nasa sl preliminary design reviewchargerrocketworks.files.wordpress.com/...presentation summary...

NASA SL Preliminary Design Review UNIVERSITY OF ALABAMA IN HUNTSVILLE

CHARGER ROCKET WORKS

NOVEMBER 17, 2016

Presentation Summary

UNIVERSITY OF ALABAMA IN HUNTSVILLE 2

•Project Overview

•Vehicle Structure

•Launch Vehicle Verification and Test Plan

•Payloads and Verification Plans

•Safety

•Educational Engagement

•Project Management

•Questions

Competition Summary Goals of Competition

•Design, build, and fly a student built rocket

•Achieve apogee of 5,280 feet, but not exceed 5,600 ft

•Payload to control flight characteristics

•Deploy chutes

•Reusable rocket

•Complete NASA design cycle


Team Summary


•16 Total Team Members • 8 Mechanical

Engineering Majors

• 8 Aerospace Engineering Majors

Concept

• Solid Rocket Motor L-Class

• Dual Deployment Recovery System

• Programmable Wing Angle

• Fiberglass Airframe

Vehicle Summary


Launch Vehicle Dimensions

• Outer diameter 6.17 in.

• Mass at lift off: 46 lbm.

• Length: 119 in.

Vehicle Structure

6

Vehicle Overview •Fiberglass construction: 119” inches from tip to tail, 6 inch inside diameter, and 46 pounds wet

•2 sets of 3 fins: forward set (3-D printed ABS plastic) is for roll/counter roll payload, aft set (fiberglass with locally machined aluminum brackets) is for stability

•Designed to recover in 3, connected sections via a dual deploy parachute system

•Center of Gravity location from Nose: 77.27 inches

•Center of Pressure location from Nose: 90.88 inches


CG CP

Vehicle Systems Locations


Forward Body Tube/ Main Recovery System

Fin Assembly (3 Places)

119”

Avionics Bay Payload

Motor Assembly Tail Cone

Aft Body Tube/ Drogue Recovery System

Lower Airframe Upper Airframe

Tracker Assembly

Nose Cone

Vehicle Concept of OperationsApogee Drogue

Primary Fire

(18.6 seconds)

Coast & Roll Phase

Drogue Main

Drogue

Main Parachute

Primary Fire

(600 feet)


Launch (0 - 3.3 seconds)

Coast & Roll Phase

600 ft.

(74 seconds)

Landing (119 seconds)

Drogue

Secondary Fire

(19.6 seconds)

Main Parachute

Secondary Fire

(550 feet)

Upper Airframe

10

Upper Airframe Overview Requirements:

•Protect and deploy recovery system

•Protect and allow transmission of vehicle landing location

•Recover entire vehicle in flyable condition


Coupler

Main/Shock Chord Compartment*

Forward Body Tube

Tracker Assembly

Nose Cone

*See Recovery Section

Upper Air Frame Sub-Sections


Coupler - Recovery Avionics Nose Cone - Tracking System

GPS Tracker

Avionics Stations

Nose Cone Subsection •Metal tipped

•Made of filament wound fiberglass with a 4:1 fineness ratio (6 inch shoulder)

•Houses Charger Rocket Work’s (CRW) GPS tracker

•Interfaces with Upper Main Body Tube (shear pins) and Main Parachute (eye bolt/shock chord)


GPS Tracker Subsystem


System • CRW design integrating an XBee Radio and Antenova GPS chip (saves ~$200) • Commercially acquired battery power source • Transmits to a receiver equipped, ground station laptop • Used on previous successful launches; will be fully tested prior to first full scale mission Structure Integration • Locally machined “L” bracket and strap combination secures it to nose cone all thread • Three axis security and battery retention

Coupler Subsection System Requirements

•Houses redundant, independent recovery avionics

•Dual black powder charges per parachute

•Provides 6 inch interface with the Upper and Lower Main Body tubes

•Shock chord connections for the Main and Drogue parachutes

Recovery Avionics Subsystem

•2x PerfectFlite Stratologger SL 100 Altimeters, 2x 9v battery stations, 2x activation switches

•4x Safe Touch terminals, 4x ematches/charges

•Full redundancy in electronics and ignition


Coupler Subsection


Black Powder Housing (4 Places)

Eye Bolt (2 Places)

Black Powder Terminal (4 Places)

All Thread (2 Places)

9 V Battery (2 Places)

Switch/Port Hole (4 Places)

Stratologger SL100 Altimeter (2 Places)

2”

14”

Avionics Mounting Assembly


•3-D printed “Sled”

•3-D Printed switch housings

•Balanced mounting

•Two All Thread rods through bulