2: Deployable Rover
Section 1.2: Adult Educators
Contact Information
Name Dr. Brian Thurow
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Title
Aerospace Engineering Department Chair, Faculty
Advisor
Email [email protected]
Phone 334-844-4874
Address
211 Davis Hall
Auburn, AL 36849
Contact Information
Name Dr. Eldon Triggs
Title Lecturer, Aerospace Engineering, Mentor
Email [email protected]
Phone 334-844-6809
Address
211 Davis Hall
Auburn, AL 36849
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In addition to the guidance provided by Dr. Thurow and Dr. Triggs, the team is lucky to have two graduate student advisors serving the
team this year who are listed in Table 1.1: Team Members. These graduate student advisors have experience competing in NASA student
launch and will serve to assist the adult educators in aiding the team
Section 1.3: Safety Officer
This year’s safety officer is Corey Ratchick, a senior in Aerospace engineering. This is Corey’s third year on the team. Over the past
two years he has been an integral part of the safety team.
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Section 1.4: Team Leader
Student Team Lead – Contact Information
Name Tanner Straker
Title Senior in Aerospace Engineering
Auburn University
Email [email protected]
Phone 847-507-1193
Address 211 Engineering Dr.
Auburn, AL 36849
Tanner Straker will be the student team leader for this year’s competition team. This is Tanner’s third year on the team. In the previous
year, Tanner served as the Recovery team leader and oversaw the successful recovery of the team’s rocket at competition and before.
He enjoys long walks across launch sites and sewing parachutes. Tanner is level one high power rocket certified through Tripoli Rocketry
Association.
Section 1.5: Project Organization
The Auburn Student Launch team is broken into five major sub-teams: vehicle body design, payload, electronic systems, testing, and
recovery. Safety and educational engagement also exist as sub-teams composed of students from the three primary groups. Each sub-
team has at least one member dedicated to identifying safety concerns and acting as the point of contact (POC) for the safety officer. In
addition, all members of the Auburn Student Launch Team are required to participate in at least one educational engagement event and
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each event has its own coordinator, all of whom are working members of other sub-teams. Figure 1.1: Team Organization Chart shows
the hierarchy of project management with all teams reporting to their team leads, the student project manager, and the safety officer,
who in turn report to the adult educators.
Figure 1.1: Team Organization Chart
Table 1.1: Team Members
Name Role Team
Dr. Eldon Triggs Adult Educator Overall Management
Dr. Brian Thurow Adult Educator Overall Management
Tanner Straker Project Manager Overall Management
Corey Ratchick Safety Officer Overall Management/Safety
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Noel C. Graduate Student Advisor Overall Management
Mariel S. Graduate Student Advisor Overall Management
Reilly B. Team Lead Vehicle Body
Tanner O. Team Lead Electronic Systems
David T. Team Lead Payload
Ben C. Team Lead Recovery
Bryce G. Team Lead Testing
Kate M. Team Lead Education
Nick R. Team Member Testing
Zac B. Team Member Education
Icis M. Team Member Education
Jaylene A. Team Member Education
Jake R. Team Member Safety
Rhett R. Team Member Safety
Ruth A. Team Member Safety
Sydney F. Team Member Safety
Zach W. Team Member Recovery
Paul L. Team Member Recovery
Omkar M. Team Member Recovery
Jaysal S. Team Member Recovery
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Bill M. Team Member Vehicle Body
Adam B. Team Member Vehicle Body
CJ L. Team Member Vehicle Body
Matthew D. Team Member Vehicle Body
Logan J. Team Member Vehicle Body
Anthony G. Team Member Vehicle Body
Victor D. Team Member Vehicle Body
Rhett R. Team Member Payload
Stephen S. Team Member Payload
Zach S. Team Member Payload
Kevin H. Team Member Payload
Matthew W. Team Member Payload
Landon B. Team Member Payload
Salaar K. Team Member Electronic Systems
Andrew R. Team Member Electronic Systems
Ruth A. Team Member Electronic Systems
Michael C. Team Member Electronic Systems
Austen L. Team Member Electronic Systems
Matthew H. Team Member Electronic Systems
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Section 1.6: NAR/TRA Sections
The Auburn Student Launch team is planning on attending launches hosted by Southern Area Rocketry (SoAR) at Phoenix Missile
Works (PMW) in Sylacauga Alabama (NAR Section #571). The team also occasionally attends launches with the Music City Missile
Club (MC2) in Manchester, Tennessee (NAR Section #589) and the South Eastern Alabama Rocket Society (SEARS) in Samson,
Alabama (NAR Section #572/TRA Prefect 38). We will also be partnering with SEARS through Christopher Short. Chris provides
technical experience and serves as a reliable rocketry vendor for the team.
Facilities/Equipment
Section 2.1: Facility Listing.
Aerospace Computational Lab
The Aerospace Computational Lab, located in Davis 330, provides sixteen Windows PC workstations for students to use while on
campus. Software packages such as MATLAB, NASTRAN, PATRAN, ANSYS, etc., are available and will be used to analyze the
technical aspects of the rocket such as projection altitudes. Student also have access to a variety of CAD programs such as Solid Edge
AutoCAD, Autodesk Inventor, SmartDraw, and SolidWorks, which will aid in the design of the rocket. Team members also have access
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to the CES EDU Pack, a materials database which provides a comprehensive database of materials and process information and it can
be used to perform various parametric trade studies with materials.
Aerodynamics Laboratory
This lab is located near campus in the Auburn Research Park. It includes two subsonic and three supersonic wind tunnels, as well as a
low-speed smoke tunnel for flow visualization. An open-circuit, low-speed wind tunnel with a 2-ft by 2-ft test section is available for
testing (see Figure 2.1). The flow speed may be varied from 0 to approximately 120 mph.
Different types of mounting hardware and balances are available, including a six degree-of-
freedom floor mounted balance and angle of attack control along with a three degree-of-
freedom sting-mounted balance. This represents the primary wind tunnel that will be used for
the project’s parachute testing. The aerodynamics lab is also equipped with a 4-inch by 4-
inch supersonic wind tunnel that is capable of flow testing at Mach numbers from 1.5 to 3.5
is also available for use. A Schlieren system is used to detect shock waves optically. Recently,
a new converging section and a test section were designed and fabricated to provide transonic
flow in this tunnel. The wind tunnel may be used to study the effects on the rocket as it approaches to supersonic speeds. Furthermore,
inserts can be used to change the geometry of the inlet of the test section of the 7-inch by 7-inch in-draft supersonic wind tunnel and
produce discrete test section Mach numbers between 1.4 and 3.28. This wind tunnel can be used for additional research on the proposed
rocket configuration at supersonic speeds if needed.
Figure 2.1: Subsonic Wind Tunnel
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Advanced Laser Diagnostics Laboratory
The Advanced Laser Diagnostics Laboratory (ALDL) located in the Woltosz specializes in the development and application of laser
diagnostics for aerodynamic measurements (see Figure 2.2). The laboratory is equipped with advanced instrumentation such as:
• MHz rate Nd:YAG pulse burst laser system. • Ultra-high speed intensified camera capable of imaging at up to 500,000 fps. • Galvanometric scanning mirrors. • High QE CCD cameras.
Areas of specialization include high-repetition rate flow visualization and high-speed
three-dimensional imaging. The centerpiece of the laboratory is a custom-built pulse
burst laser system with the ability to produce a burst of high-energy laser pulses at
repetition rates up to 10 MHz and an ultra-high speed camera capable of imaging at up
to 500,000 frames per second. The laser is an Nd:YAG base laser system and has been used in the past to make high-repetition rate
planar flow visualization, particle image velocimetry (PIV), and planar Doppler velocimetry (PDV) measurements in supersonic flow
fields. This laboratory may be used for flow visualization purposes in order to accurately characterize the flow around the rocket
including the hot plume trailing behind the motor.
Composites and UAV Laboratory
The Composites Laboratory located in Davis 222 serves as the lab space for Auburn University’s aerospace competition teams including
the Student Launch Team and the Design-Build-Fly team. This lab provides equipment and workspace for the construction of adaptive
aero structures using composite materials and additive manufacturing. The Student Launch team primarily uses this lab for design
prototyping and some testing of our airframe components. Most of the equipment in the lab has been purchased by the team and the
Figure 2.2: PIV of a Synthetic Jet Flow Field
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Auburn Aerospace Engineering department. The laboratory houses a CNC Router, 3D printer, filament winder, composites oven, and
many other pieces of equipment that make it possible for the Auburn Launch Team to manufacture our rockets. The Rockler CNC Shark
brand CNC router has a 25 in by 25 in by 7 in work area and is capable of accurately machining wood, composite materials, plastics,
and soft metals. This machine can produce high quality, precision milled components and is typically used by the team to produce fins,
bulkheads, and other flat components of the rocket. The LulzBot TAZ 4 3D printer is used in the production of a wide range of rocket
elements, ranging from custom ribbed nosecones to single-use black powder charge caps. The printer has an 11.7 in by 10.8 in by 9.8
in print bed with a print tolerance of 0.003 in. This printer has the capability to make components out of ABS, PLA, HIPS, PVA and
wood filaments. The team is expanding our additive manufacturing capabilities by printing structures and overlaying composite
materials for more control over the shape and strength. To accompany the 3D printer, the lab is equipped with a material reclaimer that
allows the manufacturing of custom 1.75 mm to 3 mm diameter ABS, PLA and HIPS filament. As part of the composites capabilities
of the lab, microprocessor-controlled, floor model, Blue-M convection oven is employed to cure composite parts. The oven has internal
dimensions of 48 in by 48 in by 36 in. Cold storage equipment is available in the lab for long-term, thermoset pre-preg carbon fiber
storage.
Computational Fluid Dynamics Laboratory
The Auburn University Computational Fluid Dynamics (CFD) Laboratory is used primarily for research. The hardware resources include
six high-end desktop workstations by Dell (8 core, 24GB memory), a cluster by Penguin Computing (60 cores with 60GB of memory),
and an additional cluster by Dell (512 core, 1.5TB memory). In addition, Dr. Majdalani’s computational laboratory consists of 16 high-
end Dell Precision workstations with 8 cores and 32 GB RAM each. The workstations are available for use during the various stages of
the CFD simulation process, including the geometric refinement, mesh generation, flow computation, and flow visualization. The
clusters are dedicated to large-scale, high-throughput, batch-style meshing and flow computations. Commercial software available in
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the CFD lab currently includes STARCCM+ from CD-adapco and ICEM/FLUENT by ANSYS. These capabilities are leveraged to
perform CFD analysis and optimization of the 3-D models generated in SolidWorks to give the team the option to test components
theoretically as well as experimentally.
Design and Manufacturing Laboratory
The Auburn University Design and Manufacturing Laboratory (DML) aids in the manufacturing of large metal parts required for the
fabrication process. The DML is a machine shop that provides various work areas for machining metal. The machine shop tools include
lathes, mills, drill presses, saws, a CNC milling machine, a metrology section, and various sanders. The DML specializes in making
high precision metal parts that can be machined with tolerances as low as 0.001 in.
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Flow Visualization Laboratory
The Flow Visualization Laboratory utilizes a 45 cm by 45 cm test section water tunnel for
flow visualization, shown in Figure 2.3. The water tunnel has a maximum speed of 1.2 meters
per second and is equipped with the latest instrumentation for visualization and flow
measurements. This includes a planar and stereoscopic particle image velocimeter, hot film
anemometer, high speed imager, pulsed and continuous wavefront lasers for laser induced
fluorescence, and a multiple color dye injection system. Specially designed flow tanks and
channels are also available to study the evolution of vortex dominated flows and vortex
filaments. This facility will be extensively used for visualizing the flow field around the
rocket structure.
GKN Aerospace Tallassee, Alabama
GKN Aerospace’s facility in Tallassee, Alabama has 380,000 sq ft of manufacturing
space. Their facility includes clean rooms and laser ply projections for composite
assembly, Gerber cutting systems for precision fabrication, and autoclaves for curing
and consolidation of composite materials. Their largest autoclave is 15 ft by 50 ft
(shown in Figure 2.4). Additionally, GKN has CNC milling capabilities for a wide
range of part sizes as well as Honeycomb machining. For composite curing and
consolidation of the airframe, GKN has kindly allowed the use of their facilities.
Figure 2.3: Water Tunnel
Figure 2.4: GKN Autoclave
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Machine Tool Laboratory and the Aerospace Wood Shop
The Machine Tool Laboratory and the Aerospace Wood Shop will both be used for the fabrication of the internal components of the
rocket. The “Machine Lab” has a CNC milling machine that may be used to fabricate precision parts. The Wood Shop has multiple tools
such as drill presses, lathes, belt sanders, band saws, and pneumatic rotary tools for the fabrication of parts, especially the cutting of
composites.
Structures Laboratory
Auburn’s Structures Laboratory is equipped with a hydraulic loading system for tensile, compression, and fatigue testing. Facilities are
available for strain gage and dynamic measurements. Structural test data may be obtained from the manufactured composite specimens
in the Composites Laboratory by using the servo-hydraulic testing machine and the data acquisition equipment that are available in the
Structures Laboratory (Figure 2.5). This laboratory serves as a construction and component storage facility as it is adequately spacious
to hold the variety of rocket components while providing a sufficiently large area for material testing. In addition, it also holds freezers
large enough to contain thermoset pre-preg carbon fiber. This, coupled with the large manufacturing space, and large storage spaces
within the laboratory make it an ideal location for the majority of the construction required on the rocket.
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Two new pieces of equipment in the Structures Laboratory that will be useful for the team this year are a Universal Testing Machine
and a Split Hopkinson Pressure Bar Apparatus. The Universal testing machine can perform a wide variety of quasi-static loading
configurations, such as tension, compression, and three point bend testing. The Split
Hopkinson Bar, meanwhile, can provide high strain rate testing on materials samples,
similar to what would be experienced during impacts with the ground or other rapid
changes in acceleration.
Figure 2.5: Hydraulic Loading System
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Safety
Section 3.1: Personnel and Responsibilities
The Auburn Student Launch organization has a team in place to ensure that all activities and property of the organization is prepared,
handled, and operated in a safe manner while still achieving the organizations goals. The role of safety officer will be fulfilled by Corey
Ratchick. Corey is a senior in aerospace engineering and is entering his third year working with Auburn Student Launch. His previous
work included recovery system design and manufacturing. He will oversee a safety team consisting of liaisons from each Auburn Student
Launch team. This group will facilitate frequent interaction, communication, and documentation of safety practices for every aspect of
Auburn Student Launch. This organizational strategy will improve every member’s awareness and knowledge of safety procedures and
allow quick access to a safety expert for each team.
In accordance with the NASA Student Launch handbook, Corey will:
1. Monitor team activities with an emphasis on Safety during
a. Design of the vehicle and launcher
b. Construction of the vehicle and launcher
c. Assembly of the vehicle and launcher
d. Ground testing of the vehicle and launcher
e. Sub-scale launch test(s)
f. Full-scale launch test(s)
g. Launch Day
h. Recovery activities
i. Educational Engagement Activities
2. Implement procedures developed by the team for construction, assembly, launch, and recovery activities
3. Manage and maintain current revisions of the team’s hazard analyses, failure mode analyses, procedures, and MSDS/Chemical
inventory data
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4. Assist in the writing and development of the team’s hazard analyses, failure mode analyses, and procedures.
The Auburn Student Launch organization will adhere strictly to all NAR and TRA regulations. The team mentor will be Dr. Eldon
Triggs, a professor at Auburn University who holds a Level 2 high power rocket certification. This certification allows him to handle
up to class L rocket motors which is sufficient for this project. Dr. Eldon Triggs will be primarily responsible for overseeing the
transportation and handling of rocket motors and of launch procedures. He will review the design of the rocket at each stage of the
design process and ensure that it is within the safety requirements set by NAR and TRA. He will travel with the team on launch day and
collaborate with the safety officer to produce a launch checklist that the safety officer will be responsible for adhering to and ensuring
other members adhere to. This checklist will include ensuring safe weather conditions, clearing and preparing the launch area, locating
observers a safe distance from the launch pad, and meeting all NAR and TRA launch safety requirements. The handling of any hazardous
material will be the responsibility of the mentor, the safety officer, or another certified member of the team with permission from either
the mentor or the safety officer.
The team website will serve as an online archive for safety materials. In addition, physical copies of MSDS sheets, hazard analyses, risk
mitigation procedures, and NAR and TRA regulations will be printed and available in the lab where construction will take place.
Section 3.2: Hazard Analyses
The safety team’s responsibilities will include the identification and analysis of the hazards involved with every step of the project. This
will include hazards to personnel, hazards to the rocket, and hazards to the environment.
A risk assessment matrix has been prepared to unambiguously categorize hazards that the team identifies. The matrix can be found
below in Table 3.3: Risk Assessment Matrix.
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Severity levels ranging from 1 (very minor) to 5 (catastrophic) and Probability levels ranging from 1 (extremely unlikely) to 5 (almost
guaranteed) will be utilized. These quantities have been provided with a qualifying descriptor to help classify hazards as they are
determined.
Table 3.1: Severity Levels
Severity Level Descriptor Example
1
Minor or cosmetic:
No impact on construction, assembly or
operation; no threat to personnel or the
environment
A fin utilized for stability is made
a color that does not match the
rocket
2
Moderate:
Delayed threat to partial mission
completion or minor environmental
concerns; no threat to personnel
One nylon screw on the nose
cone requires replacement
3
Significant:
Sparks or exhaust from the rocket
motor ignite a small brush fire on
launch
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Immediate or delayed threat to partial or
total mission completion or any threat to
personnel or environmental concerns
requiring attention
4
Critical:
Immediate threat to mission completion or
potential harm to personnel or
environmental destruction
The rocket must be recovered
from power lines, an active
roadway, or another active
hazard.
5
Catastrophic:
Immediate loss of mission or loss of
rocket or significant safety risk to one or
multiple personnel or the environment
A rocket motor is improperly
constructed or assembled in such
a way to cause a misfire
Table 3.2: Probability Levels
Probability Level Descriptor
1 Extremely Unlikely
2 Remote
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3 Reasonably Possible
4 Frequent
5 Almost Guaranteed
Table 3.3: Risk Assessment Matrix
Probability Level
Severity Level
1
Minor
2
Moderate
3
Significant
4
Critical
5
Catastrophic
1 - Extremely unlikely 1 2 3 4 5
2 - Remote 2 4 6 8 10
3 - Reasonably possible 3 6 9 12 15
4 - Frequent 4 8 12 16 20
5 - Almost guaranteed 5 10 15 20 25
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Section 3.3: Checklists
The safety officer will work closely with the other team leads and safety liaisons to compose a thorough list of procedures that team
members will follow prior to the launch of any sub-scale or full-scale rocket as well as safety lists for the construction process and day
to day lab work. The purpose of these checklists is to centralize the preparation process and unambiguously detail the actions the team
should take and in what order they should be taken.
Checklists will be created for each of the rocket’s subsystems, a final assembly checklist, and a final launch time checklist. Team leads
will be responsible for checklists that cover the subsystem they have authority over and will see to it that they are followed closely.
Upon completion of the subsystem checklists they will sign the checklist and report the checklist to the safety officer. The safety officer
will have the authority over the final signature for the overall assembly checklist and the team mentor will have authority to sign off on
the final launch time checklist. In the event that a team member deviates from the checklist, the team lead or safety officer will
immediately determine what actions were taken and what actions can be further taken to return to following the checklist as closely as
possible.
Section 3.4: Team Briefings and Checks
Before lab work begins on the project, a meeting will be held with the entire membership of Auburn Student Launch to inform members
of the risks and responsibilities they will encounter in the lab, during testing, and on launch day. The material used in these briefings
will be made available online and the safety liaisons for each team will be available to team leads and team members during general
construction and testing for questions. The briefing will include machine and tool hazards, chemical and material handling procedures,
and instruction regarding the use of personal protection equipment (PPE). Team members will be required to attend this meeting and to
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acknowledge they understand this information and will comply with it at all times by signing a waiver that will be available at the
briefing and kept on file.
Materials and chemicals in the laboratory will be stored properly per their hazard level. Flammable chemicals will be stored in a
flammable cabinet alone with toxic chemicals to protect them from accidentally being released. One of the major roles of the safety
team is to keep an accurate and complete inventory of all materials and chemicals in the laboratory areas. Clear and readable labels will
be in place to identify hazard levels and make them easier to locate. Team members will be briefed on the proper disposal of materials
and chemicals per the hazard levels of each material and chemical.
All machinery must be used exclusively by properly trained and brief members. Before using a machine, team members must
demonstrate to the safety officer or another member of the safety team that he or she can properly and safely use the equipment. Members
will be briefed on 18 different hazards that could occur and what to be aware of while operating machines to avoid accidents. Team
members will keep a safe distance from a machine making sure that hands and body are clear before starting the machine to avoid
accidents. Machines will not be operated alone; there will be at least two people present always when machinery is being used. Before
operating a machine, team members will check to make sure that safety shields are in place and secure (if applicable). Team members
will be briefed on the use of proper personal protective equipment (PPE) to wear operating machines.
Section 3.5: Energetic Device Handling
The purchase of rocket motors will be done only by a certified NAR/TRA instructor. Motors purchased will be limited to a total impulse
of 5,120 Newton-seconds (Class L) as regulated by the 2018 NASA Student Launch Handbook (Vehicle Requirement 2.15). Rocket
motors will be stored in a designated casing designed to keep the motor secure, prevent damage to the propellant and motor casing, and
to avoid sparks or any dangerous complications. The motor will be kept at least 25 feet away from any heat sources or flammable liquids.
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A no-smoking policy will be strictly enforced always within 25 feet of the rocket motor and its components. Transportation of the rocket
motor will be accomplished independently of other rocket components and it will be securely immobilized and padded to prevent
damage. The rocket will include some small energetic systems that will also be purchased by the NAR/TRA mentor. The energetic
systems will be stored securely and padded to prevent damage independently of the rocket motors. The electrical systems will also be
transported and installed on the rocket only in the designated assembly area. All the components of this system will be inhibited except
when the rocket will be in the launching position and all personnel are at the minimum safe distance and the NRA/TRA mentor can
confirm so. During the use of the rocket motors and energetic devices specific requirements will be followed per the regulations set
forth by NAR. Also per team requirements, specific guidelines and documentation will be followed to ensure the safety of all team
members and observers present at either the launches or tests for specific systems.
Section 3.6: Law Compliance
For the purposes of this project, regulations imposed nationally by the FAA and within the state of Alabama due to the adoption of
National Fire Protection Agency (NFPA) codes are relevant and will be complied with.
FAA Regulations
In accordance with FAA Regulations outlined in Part 101 Subpart C:
• No member shall operate an unmanned rocket in a manner that creates a collision hazard with other aircraft.
• No member shall operate an unmanned rocket in controlled airspace.
• No member shall operate an unmanned rocket within five miles of the boundary of any airport.
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• No member shall operate an unmanned rocket at any altitude where clouds or obscuring phenomena of more than five-tenths
coverage prevails.
• No member shall operate an unmanned rocket at any altitude where the horizontal visibility is less than five miles.
• No member shall operate an unmanned rocket into any cloud
• No member shall operate an unmanned rocket within 1,500 feet of any person or property that is not associated with the
operations or between sunset and sunrise.
Alabama, Tennessee, and NFPA Codes
In accordance with the 2013 NFPA codes adopted by the state of Alabama:
• Only a certified user shall be permitted to launch a high power rocket.
• Only certified high power rocket motors or motor reloading kits or motor components shall be used in a high power rocket.
• A single-use high power rocket shall not be dismantled, reloaded, or altered.
• A reloadable high power rocket motor shall not be altered except as allowed by the manufacturer and certified by a recognized
testing organization acceptable to the authority having jurisdiction to meet the certification requirements set forth in NFPA
1125.
• The stability of a high power rocket shall be checked by its user prior to launch.
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• If requested by the RSO, the user shall provide documentation of the location of the center of pressure and the center of gravity
of the high power rocket.
• The maximum liftoff weight of a high power rocket shall not exceed one-third (1/3) of the certified average thrust of the high
power rocket motor(s) intended to be ignited at launch.
• A high power rocket shall be launched only if it contains a recovery system that is designed to return all parts of the rocket to
the ground intact and at a landing speed at which the rocket does not present a hazard.
• The person who prepares the high power rocket for flight shall install only flame resistant recovery wadding if the design of
the rocket necessitates the use of wadding.
• No attempt shall be made to catch a high power rocket as it approaches the ground.
• No attempt shall be made to retrieve a high power rocket from a power line or other life-threatening area.
• A high power rocket shall be launched using an ignition system that is remotely controlled, is electrically operated, and
contains a launching switch that returns to the “off” position when released.
• The ignition system shall contain a removable safety interlock device in series with the launch switch.
• The launch system and igniter combination shall be designed, installed, and operated so that liftoff of the rocket occurs within
3 seconds of actuation of the launch system.
• An ignition device shall be installed in a high power rocket motor only at the launcher or within the prepping area.
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• A high power rocket shall be pointed away from the spectator area and other groups of people during and after the installation
of the ignition device.
• A high power rocket shall be launched in an outdoor area where tall trees, power lines, buildings, and persons not involved in
the rocket launch do not present a hazard.
• Fire suppression devices and first aid kits shall be located at the launch site during the launch of a high power rocket.
• No person shall ignite and launch a high power rocket horizontally, at a target, or so that a rocket’s flightpath during ascent
phase is intended to go into clouds, directly over the heads of spectators, or beyond the boundaries of the launch site, or so that
the rocket’s recovery is likely to occur in spectator areas or outside the boundaries of the launch site.
• No person shall launch a high power rocket if the surface wind at the launcher is more than 32 km/h (20 mph).
• No person shall operate a high power rocket in a manner that is hazardous to aircraft.
• A high power rocket shall be launched only with the knowledge, permission, and attention of the RSO, and only under
conditions where all requirements of this code have been met.
• High power rocket motors, motor reloading kits, and pyrotechnic modules shall be stored at least 7.6 m (25 ft) from smoking,
open flames, and other sources of heat.
• Not more than 23 kg (50 lb) of net rocket propellant weight of high power rocket motors, motor reloading kits, or pyrotechnic
modules subject to the storage requirements of 27 CFR 555, “Commerce in Explosives,” shall be stored in a Type 2 or Type 4
indoor magazine.
• A high power rocket motor shall not be stored with an ignition element installed.
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Section 3.7: NAR/TRA Safety Codes
Table 3.4: NRA/TRA Safety Codes
NRA/TRA Code Topic Details Additional Information or
Precautions
Materials
I will use only lightweight,
non-metal parts for the nose,
body, and fins of my rocket.
Carbon fiber and fiberglass
will be used for the body and
flight stabilization systems of
the rocket. 3D printed plastics
will be used for the nose.
These materials are non-
metal, extremely lightweight,
and also very durable.
Motors
I will use only certified,
commercially-made model
rocket motors, and will not
tamper with these motors or
We will stay within the
limitation of the motors and
inspect the quality of the
motor before using it.
39
use them for any purposes
except those recommended by
the manufacturer.
Ignition System
I will launch my rockets with
an electrical launch system
and electrical motor igniters.
My launch system will have a
safety interlock in series with
the launch switch, and will use
a launch switch that returns to
the “off” position when
released.
After following these
guidelines, A Range Safety
Officer certified by NAR or
the TRA will have ultimate
authority regarding launches
and will be the person to
launch the rocket.
Misfires
If my rocket does not launch
when I press the button of my
electrical launch system, I will
remove the launcher’s safety
interlock or disconnect its
battery, and will wait 60
Following the 60 second
period of inactivity, the rocket
will be approached by either
the safety officer or the team
mentor. Safety devices will be
on hand for any circumstance
40
seconds after the last launch
attempt before allowing
anyone to approach the rocket.
and, all other team members
will remain a safe distance
from the rocket.
Launch Safety
I will use a countdown before
launch, and will ensure that
everyone is paying attention
and is a safe distance of at
least 15 feet away when I
launch rockets with D motors
or smaller, and 30 feet when I
launch larger rockets. If I am
uncertain about the safety or
stability of an untested rocket,
I will check the stability
before flight and will fly it
only after warning spectators
and clearing them away to a
safe distance. When
conducting a simultaneous
launch of more than ten
A highly visible object will be
used to mark the minimum
distance team members
should be away from the
rocket. The visible object will
be in the form of a bright line
on the ground created by tape
or paint and a vertical object
that the safety officer will
hold. All team members and
observers will remain soundly
behind this line.
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rockets I will observe a safe
distance of 1.5 times the
maximum expected altitude of
any launched rocket.
Launcher
I will launch my rocket from a
launch rod, tower, or rail that
is pointed to within 30 degrees
of the vertical to ensure that
the rocket flies nearly straight
up, and I will use a blast
deflector to prevent the
motor’s exhaust from hitting
the ground. To prevent
accidental eye injury, I will
place launchers so that the end
of the launch rod is above eye
level or will cap the end of the
rod when it is not in use.
Beyond this guideline, only
safety personnel, team leads,
and the team mentor will be
allowed to approach the
launch rod and to prep the
rocket for launch. This is to
minimize the number of
people around the rocket
immediately prior to launch,
helping to prevent accidents to
either personnel or the launch
system.
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Size
My model rocket will not
weigh more than 1,500 grams
(53 ounces) at liftoff and will
not contain more than 125
grams (4.4 ounces) of
propellant or 320 N-sec (71.9
pound-seconds) of total
impulse.
Each system of the rocket and
section of the body will be
weighed independently before
transportation and directly
prior to assembly. The
assembled weight will be
known prior to launch.
Flight Safety
I will not launch my rocket at
targets, into clouds, or near
airplanes, and will not put any
flammable or explosive
payload in my rocket.
During a rocket launch and
prior to launch, all team
members will be required to
remain together and be
vigilant of impeding objects
as well as a recovery failure in
case the rocket returns at a
dangerous speed in the
direction of personnel.
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Launch Site
I will launch my rocket
outdoors, in an open area at
least as large as shown in the
accompanying table, and in
safe weather conditions with
wind speeds no greater than
20 miles per hour. I will
ensure that there is no dry
grass close to the launch pad,
and that the launch site does
not present risk of grass fires.
All launches will take place at
certified NAR or TRA events
and locations.
Sites include the SEARS
launch site in Samason, AL
and the Phoenix Missile
Works launch site in
Sylacauga, AL.
Recovery System
I will use a recovery system
such as a streamer or
parachute in my rocket so that
it returns safely and
undamaged and can be flown
again, and I will use only
flame-resistant or fireproof
recovery system wadding in
my rocket.
The team will calculate the
optimum heights at which to
deploy the drogue and main
parachutes to maximize drag
and minimize drift. This will
aid in a safe and undamaged
recovery. The parachutes will
also be made of flame
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resistant material to avoid heat
related failures of the system.
Recovery Safety
I will not attempt to recover
my rocket from power lines,
tall trees, or other dangerous
places.
In the event that the rocket
does land in a dangerous
place, appropriate help will be
consulted immediately to
avoid danger to any other
peoples or infrastructure.
Section 3.8: Caution Statements
Safety is of the highest importance in all aspects of the competition and critical to the design philosophy of Auburn Student Launch. To
ensure that this is kept as the first priority of all the team members before any procedures are undertaken there will be a safety briefing
led by the safety officer and safety liaisons of each team lead. The briefing will cover all the important procedural and safety
acknowledgements necessary to construction, assembly, and launch day activities. The safety liaison members will be responsible for
reporting back changes to the design that affect safety considerations and providing an accessible and knowledgeable voice for safety
concerns.
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Team members will be briefed on the proper personal protection equipment (PPE) to wear while working in the laboratory. This includes
hand, foot, ear, eye, and respiratory protection. Loose clothing must be secure and jewelry must be removed before operating machinery.
Members will be required to wear long pants, closed toed shoes, safety glasses, and gloves while working in the laboratory. Respiratory
protection will also be used when toxic chemicals or small particle forming machines are in use. Team members will be required to wear
lab coats when handling chemicals along with proper skin protection and respiratory protection as appropriate.
To avoid accidents, listening to music with earbuds or headphones will be prohibited while operating machines. Team members will
look over machines before operating to ensure the machine is in proper condition. Ventilation systems will be checked prior to work to
make sure they are also in proper working condition. An inventory of all materials and chemicals in the laboratory will be maintained
along with labels to identify the hazard levels and what precautions to take with each of them. A waiver has been created for all team
members to sign prior to entry to the lab that states their knowledge and understanding of these statements, the hazards they may
encounter and their responsibilities to keep a safe work environment, and their intent to follow them closely.
Section 3.9: Team Safety Statement
All members of the Auburn University Student Launch team understand and will follow certain rules as set forth by NASA. Before each
flight a safety inspection will be completed by the Range 27 Safety Officer (RSO). If any changes need to be made as per request of the
RSO they will be completed immediately. Auburn University Student Launch will comply with the safety decisions of the RSO to ensure
the flight capability of the rocket and continued participation in the competition. The team members of Auburn University Student
Launch understand that the RSO has ultimate authority on the flight readiness of any rocket to be flown by the team. Members of the
team understand that this means the RSO has the authority to deny the launch of a rocket for any safety issue that is determined to be
46
risky or of concern. The team will ensure that the rocket follows all safety requirements of the competition, NASA, NAR, local and
federal agencies, and the RSO in order to achieve permission to launch.
All team members present at assembly and launch will sign a safety waiver that acknowledge their complete understanding of these
safety statements and their intent to comply. These waivers can be found in Appendix B.
.
Section 3.10: Ongoing Training
Auburn Student Launch is committed to continuous improvement and education in matters of safety and has prepared opportunities for
its members to become more knowledgeable about their environments, activities, and resources. Auburn Student Launch will sponsor
an OSHA training course hosted by the Auburn Office of Risk Management to teach its members about better workplace safety. This
will directly translate to activities in the lab during the construction of the rocket’s components and systems and to activities during
assembly of the rocket. Additionally, a laser training course available online from the Office of Risk Management will be available to
all team members. As the year progresses, new members will be instructed in the proper use and safety guides of the labs manufacturing
equipment by qualified members of the organization.
Section 3.11: Risk Assessments
The risk assessment tables are located in Appendix B.
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Technical Design
Section 4.1: General Vehicle Design
Figure 4.1: Vehicle Rendering
The main body of the launch vehicle is composed of five major structural elements: the nose cone, the avionics section, the rover,
air-brakes, and the booster section. The preliminary model showing the general layout of the launch vehicle is shown in Figure 4.2.
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Figure 4.2: Design Layout
Table 4.1: Section Lengths displays the predicted section lengths, resulting in a 117-inch-long rocket. This table will be continuously
updated as the design develops further.
Table 4.1: Section Lengths
Section Lengths
Nose Cone 16 in
Avionics Section 54 in
Rover 12 in
Altitude Control 12 in
Booster Section 23 in
Total 117 in
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The outer diameter of our rocket is 6.25 inches, while the inner diameter will be 6 inches. This gives the vehicle a wall thickness of
0.125 inches. Finite element analysis will be performed to ensure that the wall thickness will be adequate for a successful and safe flight.
The inner diameter of 6 inches was chosen to maximize the amount of usable space within the rocket. The length of each section was
chosen in order accommodate the needs of each subsystem. Work will be done to limit or reduce the lengths of each subsystem to create
the lightest vehicle possible.
The main body of the rocket will be constructed using composite materials. The body tubes will be constructed using two methods:
carbon fiber braiding and filament winding. The carbon fiber braiding process weaves cords of carbon fiber into a braid which is then
turned into an open-architecture composite isogrid structure by using filament winding. Isogrid structures are a lighter alternative when
compared to solid tubes. Using current samples of the isogrid structure, the body tube will potentially be 20 to 30 percent lighter than
using a solid carbon fiber structure. In previous years, there was success using this method, so the team has a high level of confidence
in incorporating this unique structure into the airframe. A sample of the isogrid structure is displayed in Figure 4.3: Braided Section
Sample.
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Figure 4.3: Braided Section Sample
A thin sheet of fiberglass will be secured inside the structure to create a smooth surface to allow for incorporation of the subsystem
components. Additionally, the outside will be covered in a thin layer of filament wound carbon fiber to create a smooth surface to
decrease aerodynamic drag. The thickness of these sections will be minimal, as they are not going to be carrying the structural load
during launch. The team also has access to a filament winder which will be used for manufacturing carbon fiber tubes. Filament winding
is a fabrication technique used mainly for manufacturing a cylindrical hollow product. Filament winding is highly beneficial because it
is automated and precise, creating lightweight, strong composite parts, with minimal labor required. The different variables when
winding are fiber type, resin content, wind angle, tow and thickness of the fiber bundle. The filament winder will use a 6-inch diameter
aluminum mandrel. Using an aluminum mandrel allows the team to produce very accurate body tubes. Due to the fact that filament
winding is highly repeatable and has a high degree of accuracy, several spare body tubes could be created and tested to help the team
eliminate undesirable configurations before getting to full-scale testing. Filament winding also introduces opportunities to develop more
51
technically innovative designs, such as using unidirectional composite strengths in alternate orientations for more specifically tailored
strengths.
Couplers and the ballast tank will be made using one of the team’s 3D printers. These parts will be 3D printed due to the relatively low
cost of production, as well as the teams past experience of using 3D printed parts in rockets. This also provides rapid production of
prototype subscale models for use in wind tunnel testing.
By virtue of Dynetics, the team is capable of acquiring a custom mold which will be used to manufacture our nose cone into a specific
desired shape. Dynetics will have the ability to create an extremely accurate mold due to their advanced machine shop. The nose cone
will incorporate a tangent-ogive shape, and will be constructed using a wet layup of carbon fiber.
Finally, the last few primary pieces of the rocket will be constructed utilizing a much different form of composite layup. Since bulk-
plates and fins require very little special geometric variance from a flat plate, several plates of varying thickness composites will be
made using a compaction method. This approach will significantly reduce the cost and difficulty of composites manufacturing, since
vacuum bagging is not required in a compaction method. An added benefit will be the ability to achieve effective ply consolidation
while remaining relatively easy to layup. Once post-cured the flat plates of cured composites will be milled and machined into the final
shape required.
The stability of the rocket will be controlled by the fins. The fin’s primary purpose is to locate the center of pressure aft of the center of
gravity. The greater drag on the fins will keep them behind the upper segments of the vehicle, allowing the rocket to fly straight along
52
the intended flight path, while minimizing the chances of weather-cocking. A trapezoidal planform has been selected for the fins.
Trapezoidal fins provide an easily machinable avenue for achieving a large section of wetted surface area. In addition, the trapezoidal
design produces a large, easily machinable surface area to bond and secure the fin to the structural assembly beneath it. Four trapezoidal
fins will be machined from .25-inch-thick carbon fiber plates. The trailing edge of the fins will be located one inch forward of the end
of the body tube. This design feature will theoretically provide some impact protection for the fins when the rocket hits the ground.
Carbon fiber of 1.03 oz/in3 density has been selected due to its stiffness, strength, and light weight. Each fin will have a surface area of
56.88 in2 respectively (summing both sides), making the fin surface area total to 227.52 in2. These dimensions provide the vehicle with
a projected stability of 2.53 calibers. This level of stability is ideal, as it is well above stable, yet still below over-stable. Detailed
dimensions of the fins are provided in Table 4.2: Fin Dimensions.
Figure 4.4: Fin Image
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Table 4.2: Fin Dimensions
Trapezoidal Fin Dimensions
Root Chord 6.25 in
Tip Chord 2.5 in
Height 6.5 in
Sweep 3.677 in
Sweep Angle 29.5°
Although the initial model of our rocket uses trapezoidal fins, the team is attempting to incorporate the grid fin technology that has been
used in the previous two years of the competition into use as tail fins. This will require more research into the aerodynamic forces that
the grid fins will encounter and how that will impact stability. Additionally, the results will be compared with the standard trapezoidal
fins to determine if the technology will have a positive impact. Strength is not a concern, as the team now has access to a 3D printer that
can print carbon fiber or kevlar, which has superior strength compared to the material used in previous years. A model of the grid fin
technology is shown in Figure 4.5: Grid Fin Rendering.
54
Figure 4.5: Grid Fin Rendering
Projected Altitude
In order to get an initial, fairly accurate projection of the altitude, the team used OpenRocket, a freeware program designed to calculate
various parameters in rocket flight. Given the team’s experience with this software in the previous years, the team is confident in the
ability of OpenRocket to produce accurate estimates of the altitude. With the current motor selection, discussed in section 4.4, the current
projected apogee for the vehicle is 5369 ft. While this is currently above the maximum allowed altitude, given a mass increase of just 1
pound, the selected motor fails to deliver the rocket to the required altitude. Since mass increases of up to 25% are very common in the
manufacturing process, the team considers this to be an acceptable initial altitude estimate. In addition, a chart of the altitude over time
is provided in Figure 4.6: Simulated Altitude.
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Figure 4.6: Simulated Altitude
Motor Selection
The rocket motor initially selected for the competition is the Loki L1482. The L1482’s specifications are listed below in Table 4.3:
Motor Specifications. Additionally, the thrust curve for this motor is shown in Figure 4.7: Motor Thrust Curve below:
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Table 4.3: Motor Specifications
Motor Specifications
Manufacturer Loki
Motor Designation L1482
Diameter 2.99 in
Length 19.6in
Impulse 3863 N-s
Total Motor Weight 125 oz
Propellant Weight 64.2 oz
Propellant Type Solid
Average Thrust 344 lbs
Maximum Thrust 395 lbs
Burn Time 2.52 s
57
Figure 4.7: Motor Thrust Curve
This motor was chosen based on initial OpenRocket simulations, as it provides the roughly 13-to-1 thrust to-weight ratio desired for stable
and predictable flight. In addition, as shown in the motor thrust curve above, the motor achieves a higher than average thrust early on in the
thrust profile, thus reaching the required 13-to-1 thrust ratio in approximately half of a second.
58
Section 4.2: Recovery System Design
The 2017-2018 Auburn Student Launch team plans on utilizing a dual-stage recovery system with the first event being a drogue
parachute and a rifled upper main being deployed at apogee (target height 5280 ft.) with black powder charges. The second event will
occur at 750 ft. and have the upper main parachute unfurling with the Jolly Logic Chute Release System as well a second set of black
powder charges going off resulting in a full separation in the middle of the rocket and releasing a lower main parachute. In this
configuration the rocket will fall in one piece under drogue until 750 ft. where it will fall the remainder of the distance to the ground as
two separate pieces under two separate main parachutes.
Recovery Structural Elements
The centerpiece of the Auburn's recovery system will be the Barometric Avionics Enclosure (BAE). Every recovery subsystem will be
either attached to or contained inside the BAE. The BAE will be formed by a 12-inch-long cylinder of carbon fiber. There will be one
inner bulk plate attached inside of BAE that serves as the top cap of the avionics bay. Inside the avionics bay there will be two sets of
rails to secure the avionics board, to which all recovery electronics will be mounted. The bottom of BAE will be closed off by another
bulk plate. The two bulk plates will be linked by two rods and secured by locking nuts. Both bulk plates will have holes in them that
allow the ejection charge wires to run from the altimeters to their proper e-matches. The BAE will serve as the coupler between the
upper and the lower parachute housings, and each section will be secured with machine bolts. Neither of these sections separate once
59
the rocket is assembled. On the outside of the BAE will be a ring of the vehicle body tube taken from the same tube the upper section
will be constructed from. This will be done so the tube connections between the upper parachute housing, the BAE, and the lower
parachute housing are continuous and smooth, minimizing the impact on the aerodynamic performance of the rocket due to these
connections. This ring will be the only surface of the BAE that is on the outside of the rocket, so key switches and pressure holes will
be located here. The key switches located on the ring will allow the team to externally arm the altimeters while the rocket is assembled.
Materials
The materials chosen to create the team's recovery subsystems are of the utmost importance. They must work properly for the team’s
payload, a rover, which cannot be damaged when it returns to Earth. The material must be both strong and lightweight in order to
effective, as well as not adding unnecessary weight to the rocket. The parachutes will be made from ripstop nylon. Ripstop nylon is an
ideal material for this application; the fabric is thin and lightweight although its reinforced woven composition makes is resistant to
tearing. The 70 denier ripstop nylon fabric has been chosen for the parachutes because it has a tensile strength of 1500 psi, which is
more than sufficient for the needs of this project. The drogue shroud lines will be made of paracord, unlike the main parachutes shroud
lines, which will both be made of tubular nylon. Tubular nylon was chosen for the main parachutes due to its high strength and ability
to stretch slightly, absorbing some of the shock from deployment without failing. Tubular nylon will be used for the shock cord for the
same reasons, with sections being reinforced with tubular Kevlar as needed. Kevlar was chosen for the reinforcing material because it
is even stronger and able to withstand more impact than tubular nylon. Nylon shear pins will be used to attach the nosecone to the BAE
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as well as the lower parachute housing to the lower section of the rocket to prevent drag separation. In the proposed configuration, #4-
40 nylon screws are used to secure these sections together. These machine screws have a double shear strength of 50 lbs. This shear
strength will be verified via ground testing to ensure safety.
Ejection System
The Auburn University Student Launch team will be using a combination of black powder charges and Jolly Logic chute releases for
the ejection systems. There will be two separation points on the rocket with two black powder charges at each location for redundancy
purposes. Testing will be done to determine the amount of black powder that will be needed at each separation point. The first set of
black of black powder charges will be housed above the BAE in the rocket and will be deployed at apogee to separate the nose cone and
release the drogue and closed upper main parachutes. The Jolly Logic chute releases will be used to keep the upper main parachute
closed until the second event at 750 ft. They will be attached in series for redundancy. The second set of black powder charges will be
housed below the BAE in the rocket and will be deployed at 750 ft. and will fully separate the rocket above the rover section.
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Figure 4.8: Jolly Logic Chute Release
The Jolly Logic chute release system is an efficient system that does not require any extra black powder charges, decreases the amount
of wires connected to the altimeter bay, as well as reducing risk of entangled shock cord in the main body. The Jolly Logic system
allows for the deployment of both a drogue and main parachute simultaneously in a single separation at apogee. This system deploys
more parachutes with fewer separations, reducing the chance of failure of the recovery portion of flight. There will not be a need for the
lower main parachute to have a Jolly Logic system attached to it as it will be contained inside the rocket until the second event occurs.
The Jolly Logic system consists of an independent altimeter device which releases a mechanical pin an altitude that is preset. The pin is
connected to the Jolly Logic device via a rubber band which provides tension on the pin so that when it is released, it is pulled from its
socket. Since the Jolly Logic system consists of rubber bands which can easily break if put under stress, the recovery system is set up
62
so that tension is never put on the Jolly Logic devices. To do this, the main parachute is not folded with the shock cord inside as is
normal. Instead the parachute is located on the shock cord so that the shroud lines are at full extension and so that the drogue line, which
runs through the main parachute spill hole is able to deploy to its full length during the initial separation. The main parachutes are then
carefully gathered and positioned in the body tubes so that the drogue line will pull it out without putting any forces on the actual
parachutes and Jolly Logic system. To preserve the redundancy of our recovery system, the team is using two Jolly Logic chute releases
in series to gather the main parachutes. If either of the Jolly Logic devices happens to malfunction, the other will still release, allowing
the main parachute to deploy.
Figure 4.9: Manufactured Parachute and Chute Release
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Parachutes
Auburn’s double deploy recovery approach will make use of three separate parachutes designed and constructed in house by the AUSL
team. The team has been making its own parachutes for five years and has refined its manufacturing process to produce quality, custom
chutes that produce the desired drag and drift for all sections of the rocket.
The drogue parachute will be a small, circular parachute constructed of rip-stop nylon with paracord shroud lines. Following the first
event at apogee, the drogue along with the upper main parachute bundled with a jolly logic chute release system will be deployed from
the top of the rocket. This will stabilize descent until main deployment at the second event. A drogue parachute size can be estimated
by the following calculation based on the length and diameter of the rocket body.
𝑑𝑑𝑟𝑜𝑔𝑢𝑒 = √ 4 × 𝐿𝑇𝑢𝑏𝑒 × 𝐷𝑇𝑢𝑏𝑒𝜋
The team’s rocket will have a length of approximately 126 in and a diameter of 6 in, yielding a drogue chute diameter of 31 in.
The recovery system will have two main parachute constructed of ripstop nylon with 0.5-inch tubular nylon shroud lines.
The main parachutes will be hemispherical. The hemispherical shape can be more difficult to manufacture, but will produce the most
drag, allowing the rocket to have maximum drag with minimum weight. A Pugh chart can be seen below comparing different parachute
shapes.
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Table 4.4: Parachute Shape Comparison
Baseline Square Circular Hemispherical
Drag Produced 3 1 1 2
Ease of
Manufacturing
2 1 2 1
Stability 1 2 1 1
Total 7 8 9
The shape of the main parachutes and their gores can be seen in Figure 4.10: Gore Template and Figure 4.11: Hemisphere Dimensions.
When the rocket reaches 750 feet in altitude, a second charge will separate the top section of the rocket to release the lower main chute,
and the jolly logic chute release system will release the bundled upper main chute. A spill hole will be added to the main parachutes.
This spill hole will be necessary with our configuration of dual-deployment from the same compartment at the top of the rocket body.
In accordance with the general rule of thumb, the spill holes will be close to 20% of the total base diameters of the chutes. The 20%
diameters of the spill holes are chosen because it only reduces the areas of the parachutes by about 4%, allowing enough air to go through
the spill hole to stabilize the rocket without drastically altering the descent rate.
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Figure 4.10: Gore Template
Figure 4.11: Hemisphere Dimensions
66
Parachute areas for hemispherical shaped chutes are determined using the following equation:
𝐴 = 2 ∗𝐹𝜌∗𝐶𝐷∗𝑉2
Where F is force, ρ is density of the air, CD is the drag coefficient and V is descent velocity. The team will use this equation to calculate
an appropriate area for the main parachute so that the kinetic energy of the rocket does not exceed 75 ft-lbs during recovery and remains
within safe limits.
Parachute Manufacturing
The parachutes will be manufactured at Auburn University by recovery team members. The drogue is created by cutting an appropriately
sized circle out of orange ripstop nylon. Sizing for the drogue can be seen in Section 4.2.4:. Orange ripstop nylon is chosen because it
is easier to see whether or not the drogue has deployed as compared to blue ripstop nylon. Shroud lines are then attached in four evenly
spaced intervals around the drogue with four inches of the paracord being sewn on at each point. Once they have been designed, 1:1
gore templates will be made for the main parachutes using SolidWorks. These templates will include an extra inch around the perimeter
of the gore for sewing and hemming purposes. Once they have been cut out, templates will be lain over the team's stock of orange and
blue ripstop nylon and used for cutting out all of the gores from the team's stock of orange and blue ripstop nylon. The main parachutes
for the 2017 rocket will consist of six gores each. The gores will be sewn together with a butterfly stitch; wherein, the gores will be
pinned along the edges and sewn together using strong nylon thread and a straight stitch. These seams will then be inverted and a new
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seam will be added to encase the first seam. This process will be repeated for all the gores until the parachute is fully assembled and
reinforced to ensure safety. After the assembly is completed, the spill-hole will be traced onto the top of the parachute and the excess
fabric will be removed. Next the spill-hole edges and the outer circumference of the parachute will be hemmed utilizing a straight stitch.
Finally, the shroud lines will be added around the circumference of the parachute. Due to the thickness of the shroud lines, two parallel
zigzag stitches -- one on each edge of the shroud lines -- will be used to attach them firmly to the parachute. Once the parachute is
completed, it will be inspected for any flaws in the workmanship or materials that could lead to failure in the recovery system.
Drift
The distance the rocket will drift during descent can be estimated with the following equation.
𝐷𝑟𝑖𝑓𝑡 = 𝑊𝑖𝑛𝑑 𝑆𝑝𝑒𝑒𝑑 × 𝐴𝑙𝑡𝑖𝑡𝑢𝑑𝑒 𝐶ℎ𝑎𝑛𝑔𝑒 𝐷𝑒𝑠𝑐𝑒𝑛𝑡 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦
However, this drift estimation assumes wind speed and descent velocity are constant and does not account for the horizontal distance
the rocket travels during ascent. There will be two stages of descent. First, the rocket will descend under the drogue parachute from an
altitude of 5280 ft. to 750 ft. At 750 ft., the second event will occur and the rocket will separate into two pieces and the upper and lower
sections of the rocket will continue the rest of the way to the ground under separate main parachutes. The rate of descent under drogue
can be calculated with the following equation:
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Descent Velocity = √ 2 × 𝐹𝑜𝑟𝑐𝑒 𝐴𝑖𝑟 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 × 𝐷𝑟𝑎𝑔 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 × 𝑃𝑎𝑟𝑎𝑐ℎ𝑢𝑡𝑒 𝐴𝑟𝑒𝑎
Using this information and weight of the rocket, the team will be able to calculate an estimated descent velocity. This descent velocity
will then be used to ensure drift is kept to a reasonable amount.
Altimeters
The BAE will house two altimeters to satisfy redundant system requirements. Both altimeters will fire an initial charge at apogee (target
altitude: 5280 feet) to eject the nosecone, upper-main parachute, and the drogue parachute. Then both altimeters will fire the main
deployment charges at an altitude of 750 ft, releasing the lower-main parachute. The team will use an Altus Metrum TeleMega (Figure
4.10) as the primary altimeter, and an Altus Metrum TeleMetrum(Figure 4.11) as the secondary altimeter. Both Altus Metrum altimeters
gather flight data via a barometric pressure sensor and an onboard accelerometer. The TeleMega has an advanced accelerometer for
more detailed flight data acquisition. Additionally, using two AltusMetrum altimeters will make programming quicker and easier, as
they share an interface program. This will ensure any last minute or on-site changes are more efficient and less prone to error. Altus
Metrum altimeters are capable of tracking in flight data, apogee and main ignition, GPS tracking, and accurate altitude measurement up
to a maximum of 25,000 feet. This height is much higher than the team's anticipated maximum altitude of 5280 ft. They are also capable
of being armed from outside the rocket using a key switch.
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Figure 4.12: Altus Metrum Telemega Altimeter
Figure 4.13: Altus Metrum Telemetrum Altimeter
Another reason that the Altus Metrum altimeters are preferred are their radio frequency (RF) communication capabilities. Both
TeleMega and TeleMetrum are capable of communicating with a Yagi-Uda antenna operated by the team at a safe distance during the
launch. It can be monitored while idle on the ground or while in flight. While on the ground, referred to as “idle mode”, the team can
use the computer interface to ensure that all ejection charges are making proper connections. Via the RF link, the main and apogee
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charges can be fired to verify functionality, which will be used to perform ground testing. The voltage level of the battery can also be
monitored, and should the battery dip below 3.8V, the launch can be aborted in order to charge the battery to a safer level. Additionally,
the apogee delay, main deploy height, and other pyro events can be configured to almost any custom configuration. The altimeter can
even be rebooted remotely. Furthermore, while in flight, referred to as “flight mode”, the team can be constantly updated on the status
of the rocket via the RF transceiver. It reports altitude, battery voltage, igniter status, and GPS status. However, in flight mode, settings
can’t be configured and the communication is one way from the altimeter to the RF receiver. Both Altus Metrum altimeters transmit on
one of ten channels with frequencies ranging from 434.550 MHz to 435.450 MHz.
In past years, this radio frequency communication has caused trouble due to signal strength. Communication could intermittently be
established with the rocket while on the ground, and settings could be configured. Once launched however, connection with the on-
board altimeters was soon lost due to weak signal strength. This is likely due to several causes such as the antenna not being straight
inside the rocket, the conductive carbon fiber body blocking the signal, or low power output of the altimeter’s whip antenna. To prevent
these issues, the team will replace the altimeters' default antennae with new antennae.
Isolating one altimeter system (altimeter, battery, and wires) from the other will help prevent any form of coupling or cross-talk of
signals. Isolation will be realized via distancing the two systems, avoiding parallel wires, and twisting wires within the same circuit.
Additionally, the most apparent form of radio-frequency interference (the antennae) will resonate on wires any multiple of ¼ λ (1/4 of
~70cm). Avoiding resonant lengths of wire will be done wherever possible. Within the BAE, the altimeters and batteries will be mounted
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on opposing sides of the carbon fiber avionics board, with one battery and altimeter per side. Since carbon fiber is an effective shielding
material (50dB attenuation), this board will act as shielding between the two altimeters and will minimize cross-talk as well as near-
field coupling. This board will also be easily removable for connecting the altimeters to computers for configuration and for charging
the altimeters’ batteries.
Section 4.3: Testing
This year, Auburn’s USLI organization is introducing a new testing team. In previous years, testing and verification of design fulfillment
of project requirements was performed by the different teams responsible for aspects of the project’s design in addition to all their
regular duties. With a team devoted solely to assisting with the creation of testing setups, test samples, and checking equipment, it is
hoped that testing will be accomplished in a timely manner and to a higher standard. Additionally, this team will provide a source of
extra hands for any team that finds itself short staffed. Finally, as the rocket is assembled, this team will ensure that all the systems that
make up rocket are able to be integrated successfully. With that in mind, this team is still relatively new, and so expect changes to occur
as the team and the rocket begins to better define this team’s new role. Close cooperation with the safety team is anticipated, as testing
must verify that all components will operate safely.
Vehicle Body
Structural testing of the body will consist of electronic simulation, followed by physical testing to verify models or point to needed
changes. First, finite element analysis within computer aided design software will ensure that body components will be capable of
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withstanding expected loadings. Material samples of carbon fiber, plastics, and fiberglass will be tested to provide these models with
accurate data. As construction moves forward, complete flat plates and sections of the open architecture structure will be tested to
ensure their structural properties are still sufficient.
Since the team may use fixed position grid fins at the rear of the rocket this year, wind and water tunnel testing of both grid fins and
conventional fins will be performed. This will provide useful data on drag characteristics.
Systems and Electrical
One of the primary performance requirements for this year’s competition is for the rocket will be to reach the mile-high mark. To make
sure that the rocket does not over shoot the mile mark, adjustable position flat plates on the rocket will need to be able to adjust the drag
forces on the rocket. The team will be testing the plates in a wind tunnel to determine how much drag is produced by the plates. This
data will be fed to a program in a processor on the rocket where a formula will be constantly determining the projected altitude. When
that value is determined, the rocket will be able to adjust position of the plates and therefore drag accordingly. Determining how much
drag this system produces and how it will affect the final altitude of the rocket will be an essential part of testing.
In the rocket there will be multiple electrical components such as batteries, circuitry, and controllers. These devices will have to be
verified to be able to function after being left on for over an hour on the launch pad. Additionally, the altimeter(s) and accelerometers
used will have to be verified to be accurate, since they are managing the energy of the rocket. These will be tested by the team to make
sure that they are safe and will accomplish their designed function and not cause any potential environmental harm by exiting their
designed space in or on the rocket. These components will be tested so that through the entirety of the flight of the rocket the forces
from the rocket launching do not disrupt the electrical or software components. Another concern for the electrical and software
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components will be environmental challenges. The main concern being humidity. The electrical and software components will be tested
to make sure there are no potential hazards that could come from humidity damage.
Computational Fluid Dynamics (CFD)
The team will be using computational fluid dynamics (CFD) to analyze this year’s vehicle. CFD is a process that numerical analysis
and algorithms to analyze how fluids interact with boundary conditions. The team will be creating a mesh that will then be used to run
a CFD analysis. This analysis is being done to better evaluate our vehicle, and to be able to acquire better predictions as to how our
vehicle will perform during flight. Using this data, the team will modify the vehicle however necessary to help ensure a successful,
accurate flight.
Rover
To ensure that the rover is secure during flight, the Rover team will develop an inner capsule that prevents movement while also allowing
enough space for the rover to exit the capsule. The rover will be held into place by a small “door” placed at the mouth of the capsule,
which will be pushed out by the rover as it exits. This door will be directly adjacent to the black powder charge that deploys the
parachutes. The testing team will have to test the strength and placement of the door to ensure that it can withstand the black powder
charge while also being light enough for the rover to push it out of the way. The team will also test the door assembly and rover to
ensure that the rover can still be deployed if the rocket lands on a slope. The entirety of the rover mounting and deployment systems
will be ground tested with vibrations and/or a centrifuge to ensure their function after launch. Additionally, tests will be performed to
ensure that the rover will be able to cross the kinds of rough terrain found typically at launch fields (plough tracks, dips, tufts of grass,
etc.). Finally, a way to verify and demonstrate that the solar panels are deployed properly and functioning will have to be developed.
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Recovery
The Recovery system will have to undergo intensive testing to help ensure the successful final recovery of the rocket. Testing will
follow similar methods as previous years.
The team will be using parachutes manufactured by the team for the drogue and main section of the vehicle. In order to test the
parachutes, the team will construct a scaled hemispherical main parachute. These will then be tested in the Auburn University wind
tunnels at Reynolds numbers comparable to the conditions expected during launch. Drag data from the tests will averaged and used to
compute a coefficient of drag for the hemispherical parachute with a spill hole. The data will be compared to the coefficients of drag
obtained via research and from last year to confirm accurate sizing and performance of the team's parachutes. With this data, the team
will be able to more accurately size the parachute to ensure a safe descent. Finally, when the parachutes are completed, the team will
conduct drop tests to ensure the recovery system deploys properly.
The team will be conducting extensive ground testing of the black powder ejection system. These tests will be performed by assembling
the avionics bay along with the sections of the rocket to be separated and fixing them in a testing rig oriented horizontally. The nose
cone will be aimed at a backstop so as to prevent injury and damage. The altimeters will be connected to our ground computer, from
which the charges are triggered. Safety equipment will be on site, including fire extinguishers. For the black powder system, testing will
begin with the smallest black powder charge from a calculated range. The testing will iterate with increasing black powder charges until
the minimum charge is reached which safely separated the nose section.
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Section 4.4: Proposed Payloads
A detailed look at the payloads the team has decided to fly this year can be found in Section 5.
Section 4.5: Technical Requirements
The team has designed a rocket that will meet all of the mission requirements presented in the 2016 NASA Student Launch Handbook.
The technical requirements are divided into three sections: vehicle, recovery, and payloads and are presented in TABLES.
Vehicle Requirements
Requirement Number Requirement Statement Verification Method Execution of Method
1.1
The vehicle shall deliver
the science or engineering
payload to an apogee
altitude of 5,280 feet
above ground level
(AGL).
Analysis Demonstration
Testing
Launch vehicle and check
altimeters
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1.2
The vehicle shall carry
one commercially
available, barometric
altimeter for recording the
official altitude used in
determining the altitude
award winner.
Inspection
Demonstration
Purchase and calibrate one
commercially available
altimeter.
1.2.1
The official scoring
altimeter shall report the
official competition
altitude via a series of
beeps to be checked after
the competition flight
Demonstration Test the altimeter to verify
it creates audible beeps
1.2.2
Teams may have
additional altimeters to
control vehicles
electronics and payload
experiment(s).
Demonstration The team may use
additional altimeters
1.2.3
At the LRR, a NASA
official will mark the
altimeter that will be
used for the official
scoring.
Inspection
Demonstration
Complete safety check at
LRR
1.2.4
At the launch field, a
NASA official will
obtain the altitude by
listening to the audible
beeps reported by the
official competition,
marked altimeter.
Inspection
Demonstration
Ensure beeps are audible,
launch successfully
77
1.2.5
At the launch field, all
audible electronics,
except for the official
altitude-determining
altimeter shall be capable
of being turned off.
Inspection
Demonstration Testing
Ensure all electronics can
be turned off and back on
1.2.6 The following circumstances will warrant a score of zero for the altitude portion of
the competition:
1.2.6.1
The official, marked
altimeter is damaged
and/or does not report an
altitude via a series of
beeps after the team’s
competition flight.
Inspection Analysis
Testing
Design the electronics
housing to prevent damage
to altimeter
1.2.6.2
The team does not report
to the NASA official
designated to record the
altitude with their official,
marked altimeter on the
day of the launch.
Demonstration
The team is timely and
organized in gathering
data and reporting to
NASA official
1.2.6.3
The altimeter reports an
apogee altitude over 5,600
feet AGL.
Demonstration Testing
Design and test launch
vehicle to meet altitude
requirement
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1.2.6.4
The rocket is not flown at
the competition launch
site.
Demonstration Team will launch the
rocket
1.3
All recovery electronics
shall be powered by
commercially available
batteries.
Demonstration
The team will use
commercially available
batteries
1.4
The launch vehicle shall
be designed to be
recoverable and reusable.
Reusable defined as being
able to launch again on the
same day without repairs
or modifications.
Testing
Analysis Demonstration
Inspection
Trajectory simulations and
testing will ensure the
launch vehicle is
recoverable and reusable
1.5
The launch vehicle shall
have a maximum of four
(4) independent sections.
Demonstration
Team will design and
build launch vehicle that
can have, but does not
require, four independent
sections
1.6
The launch vehicle shall
be limited to a single
stage.
Demonstration
Team will design and
build a single-stage launch
vehicle
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1.7
The launch vehicle shall
be capable of being
prepared for flight at the
launch site within 4 hours,
from the time the Federal
Aviation Administration
flight waiver opens.
Demonstration
Team will be timely and
organized to ensure
vehicle is prepared on time
1.8
The launch vehicle shall
be capable of remaining in
launch-ready
configuration at the pad
for a minimum of 1 hour
without losing the
functionality of any
critical on-board
component.
Demonstration
Team will design vehicle
with ability to remain
launch-ready for at least
one hour.
1.9
The launch vehicle shall
be capable of being
launched by a standard 12
volt direct current firing
system. The firing system
will be provided by the
NASA-designated Range
Services Provider.
Testing
Batteries shall be tested
with full electronics to
verify their life
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1.10
The launch vehicle shall
require no external
circuitry or special ground
support equipment to
initiate launch (other than
what is provided by Range
Services).
Demonstration
The team will design a
vehicle requiring no
external circuitry or
special ground support
equipment
1.11
The launch vehicle shall
use a commercially
available solid motor
propulsion system using
ammonium perchlorate
composite propellant
(APCP) which is approved
and certified by the
National Association of
Rocketry (NAR), Tripoli
Rocketry Association
(TRA), and/or the
Canadian Association of
Rocketry (CAR).
Demonstration
Vehicle will be designed
around commercially
available, certified motors
1.11.1
Final motor choices must
be made by the
Critical Design Review
(CDR).
Demonstration
CDR will determine which
motor the team will use for
competition.
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1.11.2
Any motor changes after
CDR must be approved by
the NASA Range Safety
Officer (RSO), and will
only be approved if the
change is for the sole
purpose of increasing the
safety margin.
Demonstration
If the change is made to
increase safety margin,
NASA RSO will allow the
change
1.12
Pressure vessels on the
vehicle shall be approved
by the RSO and shall meet
the following criteria:
Analysis
Testing
Inspection of pressure
vessel by RSO standards
by testing.
1.12.1
The minimum factor of
safety (Burst or Ultimate
pressure versus Max
Expected Operating
Pressure) shall be 4:1 with
supporting design
documentation included in
all milestone reviews.
Inspection
Analysis
Testing
Team will design the
pressure vessels to have a
factor of safety of 4:1.
1.12.12 The low-cycle fatigue life
shall be a minimum of 4:1.
Inspection
Analysis
Testing of the low-cycle
fatigue
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Testing
1.12.3
Each pressure vessel shall
include a solenoid
pressure relief valve that
sees the full pressure of the
tank.
Inspection
Analysis
Testing
Inspection of each
pressure vessel and testing
of the pressure relief valve
to see that it works
correctly
1.12.4
Full pedigree of the tank
shall be described,
including the application
for which the tank was
designed, and the history
of the tank, including the
number of pressure cycles
put on the tank, by whom,
and when.
Inspection
Demonstration
The team will inspect the
tank along with
documentation of testing
and history
1.13
The total impulse
provided by a College
and/or University launch
vehicle shall not exceed
5,120 Newton-seconds
(L-class).
Demonstration
Analysis
The team will choose a
motor with a total impulse
that does not exceed 5,120
Newton-seconds (L-
class).
1.14
The launch vehicle shall
have a minimum static
stability margin of 2.0 at
the point of rail exit.
Testing
Demonstration
The team will design and
test the vehicle to ensure
that it has a stability
83
Analysis margin of 2.0 at the point
of rail exit.
1.15
The launch vehicle shall
accelerate to a minimum
velocity of 52 fps at rail
exit.
Demonstration
Analysis
Testing
The team will design the
and test the vehicle to
ensure that it’s minimum
velocity at rail exit is at
least 52 fps.
1.16
All teams shall
successfully launch and
recover a subscale model
of their rocket prior to
CDR.
Demonstration
Testing
A demonstration of the
launch will be exhibited
through testing.
1.16.1
The subscale model
should resemble and
perform as similarly as
possible to the full-scale
model, however, the full-
scale shall not be used at
the subscale model.
Demonstration
The subscale model will
be designed to resemble
and perform similarly to
the full scale model.
1.16.2
The subscale model shall
carry an altimeter capable
of reporting the model’s
apogee altitude.
Demonstration
An altimeter capable of
reporting the model’s
apogee altitude will be
implemented on the
subscale model.
1.17
All teams shall
successfully launch and
recover their full-scale
rocket prior to FRR in its
final flight configuration.
The rocket flown at FRR
must be the same rocket
Testing
Demonstration
Analysis
A test of the rocket will be
exhibited, demonstrating
all hardware functions
properly.
84
flown on launch day. The
following criteria must be
met during the full scale
demonstration flight:
1.17.1 The vehicle and recovery
system shall have
functioned as designed
Testing
Testing of vehicle will
show how recovery
system functions.
1.17.2
The payload does not have to be flown during the full-
scale test flight. The following requirements still
apply:
1.17.2.1
If the payload is not flown,
mass simulators shall be
used to simulate the
payload mass.
Testing
Demonstration
Analysis
Payload will be flown
1.17.2.1.1
The mass simulators shall
be located in the same
approximate location on
the rocket as the missing
payload mass.
Inspection
Inspection of the rocket
payload will be done by
the team to ensure it is
properly placed.
1.17.3
If the payload changes the
external surfaces of the
rocket (such as with
camera housings or
external probes) or
manages the total energy
Demonstration
Testing
Demonstration of the
adaptability of the systems
notice to payload changes
of the external surfaces
through testing.
85
of the vehicle, those
systems shall be activated
during the full-scale
demonstration of flight
1.17.4
The full-scale motor does
not have to be flown
during the full-scale test
flight.
Inspection
Demonstration
Inspection of the motor
will be done by the team to
ensure it is flown through
full-scale testing.
1.17.5
The vehicle shall be flown
in its fully ballasted
configuration during the
full-scale test flight.
Testing
Demonstration
Testing of the ballast
systems to ensure proper
mass locations
1.17.6
After successfully
completing the full-scale
demonstration flight, the
launch vehicle or any of its
components shall not be
modified without the
concurrence of the NASA
Range Safety Officer
(RSO).
Demonstration
The team will demonstrate
that it did not alter any
components or vehicle
after demonstration flight.
86
1.17.7
Full scale flights must be
completed by the start of
FRRs (March 6th, 2018).
If necessary, an extension
to March 24th, 2018 will
be granted. Only granted
for re-flights.
Demonstration
If the full scale flight is not
completed by March 6th,
2018, NASA will grant an
extension to March 24th,
2018 for a re-flight
attempt.
1.18
Any structural
protuberance on the rocket
shall be located aft of the
burnout center of gravity.
Demonstration
Team will design all
structural protuberances
on the vehicle to be aft of
the burnout center of
gravity.
1.19 Vehicle Prohibitions:
1.19.1
The launch vehicles shall
not utilize forward
canards.
Demonstration
The team will
demonstrate how the
launch vehicle does not
utilize canards.
1.19.2
The launch vehicle shall
not utilize forward firing
motors.
Demonstration
The team will design the
vehicle so that it does not
utilize forward firing
motors.
1.19.3
The launch vehicle shall
not utilize motors that
expel titanium sponges
Demonstration
The team will not utilize a
motor that expels titanium
sponges.
87
(Sparky, Skidmark,
MetalStorm, etc.)
1.19.4 The launch vehicle shall
not utilize hybrid motors. Demonstration
The team will not utilize a
hybrid motor.
1.19.5
The launch vehicles shall
not utilize a cluster of
motors.
Demonstration
A demonstration and
inspection of the launch
vehicle shall be carried
out to validate it does not
use a cluster of motors.
1.19.6
The launch vehicle shall
not utilize friction fitting
for motors.
Demonstration
The team will design the
vehicle so that it does not
utilize friction fitting for
the motor.
1.19.7
The launch vehicle shall
not exceed Mach 1 at any
point during flight.
Demonstration
Testing
Analysis
The team will test and
demonstrate to ensure that
the vehicle does not
exceed Mach 1 at any
point during the flight.
1.19.8
Vehicle Ballast shall not
exceed 10% of the total
weight of the rocket.
Demonstration
Testing
Analysis
The team will design
ballast so that it does not
exceed 10% of the total
weight of the rocket.
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Recovery System Requirements
Requirement Number Requirement Statement Verification Method Execution of Method
2.1
The launch vehicle shall
stage the deployment of its
recovery devices, where a
drogue parachute is
deployed at apogee and a
main parachute is
deployed at a much lower
altitude. Tumble recovery
or streamer recovery from
apogee to main parachute
deployment is also
permissible, provided that
kinetic energy during
drogue-stage descent is
reasonable, as deemed by
the Range Safety Officer.
Design
Testing
The team will stage the
deployment of our
recovery devices with a
drogue parachute
deployed at apogee (5280
ft.), and two main
parachute deployed at 750
ft.
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2.2
Each team must perform a
successful ground ejection
test for both the drogue
and main parachutes. This
must be done prior to the
initial subscale and full
scale launches.
Testing
Prior to the initial subscale
and full scale launches, the
team will perform a
ground ejection test for
both the drogue and upper
main parachute section as
well as the lower main
parachute section.
2.3
At landing, each
independent sections of
the launch vehicle shall
have a maximum kinetic
energy of 75 ft-lbf.
Design
Demonstration
The team will calculate
and test both sections of
our launch vehicle to
ensure that a maximum
energy of 75 ft-lbf at
landing is not exceeded.
2.4
The recovery system
electrical circuits shall be
completely independent of
any payload electrical
circuits.
Design
The team will create
independent circuits for
our recovery system so
that they are independent
of any payload electrical
circuits.
2.5
The recovery system shall
contain redundant,
commercially available
altimeters. The term
“altimeters” includes both
Design
The recovery system will
include a TeleMetrum and
TeleMega altimeter each
with their own
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simple altimeters and
more sophisticated flight
computers.
independent set of charges
for each section.
2.6
Motor ejection is not a
permissible form of
primary or secondary
deployment.
Design
The team will not use
motor ejection as a
primary or secondary
deployment. An electronic
form of deployment will
be used.
2.7
Each altimeter shall be
armed by a dedicated
arming switch that is
accessible from the
exterior of the rocket
airframe when the rocket
is in the launch
configuration on the
launch pad.
Design
The team will use a
dedicated arming switch to
arm each altimeter, and it
will be accessible from the
exterior of the rocket
airframe directly outside
of the BAE when the
rocket is in the launch
configuration
2.8 Each altimeter shall have a
dedicated power supply Design
Each altimeter will have
its own battery attached to
it.
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2.9
Each arming switch shall
be capable of being locked
in the ON position for
launch
Verification
The team will make sure
the locking mechanism
locks the switch in the ON
position for launch.
2.10
Removable shear pins
shall be used for both the
main parachute
compartment and the
drogue parachute
compartment.
Design
The team will use
removable shear pins for
both the main parachute
compartment and the
drogue parachute
compartment.
2.11
An electronic tracking
device shall be installed in
the launch vehicle and
shall transmit the position
of the tethered vehicle or
any independent section to
a ground receiver.
Design
The team will install a
tracking device on both
sections of the launch
vehicle so that the location
of both pieces can be
determined after landing.
2.11.1
Any rocket section, or
payload component,
which lands untethered to
the launch vehicle, shall
also carry an active
electronic tracking device.
Design
All separating sections of
the rocket will contain
their own tracking device.
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2.11.2
The electronic tracking
device shall be fully
functional during the
official flight on launch
day
Verification
The team will test and
make sure the electronic
tracking devices will be
fully functional during the
official flight.
2.12
The recovery system
electronics shall not be
adversely affected by any
other on-board electronic
devices during flight (from
launch until landing).
Testing
The team will test and
make sure that the
recovery system will not
be adversely affected by
any other on-board
electronic devices during
flight.
2.12.1
The recovery system
altimeters shall be
physically located in a
separate compartment
within the vehicle from
any other radio frequency
transmitting device and/or
magnetic wave producing
device.
Design
The recovery system
altimeters will be located
in a separate compartment
within the vehicle from
any radio frequency
transmitting devices, and
magnetic wave producing
devices.
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2.12.2
The recovery system
electronics shall be
shielded from all onboard
transmitting devices, to
avoid inadvertent
excitation of the recovery
system electronics.
Design
The recovery electronics
will be sealed in their own
separate compartment
separate from all other
transmitting devices in the
rocket.
2.12.3
The recovery system
electronics shall be
shielded from all onboard
devices which may
generate magnetic waves
(such as generators,
solenoid valves, and Tesla
coils) to avoid inadvertent
excitation of the recovery
system.
Design
The recovery electronics
will be sealed in their own
separate compartment
separate from all other
magnetic wave inducing
devices in the rocket.
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2.12.4
The recovery system
electronics shall be
shielded from any other
onboard devices which
may adversely affect the
proper operation of the
recovery system
electronics.
Design
The recovery electronics
will be sealed in their own
separate compartment
separate from all other
devices in the rocket
which could adversely
affect the proper operation
of the recovery system.
Payload Requirements
Requirement Number Requirement Statement Verification Method Execution of Method
4.5.1
Teams will design a
custom rover that will
deploy from the internal
structure of the launch
Pre-launch and after
landing
Design treaded rover that
will be completely housed
inside the body of the
rocket
4.5.2
At landing, the team will
remotely activate a trigger
to deploy the rover from
the rocket
Pre-launch and after
landing
Communicate via SMS
message to rover to
activate deployment
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4.5.3
After deployment, the
rover will autonomously
move at least 5 ft from the
launch vehicle
Pre-launch and after
landing
After deployment,
ultrasonic range finders
will confirm a distance of
at least 5 feet from any
object
4.5.4
Once the rover has
reached its final
destination, it will deploy
a set of foldable solar cell
panels
Pre-launch and after
landing
A motor will deploy the
cells
Section 4.6: Major Technical Challenges
There are many technical challenges facing the team this year, but the students of Auburn University feel prepared to tackle them. The
main challenge the team will face is that of the rover payload’s electronics. Manually deploying the rover from a distance and then
having the vehicle autonomously control itself present major electrical, software-based, and design challenges. To address these, the
team has brought on board individuals specialized in these fields more so than the aerospace engineering majors on the team. Electrical
and software engineering majors have joined AUSL to assist with the challenges, and certain team members have previous experience
with robotics that will be invaluable.
In addition, the open architecture body tubes that the team will be using are a new design that the team has limited prior experience with.
In years past, the design has showed great potential but was difficult to properly integrate into the system. This year, the team is confident
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that with enough testing and research the open architecture matrix will be able to be integrated into the rocket to improve the performance
of the project.
As the team expects the rover to add a notable amount of weight to the rocket, safe recovery of the project became a concern. The team
has decided to use two main parachutes to address this, but this design increases the overall length of the rocket substantially. Handling
and constructing such a long rocket will present another challenge, but one that can be mitigated by experience and careful manufacturing
techniques.
Payloads
Section 5.1: Rover
Overview
For the 2017-2018 competition, Auburn University’s USLI team has chosen to complete the deployable rover experiment. After rocket
landing, the rover will be remotely deployed from the rover. It will autonomously travel 5 feet from the rocket and then deploy solar
panels from its body. Both the rover and the housing bay will be built using in-house manufacturing processes such as 3D printing and
composite layup.
Design
Initial design ideas included using a sphere that would be powered by internal reaction wheels to induce angular momentum and a typical
wheeled design powered by simple hobby motors. Due to expected complications with the sphere and physical limitations with the
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wheeled design, the team has decided to use a tracked idea, like a tank. This allows the rover to deploy right-side-up or upside-down
and provides excellent traction. The main structure of the rover, the body, will be made of two panels with space in between them for
motors and electronics. The treads of the rover will be much taller than the body to allow for successful terrain traversing. The rover
will be powered by two motors sandwiched in between the two panels that have enough power to allow the experiment to travel on the
unknown ground of the landing zone. To account for the rocket landing in an orientation such that the rover is not right-side-up or
upside-down, the rover will have dome-like structures on the sides. Upon deployment, and assuming a sideways orientation, the dome-
like structures on the side will roll the rover onto its treads. Solar panels will be stored in between the two body panels and will be
deployed from the side of the rover by a motor. The panels will be attached to arms that, when panel motor activates, will spin the panels
outward through slits in the domes, exposing them to the sun. To account for unknown rover orientation (right-side-up/upside-down),
there will be panels on both sides so that either orientation has usable solar panels.
Figure 5.2: Rover Concept Design
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The bay that will house the rover will be 3D printed using ABS (acrylonitrile butadiene styrene) and will be fitted into the rocket body
and secured with epoxy. The dome structures on the sides of the rover will fit into slots on the sides of the bay like rails. When the rocket
lands under parachute and tips over, the activated rover will push open a door on the nose end of the rover bay. The door will be held in
place with a hinge and will rest on a lip at the front of the rover bay. All forces acting on the door (rocket flight, black powder explosion,
packed parachute) will push the door to the aft end of the rocket onto the bay lip so that the door will not open until the rover pushes it
open after landing. The parachute for the bottom section of the rocket will be secured onto a bulk plate at the back of the rover bay. The
parachute shock cord will run from the back of the bay, through a channel at the bottom of the bay, and out the front of the rover bay.
Figure 5.3: Rover Capsule Front View
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Electronics
For controlling the rover, the team has decided to use an Arduino Uno as they are simple to code and the team has previous experience
with them. An Adafruit 10-DOF IMU Breakout will be used to calculate the acceleration and orientation of the rover. The IMU Breakout
consists of a 3-DOF accelerometer, a 3-DOF gyroscopic sensor, a 3-DOF compass and barometric pressure/temperature gauge. To
activate the rover, an SMS text message will be sent to an Arduino GSM Shield attached to the rover body. After remote rover
deployment, the rover will travel at least 5 feet from the bay. Distance away from the rocket will be determined by an array of ultrasonic
range finders mounted on the body of the rover. Once the rover reaches an appropriate distance, the Uno will activate the solar panel
motor to deploy the solar panels through slots in the side dome structures.
Figure 5.4: Rover Capsule Cut-away Side View
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Section 5.2: Altitude Control Module
Overview
The current path the team has chosen to pursue along with the rover experiment is a drag system capable of climaxing the flight vehicle
at the competition apogee (5280 ft.). This system will run counter to this team’s past attempts at controlling drag with a system of
actuating grid fins. This decision was based strictly on experimental reasons as well as the opportunity to explore designs without the
implementation of drag inducing fairings.
The design this team will be pursuing utilizes composite plates that are actuated out from inside the body of the vehicle via an internal
motor. Open slots on the rocket body will allow for these plates to protrude and produce a deterministic amount of drag. Using a control
system with an Arduino microcontroller at its core, sensors capable of capturing telemetry data will be integrated to provide the inputs.
These inputs will determine the actuated position of the drag plates (the outputs). Upon the completion of reaching an apogee, the plates
will retract completely and deactivate.
Three drag plates will be evenly spaced around the rocket body. During rocket motor burn, these plates will remain retracted. After burn,
controls will become active and start processing telemetric inputs. The drag plates will respond with the appropriate output.
Structure
The housing and frames for the internal structure of this drag system will be primarily composed of composite materials. The chosen
material will be sent through testing to ensure its integrity for this application. Empirical testing will be used alongside analysis software
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to carry out this process. The team has access to a variety of potential materials as well as a 3D printer. This will be used to build a
custom housing for the electronics and the structural frame.
Electronics and Extensibility
The development of the drag system will be carried out with extensibility in mind. The core functionality of the system will be to apply
drag to maximize the accuracy of reaching apogee (5280 ft.). The motor function of this system will be driven with an Arduino
microcontroller. This controller will interface with an IMU sensor to acquire telemetric inputs. These inputs will trigger a corresponding
output from the drag plates to correct any suboptimal accent characteristics to satisfy apogee. Test data will be collected along with CFD
data to calculate drag moments produced by the drag plates in order to determine the variable for incrementing the plates. Finding this
variable will allow us to define the corrective response from the plates, thus giving us the most optimal output. Upon early completion
of the drag system, the team will aim extend the core functionality of this system, via pursuing the target detection challenge. The
changes to the core design will add a flight computer, which will communicate with both the microcontroller and a camera module used
for taking still snapshots of the ground during descent. A Raspberry Pi 3 will be used as the flight computer along with a camera module
used for interfacing with this selection. An algorithm will be implemented that analyzes the snapshots in real-time to locate and identify
colored ground targets.
Educational Engagement
The Auburn University Student Launch Initiative team (USLI), along with the Department of Aerospace Engineering at Auburn
University, is entering an exciting new era of growth, influence and leadership, as devotion for the future advancement of aeronautical
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and astronautical engineering swells throughout the department. Although the USLI competition requires teams to plan and execute
educational engagement activities as a component of the overall project, USLI does not seek to fulfill the requirement solely for the sake
of the competition. Just as NASA and the USLI competition has instilled the spirit of rocketry in USLI’s team members, USLI truly
aspires to instill a passion for science, technology, engineering, mathematics and rocketry in young students here on the Plains.
There are many middle school, high school, and college students that possess talents in math and science, and they may aspire to pursue
STEM careers in the future. Society, however, has developed a stigma that careers in STEM fields are reserved for the academic elite
and that only few have the talents or abilities to work in these fields. USLI believes that it is urgent to counter this perception toward
STEM fields, by showing how easy it is to get involved in so called rocket science, a supposedly insular field. A dramatic change of
perspective is needed so that people may realize that even though huge gains have been made in math, science, engineering and
technology, careers in these areas are still 100% accessible and attainable for those who set their minds to it.
The solutions to the world’s problems lie in the minds of generations to come. Auburn University students have great influence in the
Auburn community. USLI plans to use its influence to enrich the minds of young students in Auburn and enable them to realize their
full potential for STEM careers.
Section 6.1: Drake Middle School 7th Grade Rocket Week
This year, USLI’s primary plans begin with its venture in engaging young students by bringing a hands-on learning experience for the
seventh-grade class of J.F. Drake Middle School (DMS). The program is entitled DMS 7th Grade Rocket Week, and the goal of the
program is to encourage interests in math, science, engineering, technology and rocketry through an interactive three-day teaching
curriculum that will reach approximately 700 middle school students. In general, many students do not know much about rocketry or
any relevant interdisciplinary applications that space exploration entails. The seventh-grade science curriculum at DMS focuses on life
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science for the year. Therefore, the rocketry unit curriculum will include lessons about g-forces and how they affect the human body.
Also, most students have never built their own rockets. So, the students will be divided into teams of 2-3 and provided a small alpha
rocket to construct and launch under the supervision of USLI and certified professionals. This program was successfully implemented
during the 2013-2014 school year, and the school has requested that we return to repeat the program with each new seventh grade class.
A summarized plan of action based on last year is written below, with details to be revised as more information and planning occurs
between the school and the team. Once all formal decisions are made final for the year, a fully detailed program handbook will be
printed for the teachers and all other administration involved. The handbook will include specific details regarding the plan of action,
the launch, scheduling outlines, procedures, worksheets, teaching materials, lesson plans, feedback forms, etc. A rough draft plan of
action, an ideal launch plan, and the learning objectives for the outreach program are provided in the following section.
Rocket Week Plan of Action
Day 1: The students will participate in an engaging in-class lesson presented by USLI members. The lesson will first teach the students
about g-forces through a presentation and demonstration. Secondly, students will learn how the human body reacts under stress in high
and low g-force environments via a presentation and a video. This part of the lesson will be both educational and highly engaging. A
curriculum guide will be provided for the teacher, along with all presentation materials that are to be utilized. A worksheet will be
distributed to the students for them to fill out key concepts as they follow the lesson.
Day 2: The students will be split into teams of 2-3 and given a small alpha rocket assembly kit and the required materials to build and
decorate the rocket. The teachers will need to divide the students into teams since the teachers can more appropriately handle their
students. USLI team members will lead and guide the students and faculty in every step of assembly in a very organized and well-
prepared fashion. At no point will the students be given the motors for their rockets. USLI team members and certified professionals
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will take care of this portion at the launch event. The students and faculty will sand, glue, assemble and paint their own rockets as USLI
team members instruct them to do so.
Day 3: All science classes will head to the P.E. field on DMS’s campus during each period throughout the day. Students will also be
informed of all safety and launch procedures for the event when they first arrive on the field. A summary of what will take place at the
launch and a launching order will be announced on this day.
Rocket Week Launch Day
The launch day will be held on the DMS P.E. field on the third and final day of the program. Each period of the school day, four or five
science classes will proceed to the launch field. There will be multiple launch rails set up in sanctioned safe zones in different parts of
the field, meeting all NAR Safety Guidelines for launching model rockets.
Each class will be assigned to a launch rail, and instructions will be delivered
by an USLI member. In the order that they are called, students will have their
rockets prepped for launch by USLI team members. Together, the 7th grade
students from each team will be given a launch controller for the team’s
rocket. At the end of a cued countdown, the students will fire their rockets
and recover them once the field has been cleared by the range safety officer.
At the end of the period, students return to their classrooms and continue
the day. Figure 6.1: Photo From DMS 7th Grade Rocket Week, February 2017
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A permission slip will require parental permissions for students to launch rockets. USLI plans to invite the Southeast Alabama Rocketry
Association to supervise the launch site to ensure that all aspects of the launch are safe and successful.
Additionally, USLI plans to invite all parents, administrators, local newspaper outlets, etc. to the event to celebrate and promote the
students’ work at the launch event. The Auburn community will be able to see and appreciate the results of what its young student body
has accomplished and learned. The media attention will also recognize USLI’s goals and efforts to inspire and communicate the
importance of STEM fields, aerospace engineering, and rocketry to both the students and the greater Auburn community, just as NASA
and its Student Launch competition has inspired USLI to engineer a launch vehicle.
Rocket Week Learning Objectives
The learning objectives for the entire outreach program are outlined below:
• Students will learn about the basics about gravity and g-forces.
• Students will learn the fundamentals of Newton’s Laws of Motion.
• Students will learn how high and low gravity environments affect the circulatory system, cognitive processes, and muscle
performance in humans.
• Students will learn some specific terms related to rockets and Newton’s Laws of Motion.
• Students will gain an idea of what engineering is and why math and science are so important.
• Students will learn basic values of teamwork and why communication is important.
• Through the rocket construction and launch event, students will hopefully gain a sense of accomplishment and confidence in
their abilities to work with others to complete projects that they may have never thought they would get a chance or ability to
do.
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• Finally, USLI hopes to have at least one student realize that all he or she wants to do is become a rocket scientist. Although
truthfully, the team will be glad to have sparked any and all interests in math, science, engineering and/or technology in students’
minds throughout the experience.
Gauging Success
USLI will measure the success of the outreach program by utilizing brief feedback questionnaires. The forms will ask for feedback on
different aspects of the program. One form will be made for teachers to complete. Teachers will be able to express what they liked,
what they disliked, make suggestions for improvements, etc.
Secondly, the students will be assessed by filling out a brief worksheet that will cover some basic highlights of what they learned from
the program based on the learning objectives.
Finally, USLI will complete a group self-assessment in writing that will highlight program aspects that were favored, successful, needed
improvement, and aspects that were not favored. USLI will utilize these forms of feedback to learn and plan for better ways to execute
student engagement activities in the future. USLI will only deem this event a success if all the learning objectives are completed in full.
Section 6.2: Samuel Ginn College of Engineering E-Day
February 23, 2017
E-Day is an annual open house event during which middle and high school students and teachers from all over the southeast are invited
to tour Auburn University’s campus. They will have the opportunity to learn about the programs and opportunities that the college of
engineering offers. Students will be able to explore all the labs and facilities housed in the Samuel Ginn College of Engineering, which
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includes the Aerospace Engineering labs and competition team project facilities. They will also be able to speak with faculty, advisors,
organizations, competition teams and Auburn student engineers while visiting. USLI will be participating in the event to promote
aerospace engineering, rocketry, the organization, and NASA’s Student Launch competition. Students will be informed of the current
activities that USLI is involved in, and they can learn how they, too, could join organizations like USLI while at Auburn. At least 3,000
students and teachers attended E-Day 2016 and 2017. More than half of the attendees were exposed to the work and activities that USLI
performs, and learned about the Auburn rocket team’s accomplishments in the NASA Student Launch competition. The same results
are expected for E-Day 2018 in February. This event will be successful to USLI if we persuade at least one student to join Auburn's
Aerospace Engineering department.
Section 6.3: Boy Scouts of America: Space Exploration Badge
Through USLI, boy scouts from Boy Scouts of America can receive the Space Exploration Badge. The Space Exploration Badge is
meant to persuade young scouts to explore the mysteries of the universe and build rockets. The boy scouts will be led by students in
USLI who have at minimum earned a level one rocket certification through
either the Tripoli Rocketry Association or the National Rocketry
Association. The Boy Scouts of America have set guidelines as to how the
scouts can receive the Space Exploration Badge. USLI will follow these
requirements to ensure full completion defined by the Boy Scouts of
America. This event will be considered a success by USLI once every scout
has obtained their badge, learned a significant amount about space
exploration, and had fun. Last year, 2016, the event was successful and the
Boy Scout Troop wanted us to return to do the event again. Figure 6.2: Photo From Boy Scouts of America Educational Event
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Boy Scouts of America: Requirements
The following are defined guidelines set by the Boy Scouts of America to receive the Space Exploration Badge.
• Tell the purpose of space exploration and include the following:
1. Historical reasons
2. Immediate goals in terms of specific knowledge
3. Benefits related to Earth resources, technology, and new products
4. International relations and cooperation
• Design a collector's card, with a picture on the front and information on the back, about your favorite space pioneer. Share your card and discuss four other space pioneers with your counselor.
• Build, launch, and recover a model rocket. * Make a second launch to accomplish a specific objective. Launch to accomplish a specific objective.
• Rocket must be built to meet the safety code of the National Association of Rocketry.
• Identify and explain the following rocket parts: Body tube; Engine mount; Fins; Igniter; Launch lug; Nose cone; Payload; Recovery system; Rocket engine.
• **** If local laws prohibit launching model rockets, do the following activity: Make a model of a NASA rocket. Explain the functions of the parts. ****
• Give the history of the rocket.
• Discuss and demonstrate each of the following:
1. The law of action-reaction
2. How rocket engines work
3. How satellites stay in orbit
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4. How satellite pictures of Earth and pictures of other planets are made and transmitted.
• Do TWO of the following:
1. Discuss with your counselor a robotic space exploration mission and a historic crewed mission. Tell about each mission’s major discoveries, its importance, and what was learned from it about the planets, moons, or regions of space explored.
2. Using magazine photographs, news clippings, and electronic articles (such as from the Internet), make a scrapbook about a current planetary mission.
3. Design a robotic mission to another planet or moon that will return samples of its surface to Earth. Name the planet or moon your spacecraft will visit. Show how your design will cope with the conditions of the planet's or moon's environment.
• Describe the purpose, operation, and components of ONE of the following:
1. Space shuttle or any other crewed orbital vehicle, whether government-owned (U.S. or foreign) or commercial
2. International Space Station
• Design an inhabited base located within our solar system, such as Titan, asteroids, or other locations that humans might want to explore in person. Make drawings or a model of your base. In your design, consider and plan for the following:
1. Source of energy
2. How it will be constructed
3. Life-support system
4. Purpose and function
• Discuss with your counselor two possible careers in space exploration that interest you. Find out the qualifications, education, and preparation required and discuss the major responsibilities of those positions.
• FAILURE, BY ANY BOY SCOUT, TO COMPLETE ANY OF THE ABOVE REQUIREMENTS WILL DISQUALIFY HE/THEM FROM RECEIVING THE SPACE EXPLORATION BADGE.
Boy Scouts of America: AUSL Requirements
In addition to the guidelines set by the Boy Scouts of America, USLI has set requirements that the boy scouts will also follow to receive the Space Exploration Badge.
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• All boy scouts will follow rules/regulations set by the NAR and TRA, just like USLI.
• All boy scouts will follow safety guidelines set forth the by the USLI designated safety officer.
• ALL Boy Scouts will not tamper with their rocket in such a way as to cause the rocket to go ballistic.
• All boy Scouts will complete the required lesson plan.
• FAILURE, BY ANY BOY SCOUT, TO COMPLETE ANY OF THE ABOVE REQUIREMENTS WILL DISQUALIFY HE/THEM FROM RECEIVING THE SPACE EXPLORATION BADGE.
Boy Scouts of America: Plan of Action
In February 2017, Boy Scouts will assemble in the Haley Center at Auburn University early in the morning to sign in for activities.
USLI members will be prepared and waiting to greet the Boy Scouts. The boy scouts will be escorted to the assigned classroom for their
required lesson set by the Boy Scouts of America. The lesson plan will take a few hours and the by the time they are done with the
lesson it will be lunch. After lunch, USLI members will first explain safety rules for building the rockets. Last year, the launch field had
a building location provided nearby, and that may also be used instead of meeting outside the Hayley Center. Once the boy scouts have
completed every rocket assigned to them, everyone will travel to the designated launch site USLI has acquired, which meets all NAR,
FAA, and Auburn City requirements. While USLI members setup launch, a designated safety officer will explain all launch rules and
precautions associated with rocketry. Rocket launches will then commence. Only once the boy scouts have completed their required
launches will they then be granted the Space Exploration Badge.
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Boy Scouts of America: Goals
It is intended for every Boy Scout to receive the Space Exploration Badge. USLI wishes for the boy scouts to enjoy their learning
experience about space and rocketry. USLI also hopes to inspire at least one, if not all boy scouts to pursue a career in rocketry.
Section 6.4: Girl Scouts of America: Space Badge
Through USLI, girl scouts from Girl Scouts of the USA can receive the Space Exploration Badge. The Space Exploration Badge is
meant to persuade young scouts to explore the mysteries of the universe and build rockets. The girl scouts will be led by students in
USLI who have at minimum earned a level one rocket certification through either the Tripoli Rocketry Association or the National
Rocketry Association. The Girl Scouts of the USA have set guidelines as to how the scouts can receive the Space Exploration Badge.
USLI will follow these requirements to ensure full completion defined by the Girl Scouts of the USA. This event will be considered a
success by USLI once every scout has obtained their badge, learned a significant amount about space exploration, and had fun.
Girl Scouts of the USA: Requirements
The following are defined guidelines set by the Boy Scouts of the USA to receive their Space Exploration Badge, and will be used as
requirements for the Girl Scouts as well.
* Tell the purpose of space exploration and include the following:
1. Historical reasons
2. Immediate goals in terms of specific knowledge
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3. Benefits related to Earth resources, technology, and new products
4. International relations and cooperation
* Design a collector's card, with a picture on the front and information on the back, about your favorite space pioneer. Share your card
and discuss four other space pioneers with your counselor.
* Build, launch, and recover a model rocket.* Make a second launch to accomplish a specific objective. Launch to accomplish a specific
objective.
* Rocket must be built to meet the safety code of the National Association of Rocketry.
* Identify and explain the following rocket parts: Body tube; Engine mount; Fins; Igniter; Launch lug; Nose cone; Payload; Recovery
system; Rocket engine.
* **** If local laws prohibit launching model rockets, do the following activity: Make a model of a NASA rocket. Explain the functions
of the parts. ****
* Give the history of the rocket.
* Discuss and demonstrate each of the following:
1. The law of action-reaction
2. How rocket engines work
3. How satellites stay in orbit
4. How satellite pictures of Earth and pictures of other planets are made and transmitted.
* Do TWO of the following:
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1. Discuss with your counselor a robotic space exploration mission and a historic crewed mission. Tell about each mission’s major
discoveries, its importance, and what was learned from it about the planets, moons, or regions of space explored.
2. Using magazine photographs, news clippings, and electronic articles (such as from the Internet), make a scrapbook about a current
planetary mission.
3. Design a robotic mission to another planet or moon that will return samples of its surface to Earth. Name the planet or moon your
spacecraft will visit. Show how your design will cope with the conditions of the planet's or moon's environment.
* Describe the purpose, operation, and components of ONE of the following:
1. Space shuttle or any other crewed orbital vehicle, whether government-owned (U.S. or foreign) or commercial
2. International Space Station
* Design an inhabited base located within our solar system, such as Titan, asteroids, or other locations that humans might want to explore
in person. Make drawings or a model of your base. In your design, consider and plan for the following:
1. Source of energy
2. How it will be constructed
3. Life-support system
4. Purpose and function
* Discuss with your counselor two possible careers in space exploration that interest you. Find out the qualifications, education, and
preparation required and discuss the major responsibilities of those positions.
* FAILURE, BY ANY GIRL SCOUT, TO COMPLETE ANY OF THE ABOVE REQUIREMENTS WILL DISQUALIFY HE/THEM
FROM RECEIVING THE SPACE EXPLORATION BADGE.
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Girl Scouts of the USA: AUSL Requirements
In addition to the guidelines set by the Girl Scouts of the USA, USLI has set requirements that the girl scouts will also follow to receive
the Space Exploration Badge.
* All girl scouts will follow rules/regulations set by the NAR and TRA, just like USLI.
* All girl scouts will follow safety guidelines set forth the by the USLI designated safety officer.
* All Girl Scouts will not tamper with their rocket in such a way as to cause the rocket to go ballistic.
* All Girl Scouts will complete the required lesson plan.
* FAILURE, BY ANY GIRL SCOUT, TO COMPLETE ANY OF THE ABOVE REQUIREMENTS WILL DISQUALIFY HE/THEM
FROM RECEIVING THE SPACE EXPLORATION BADGE.
Girl Scouts of the USA: Plan of Action
In February 2017, Girl Scouts will assemble in the Haley Center at Auburn University early in the morning to sign in for activities.
USLI members will be prepared and waiting to greet the Girl Scouts. The girl scouts will be escorted to the assigned classroom for their
required lesson set by the Girl Scouts of the USA. The lesson plan will take a few hours and the by the time they are done with the
lesson it will be lunch. After lunch, USLI members will first explain safety rules for building the rockets. Once the girl scouts have
completed every rocket assigned to them, everyone will travel to the designated launch site USLI has acquired, which meets all NAR,
FAA, and Auburn City requirements. While USLI members setup launch, a designated safety officer will explain all launch rules and
precautions associated with rocketry. Rocket launches will then commence. Only once the girl scouts have completed their required
launches will they then be granted the Space Exploration Badge.
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Girl Scouts of the USA: Goals
It is intended for every Girl Scout to receive the Space Exploration Badge. USLI wishes for the girl scouts to enjoy their learning
experience about space and rocketry. USLI also hopes to inspire at least one, if not all girl scouts to pursue a career in rocketry.
Section 6.5: Auburn Junior High School Engineering Day
Date to be announced
The Auburn Junior High School Engineering Day was created to encourage student interest in engineering and to create an opportunity
for students to gain firsthand experience as to what it is like to be an engineer. All engineering majors are invited to present their major,
clubs, and teams to encourage students to become engineers. USLI will participate in the event to promote aerospace engineering,
rocketry, and the USLI Competition. USLI. We will bring example rockets and rocket components to present to the students so that they
can get an up close and hands on view of what USLI does. Last year we presented to 1,000 students, many of whom expressed interest
in engineering and rocketry, and we hope to reach similar numbers this year.
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Figure 6.3: Auburn Junior High School Engineering Day, October 2015
Section 6.6: Aeropalooza
August 22, 2017
Aeropalooza is a yearly gathering at the beginning of the fall semester that seeks to bring together the entirety of the Auburn Aerospace
community. One of the main purposes of the event is to help students find a student organization that occupies their interests. To this
end, USLI set up a table and several rockets from previous years. As students came by we explained the competition to them, answered
any questions they had, and if they were interested in joining USLI, took down their contact information. We also answered many
questions from faculty members about the teams’ plan for the upcoming year and how they could help. Aeropalooza allows USLI to
bring in a large cadre of potential new members each year from both the freshman and returning upper classmen students in Auburn
University's Aerospace program.
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Section 6.7: Organization Week
August 28-29, 2017
Organization Week, also known as O-Week, is a campus event that occurs during the second week of classes. During this event,
organizations set up tables to recruit new members, bringing in a variety of different majors and diversity to USLI. USLI set up a table
with several rockets from previous years to represent the team. As students come by, USLI members explain the competition, answer
any questions, and take down their contact information if the students are interested. USLI also answers many questions from faculty
members about the teams’ plan for the upcoming year and how they could help.
Section 6.8: Auburn University Rocketry Association
Ongoing splinter organization
The Auburn University Rocket Association (AURA) is smaller organization under USLI, and operates under the Education Outreach
team. The goal of AURA is simple: it instructs students in how to construct a rocket with which they can secure their Tripoli level one
certification. To achieve this, students are first taught how to model their rockets in the OpenRocket design software, and some of the
strengths and limitations of that program. Next, members construct their rockets in the lab, gaining familiarity with the machines and
tools within and the techniques involved. Finally, the students’ rockets are launched at the same launch day as a USLI subscale or full
scale launch, to allow for sharing rides and save time. AURA serves a dual purpose for USLI. First, it allows current-but-newer USLI
members to gain experience and appreciation for the design of an entire rocket and valuable hands-on lab experience. Secondly, it
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provides a gateway in rocketry for those initially daunted by the scale of the USLI competition, who after developing their skills feel
confident enough to take the plunge and join USLI.
Figure 6.4: Level 1 Example Rocket Designed in OpenRocket During AURA
Project Plan
Section 7.1: Timeline
A Gannt chart has been created to illustrate the project timeline, this can be found in Appendix C. As the team moves into the PDR
phase of the project, team timelines, launch dates, and educational engagement events will be added.
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Section 7.2: Budget
The budgets displayed in Table 7.4: Budget Allocation are an initial approximation of the expenditures required for the overall project.
The approximations are conservative, assuming excess quantities of materials and no price breaks. We hope to bring a large group of
team members to the competition this year, as travel from Auburn to Huntsville is relatively cheap. Assuming we travel with 20 team
members, the lodging costs will be approximately $3,000. Based on current estimates, the sub-scale vehicle is assumed to be $2,700.
Our educational outreach is estimated to cost $1,500 for this year. Assuming $3,770 for the rocket on the pad and $3,000 for travel, this
leaves $730 for overhead costs and any other testing and development costs, based on the $12,000 amount for total funding presented
in Table 7.5: Funding Sources. However, the team expects to receive additional sponsors which will increase the comfortability of the
budget and the scope of the team’s endeavors.
Table 7.1: Vehicle Costs
Vehicle (Full Scale)
Item Cost Per Unit Unit Quantity Total
Carbon fiber and
resin for open
weave structure.
$284 Per tube 2 $568
Fiber glass sleeve $33 Per tube 2 $66
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Pre-preg Carbon
Fiber $118 Per yard 10 $1,180
Loki L-1482 $185 Per unit 1 $185
RMS 75/3840
Motor Case and
Associated
Hardware
$385 Per unit 1 $385
Rail Buttons $3 Per unit 2 $6
Total $2,390
Table 7.2: Recovery Costs
Recovery (Full Scale)
Item Cost Per Unit Unit Quantity Total
Ripstop Nylon $8 Per yard 25 $200
Nylon Thread $8 Per spool 3 $24
Tubular Kevlar $1 Per foot 50 $50
Paracord $5 Per roll 1 $5
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Telemetrum $200 Per unit 1 $200
Telemega $300 Per unit 1 $300
Jolly Logic $130 Per unit 2 $260
Total $1039
Table 7.3: Payload Costs
Payload
Item Cost per unit Unit Quantity Total
HIPS (3D
printing) $30 Per roll 4 $80
Arduino Uno Rev
3 $22 Per unit 2 $44
Arduino GSM
Shield 2 $71.50 Per unit 1 $72
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SainSmart HC-
SR04 ultrasonic
range finder
$6.42 Per unit 4 $26
NeveRest Orbital
20 motor $32 Per unit 2 $64
Futaba S3003
servo $12.37 Per unit 2 $25
Small solar panel $3 Per unit 10 $30
Total $341
Table 7.4: Budget Allocation
Item Cost
Full-Scale $3,770
Sub-Scale $2,700
Cost of Rocket On the Pad $3,770
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Travel $3,000
Educational Outreach $1,500
Test flights (5) $1,000
Research and Development $2,000
Promotional Items $1,000
Total $12,270
Figure 7.1: Spending Comparison
Budget Breakdown
Full-Scale Sub-Scale Travel
Educational Outreach Test Flights (5) Development
Promotional Items
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Section 7.3: Funding Plan
The team has secured funding from the sources presented in Table 7.5: Funding Sources. This money will cover the majority of the cost
of the rocket on the pad, the purchase of capital equipment as needed, the cost of subscale and full scale test launch motors, programming
and materials for our educational engagement events, travel and housing for the team at the competition in Huntsville, Alabama, and
any other costs associated with designing, building, and launching our competition rocket. Although the team’s anticipated costs are
currently higher than the funding, the team is confident that we will have sufficient funds for the project. All of the anticipated costs
were estimated on the high end to provide a safety factor, certain non-essential budgets can be scaled down as needed, and the team is
currently awaiting response from more sponsors interested in assisting the team financially. The Auburn University Student Launch
team is confident that these factors will lead to a stable financial situation.
Table 7.5: Funding Sources
Source Amount
Alabama Space Consortium $12,000
Dynetics $2,000
Total Funding $14,000
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Section 7.4: Community Support
The Auburn University Student Launch team is lucky to have many different levels of support from a variety of different organizations,
companies, and academic communities. These resources include, but are not limited to, Dynetics, GKN Aerospace, Drake Middle
School, Auburn Junior High, Phoenix Missile Works, Chris’s Rocket Supplies, and the Auburn University Aerospace Engineering,
Mechanical Engineering, and Electrical Engineering departments. Details of these organizations can be found in the following sections.
Dynetics
This year Dynetics will be offering the team support in terms of financial means as well as technical assistance. Dynetics will be
providing use of their computers to perform computational fluid dynamics of the launch vehicle and payload system. In addition,
Dynetics will also be providing compression molds to produce a carbon fiber nose cone.
GKN Aerospace
GKN Aerospace, located in Tallassee, Alabama, provides and invaluable source of technical guidance and machining capabilities for
the production of composites. GKN graciously provides access to their autoclaves and filament winders, giving the team the ability to
make a professional-grade finished product.
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Drake Middle School
This year marks the fourth year of Auburn’s partnership with Drake Middle School for ‘Rocket Week’, our team’s most successful and
most established educational engagement event. We spend a week in the classroom with over 850 7th Graders, teaching them the basics
of space travel, the effect of gravity on the human body, and fundamental rocketry design and construction. The Auburn Student Launch
Team works closely with the teachers and administrators of the school to ensure that the team can deliver a clear and concise program
to the 7th grade students and inspire them to pursue a future in STEM fields.
Phoenix Missile Works
Auburn is incredibly lucky to be located approximately 45 minutes away from the Phoenix Missile Works (PMW) launch site in
Tallassee, Alabama. This allows us convenient access to regularly scheduled launches. The Tripoli Rocketry Association (TRA) and
National Association of Rocketry (NAR) members are always willing and able to provide useful insights into the development of our
rocket through subscale launches.
Chris’s Rocket Supplies
Chris Short served as the mentor for the Auburn Student Launch Team two years ago and since then has been a valuable resource for
his Tripoli connections, his availability and flexibility as a rocket motor vendor, and his vast experience is high powered rocketry.
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Auburn Engineering
The Auburn University Samuel Ginn College of Engineering has an amazing array of resources and laboratories available to us.
Connections within the departments of Aerospace Engineering, Mechanical Engineering, and Electrical Engineering provide us with
technical experience and laboratory access, and help us develop a network of engineers with whom we can work to solve problems. As
a team composed almost entirely of aerospace engineers, we appreciate the interdisciplinary support when solving problems.
Section 7.5: Project Sustainability
Since restarting the Auburn Student Launch team in 2013, the team’s primary focus was to build our team and our lab and establishing
our roots as a community presence. Now, as an established team, we will have ample opportunity to shift our focus to sustainability. We
have made it our initiative to develop a lasting program that will serve as a point of pride and success for Auburn Engineering and our
local community.
The Auburn Aerospace Engineering department provided a huge recruitment tool in the form of a new event, Aeropalooza, for engaging
members of the department and helping students learn about the many different opportunities available for getting involved with
aerospace. For interdepartmental recruiting, our senior members have committed a tremendous amount of time to attracting new
members in both formal events and friendly encounters. Auburn University’s ODay served as an excellent starting point. At O-Days,
campus organizations get an opportunity to reach all members of the campus community in a public forum and allow clubs to network
with students of all majors and disciplines. This event has led to contacts in many different departments and has allowed us to establish
a presence on campus, making the club more popular, even for non-engineers. This is helping Auburn to overcome its past struggles to
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form an interdisciplinary team. Reaching out to non-aerospace majors and even non-engineers is making us a well-rounded team and is
helping us to be better suited to tackle challenges and produce a stellar finished product.
The aerospace engineering department has been working to improve the capabilities of our facilities by purchasing capital equipment
such as a 3D printer, CNC router, and filament winder. This attracts more interest in rocketry projects and aerospace engineering, giving
us yet another recruiting tool.
As far as our community presence, we have now been in regular contact with many local organizations and businesses for over two
years. We have established programs for educational engagement that we can improve every year with experience and the addition of a
larger, better trained workforce. Our partnerships with Drake Middle School, Auburn Junior High School, and Auburn High School are
well developed and we hope to maintain our relationship through the continuation of successful educational engagement events.
As for financial stability, both of our primary sources of funding, the Alabama Space Consortium and Auburn University College of
Engineering, are renewable in that we do not foresee issues obtaining relatively similar amounts of money for future years assuming the
continued success of our organization. If for any reason we receive reduced funding from either source, budget gaps can be made up
with department funding, club dues, and other smaller fundraising opportunities.
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Appendix A. Safety Waiver
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131
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Appendix B. Risk Assessment
Construction & Assembly
Hazard Cause Result Severity Probability Combined Risk Mitigation
Use of power tools such as dremels,
drills, etc.
Improper use and / or improper
protection such as lack of gloves or
safety glasses
Mild to severe cuts, scrapes, and other
injuries. Additionally, reactions can result
in harm to rocket components being
worked upon.
3 2 6
Demonstration of proper use by
experienced team members, easily accessible safety
materials and protective wear, and
securely fastening the object being
worked upon
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Construction & Assembly
Hazard Cause Result Severity Probability Combined Risk Mitigation
Particles of carbon fiber
Sanding carbon fiber or other fibrous material without
using a mask or filter
Mild coughing and difficulty breathing, irritation in the eyes
and skin.
3 3 9
When sanding or cutting tools are used
on carbon fiber all members in the lab, regardless if they are
working on the carbon fiber or not,
are required to utilize a mask to prevent the
breathing in of excessive particles
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Construction & Assembly
Hazard Cause Result Severity Probability Combined Risk Mitigation
Insecure tools in the workspace
Tools are left out in the lab workspace
and not returned to a storage space where
they belong
Cuts, pricks, or tears when members sort
through items or knock loose tools
around or off tables.
2 3 6
The storage spaces for all tools are
clearly marked and easy to find.
Members are instructed to return tools they find left
out to their storage spaces
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Construction & Assembly
Hazard Cause Result Severity Probability Combined Risk Mitigation
Use of soldering tool Failure to pay proper
attention to the soldering tool
Mild to severe burns on the fingers or
hands of the team member using it.
Additionally, could result in excessive
heat and damage to the component being
worked on.
3 2 6
Members that use the soldering iron are
required to give it their full attention for the duration of their
work. They must turn off and stow the
tool somewhere away from the object
being worked on if they must attend to
something else before work is
finished
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Construction & Assembly
Hazard Cause Result Severity Probability Combined Risk Mitigation
Fumes from soldering tool
Improper ventilation of the workstation where soldering is
taking place
Excessive exposure to toxic fumes results in nausea and irritation.
Reactions could potentially damage the component(s)
being worked upon.
3 2 6
The workstation will be properly vented
and members using it are required to
confirm ventilation is functioning periodically.
Additionally, team members will not be allowed to continue
soldering for an extended period of
time and must take a break to let any
buildup of fumes disperse
Use of the belt sander, bansaw, or
drill press
Failure to pay attention, aggressive use of the tools, lack of proper protective
equipment
Severe cuts, burns, rashes, bruises, or
other harm to fingers, hands, or
arms.
4 2 8
Experienced team members will instruct inexperienced team
members before they are allowed to use
the tools, protective equipment will be easily accessible
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Construction & Assembly
Hazard Cause Result Severity Probability Combined Risk Mitigation
Use of tools
Improper maintenance of tools used in the lab and
workspace
Damage to sections of the rocket or to team members or
delays to the project due to the need for
replacements
2 2 4
All tools are maintained regularly.
Any tools deemed beyond repair are disposed of and
replaced immediately.
Use of electrical equipment
a) Improperly maintained equipment
b) Improper use of equipment
Electric shocks could occur to team
members handling the equipment
4 1 4
Electrical equipment will be maintained
regularly. Electrical equipment will only be plugged in when ready for immediate
use and will be promptly unplugged
afterward.
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Vehicle Structure
Hazard Cause Result Severity Probability Combined Risk Mitigation
Carbon fiber splinters Handling of carbon fiber components with bare hands
Slivers of carbon fiber break off and become
stuck in the skin of fingers and hands
handling it
2 4 8
Members are encouraged to handle
carbon fiber components with
gloves. In the event that gloves are
unavailable, gentle handling is enough to
avoid splinters.
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Vehicle Structure
Hazard Cause Result Severity Probability Combined Risk Mitigation
Structural integrity of the rocket is
compromised by buckling during flight
Excessive aerodynamic loading
on the airframe of the rocket
The mission is lost, the rocket becomes
unstable during flight and may be a danger to personnel or the
environment
5 1 5
Extensive testing of the materials and
structural architecture of the rocket body will be done before sub-
scale and full-scale launches to confirm that the design will
withstand forces that it will encounter.
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Vehicle Structure
Hazard Cause Result Severity Probability Combined Risk Mitigation
Sections of the rocket are poorly coupled
together
The use of weak bolts or poorly designed couplers between
sections
Sections of the rocket may wobble and the
trajectory of the rocket could be affected during ascent or during
recovery.
4 2 8
Extensive testing of the coupler will be done prior to sub-scale and full-scale
launches. The coupler will be
visually inspected before and after
assembly.
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Vehicle Structure
Hazard Cause Result Severity Probability Combined Risk Mitigation
The airframe is dropped or hits
against a hard surface during construction,
assembly, or in transport
Distracted or clumsy handlers that are not
aware of their surroundings
The body or nose cone may be
damaged by the impact and may
require replacement
3 2 6
Great care will be taken when working
on components under all conditions.
During transportation multiple personnel will carry the rocket slowly and carefully while an additional
team member removes obstacles or
opens doors as necessary.
Replaceable parts such as pins, screws, and the nose cone will have duplicate
parts available during assembly.
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Vehicle Structure
Hazard Cause Result Severity Probability Combined Risk Mitigation
Holes in the airframe leading to the inside of the rocket body
Insufficienct communication in
addition to excessive drilling or work on
components or failure to notice missing pins or
screws
The hole could result in an improper reading of air
pressure by the altimeter and result
in premature activation of the recovery system.
5 2 10
All sections of the rocket will be visually
inspected immediately after
construction, before transport to the
launch site, and on assembly. Duplicates
of objects such as pins, screws, etc. will
be available to replace any missing
ones.
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Vehicle Structure
Hazard Cause Result Severity Probability Combined Risk Mitigation
Cracks in the airframe
Excessive physical or thermal loading to
the rocket body during storage or
transport
The rocket body fractures on launch
or on ascent releasing debris in the
immediate area
5 1 5
Sections of the rocket body will be kept in a dry location at room
temperature. The rocket body will be visually inspected before and after transport, during
assembly, and immediately prior to
launch to confirm that there are no
cracks.
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Vehicle Structure
Hazard Cause Result Severity Probability Combined Risk Mitigation
A segment of the airframe is misplace
or lost
A messy or disorganized work
environment leads to poor tracking and storage of pertient
rocket segments
An incomplete rocket body is transported
or ready for assembly on launch day.
Segments may need to be
remanufactured if they cannot be
located.
4 1 4
Once segments of the rocket body are
completed they will be immediately
stored in a location exclusively for launch-ready
components. For subscale launches, some components
will be manufactured twice so that one
may serve as a backup.
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Stability and Propulsion
Hazard Cause Result Severity Probability Combined Risk Mitigation
Motor explodes on launch
Manufacturing defect
The rocket is destroyed on the
launch pad or shortly after launch.
5 1 5
Rocket motors will only be purchased
from a certified source and will be
handled with extreme care
exclusively by the team mentor or by
someone with permission of the
team mentor.
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Stability and Propulsion
Hazard Cause Result Severity Probability Combined Risk Mitigation
The rocket exceeds mach 1 on ascent
The rocket motor utilized in the design is too powerful for
the mass of the rocket
Vehicle requirement 1.19.7 is violated, compromising the
validity of the mission
4 1 4
Team members will analytically evaluate the expected speed
of the rocket prior to testing and will
confirm these results in sub-scale and full-scale testing. In the event that the mass of the rocket is too
low, additional mass will be added to the inside of the rocket
to ensure it does not exceed Mach 1.
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Stability and Propulsion
Hazard Cause Result Severity Probability Combined Risk Mitigation
Motor fails to ignite
a) Manufacturing defect
b) Failure of the ignition system
c) Delayed ignition
a) and b) The motor will not fire and the
rocket will not launch c) The motor will fire and the rocket will launch an unknown
amount of time after the button is pressed
3 2 6
In accordance with the NAR Safety Code, the safety interlock will be removed or the battery will be
disconnected and no team member will
approach the rocket for 60 seconds. After 60 seconds without activity the safety
officer will approach and check the
ignition systems. In the event that the
ignition systems are not at fault the motor will be removed and
replaced with a spare. A second
launch will be attempted if there is
time to do so.
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Stability and Propulsion
Hazard Cause Result Severity Probability Combined Risk Mitigation
Motor is physically damaged
Motor was damaged during handling or
transport
The motor will be primarily handled by the team mentor or
another member certified to do so
with the permission of the mentor or
safety officer
4 1 4
The mentor will oversee the design of
a carrying case for the motors that they will be safely stored in during transport
and will be the one to stow and remove
them from this case.
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Stability and Propulsion
Hazard Cause Result Severity Probability Combined Risk Mitigation
Epoxy used is insufficient to
stabilize fins on rocket body
a) The epoxy was mixed or cured
improperly b) The epoxy used
was not strong enough to withstand forces encounter in
flight
Fins may vibrate and cause unexpected or erratic changes to the course of the rocket. This could endanger personnel on ascent
or recovery
4 2 8
Proper procedures regarding the mixing and curing of epoxy
will be strictly followed during
construction of the rocket. During assembly team
members will apply pressure to the fins to confirm they do
not move and will not during flight.
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Stability and Propulsion
Hazard Cause Result Severity Probability Combined Risk Mitigation
Rocket center of gravity and center of
pressure are improperly placed
Rocket property calculations were made incorrectly
The rocket's ascent will be unstable and
potentially dangerous.
5 1 5
Calculations will be checked multiple
times prior to launch. Subscale launches
will provide an opportunity to confirm these
calculations prior to full scale launch. Additionally the
center of gravity will be physically checked
prior to launch.
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Scientific Payload
Hazard Cause Result Severity Probability Combined Risk Mitigation
Improper coding
Improper coding of the Ardunio
microcontroller controlling the grid
fins
The science payload do not behave as
expected during the flight. This adversely affects descent and
could endanger personnel.
4 2 8
The code that will drive the science payload will be
written and reviewed by multiple team
members and tested on the ground to
ensure that it reacts in ways it is meant to
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Scientific Payload
Hazard Cause Result Severity Probability Combined Risk Mitigation
Improper soldering
Too much or too little solder is used when
constructing the electrical equipment to control the science
payload
Electrical malfunctions and a
loss of system integrity
4 2 8
The electrical equipment will be
visually inspected by multiple team
members and tests run to ensure that it
carries electrical signals as intended.
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Scientific Payload
Hazard Cause Result Severity Probability Combined Risk Mitigation
Improper wiring
Electrical signals are transmitted
improperly resulting in unexpected
behavior
The science payload does not behave as
expected or does not function at all
4 4 16
Wires will be color-coded to
communicate their function and a
specific checklist will be created to ensure the system is wired
correctly.
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Scientific Payload
Hazard Cause Result Severity Probability Combined Risk Mitigation
The servos utilized by the science payload
jitter or do not actuate smoothly
a) Internal electrical failure
b) Worn or malfunctioning gears
The science payload may not respond as
accurately as expected
2 2 4
The servos that will be used for flight will be purchased at the
beginning of the project and will be stored in a space away from any
chemicals or excessive humidity. The servos will be
tested before transport, before and
after assembly to confirm that they actuate properly.
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Scientific Payload
Hazard Cause Result Severity Probability Combined Risk Mitigation
Grid Fin Damage (Water Tunnel)
The grid fin is not properly secured inside the water
tunnel
The grid fin is caught in the water current and forced against the interior wall of the tunnel resulting
in damage to the grid fin.
The grid fin is caught in the water current and forced against the interior wall of the tunnel resulting
in damage to the grid fin.
2 2 4
Personnel conducting the tests will ensure
that the grid fin is properly secured for
safe and valid testing.
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Scientific Payload
Hazard Cause Result Severity Probability Combined Risk Mitigation
Water Tunnel Leakage
The water tunnel is not encapsulated
fully and leaks water during testing.
The excess liquid can trigger the
electronics outfitted to the water tunnel and impose a threat of electrocution on
the personnel.
5 2 10
Personnel conducting the testing will take extra precautions
when preparing for testing in order to
ensure all variables aside from those being tested are
constant.
157
Scientific Payload
Hazard Cause Result Severity Probability Combined Risk Mitigation
Insufficient Materials
During assembly, an insufficient material
is used for construction.
The material used for construction directly
contributes to the rocket’s failure of
overcoming aerodynamic forces
and compromises the integrity of the
rocket.
1 3 3
Personnel will conduct ample
amounts of research and testing in order
to select the appropriate material for construction of
the rocket.
Faulty Servo Installation
Servo’s within the rocket are not
properly installed and/or configured in
the rocket.
The lack of a proper setup will result in a malfunction of the
rocket’s avionics. The grid fins may not
deploy.
2 4 8
Ample testing will be conducted on the avionics to ensure
proper function prior to launch.
158
Scientific Payload
Hazard Cause Result Severity Probability Combined Risk Mitigation
Grid Fin Damage (Wind Tunnel)
The grid fin is not properly secured to an instrument inside
the wind tunnel.
The grid fin is caught in the wind current and forced against the interior wall of the tunnel resulting
in damage to the grid fin.
2 2 4
Personnel conducting the tests will ensure
that the grid fin is properly secured for
safe and valid testing.
Faulty Payload Fairing Assembly
The payload fairings are not constructed and/or assembled
properly.
The improper assembly of the payload fairings
compromises the integrity of the rocket
and its ability to handle aerodynamic
forces.
3 2 6
The payload fairings will be checked and tested before the fairings make it to
launch.
159
Recovery
Hazard Cause Result Severity Probability Combined Risk Mitigation
Parachute failure on deployment
The parachute is not packed properly
The parachute becomes tangled on descent resulting in an erratic and fast-moving projectile
that endangers personnel and property below
5 3 15
Packing of the parachute will be
performed by dedicated members of the recovery team
who will have practiced previously.
160
Recovery
Hazard Cause Result Severity Probability Combined Risk Mitigation
The parachute fails to deploy in any
capacity
a) A faulty altimeter fails to detect the
altitude at which the parachute should
deploy b) Not enough black
powder is used in the recovery system
The rocket descends chaotically at a speed
that his extremely dangerous to both
the rocket and personnel.
5 2 10
a) A reliable altimeter will be selected
during the PDR phase and will be tested
prior to launch in a full-scale capacity. b) The amount of black powder that will be used will be calculated by team members before
hand. Calculations will include the
amount necessary and the amount
allowable with the final amount used lying somewhere within the range.
161
Recovery
Hazard Cause Result Severity Probability Combined Risk Mitigation
The parachute deploys early
A faulty altimeter fails to detect the
altitude at which the parachute should
deploy
The rocket's ascent will be compromised and its descent will result in the rocket drifting for a very
long distance
4 2 8
The altimeter will be thoroughly tested prior to its use in a
full-scale capacity to confirm that it will
function as intended.
162
Recovery
Hazard Cause Result Severity Probability Combined Risk Mitigation
The parachute tears after deployment
Defects in the parachute occurred during construction
The rocket's descent will not be slowed as effectively and could endanger the rocket
or personnel
4 2 8
The parachute will be visually inspected and
tested prior to its utilization in a full-scale capacity and upon assembly on
launch day. The container holding parachute will be smoothed to not contain any sharp
edges. All parachutes will be reinforced at any potential tear
location.
163
Recovery
Hazard Cause Result Severity Probability Combined Risk Mitigation
The rocket falls too quickly
Design oversight causes the rocket to
fall faster than desired
The body of the rocket will be damaged and potentially the
internal components damaged as well. This could violate
vehicle requirement 1.4 and jeopardize
mission success.
4 3 12
The exact size of the parachute needed to
slow down the descent of the rocket and the timing of its
release will be calculated and
sufficient leeway given to ensure that
recovery will not threaten the rocket
or personnel.
164
Recovery
Hazard Cause Result Severity Probability Combined Risk Mitigation
Wind blows the rocket off course
a) Strong winds on the day of the launch affect descent more
than expected b) A premature
parachute deployment causes
the rocket to be subject to more drift
Rocket could become lost, damaged, or could endanger
observers.
3 3 9
The rocket will not be launched if weather
conditions are considered
dangerous by either the team or the
range safety officer. All parts of the rocket
will have a GPS locater device
securely attached to facilitate tracking during and after
descent.
165
Recovery
Hazard Cause Result Severity Probability Combined Risk Mitigation
The parachute or chords catch fire
upon deployment
Excessive black powder and
insufficient flame retardant wadding
The descent of the rocket is accelerated and the external and internal structure of
the rocket is jeopardized. Upon landing, a flaming
parachute or chords could ignite brush.
4 3 12
Testing will be done to determine the exact amount of
black powder and wadding needed to
safely deploy the parachute. No more
than is needed will be used. A fire
extinguisher will be available to combat any fires that may
occur once the rocket lands. If the fire
spreads or is significantly large, authorities will be
contacted.
Appendix C. Gannt Chart
AUSL 2017 - 2018
8/23/17 9/13/17 10/4/17 10/25/17 11/15/17 12/6/17 12/27/17 1/17/18 2/7/18 2/28/18 3/21/18 4/11/18
Conceptual Design
Proposal
Preliminary Design Review
CFD Testing
Materials Testing
Trade Studies
Detailed Design
Critical Design Review
Sub-Scale Development
Payload Development
Detailed Design Review
Full-Scale Development
Flight Readiness Review
Competition Preparation
Huntsville Competition
Post-Launch Assessment Review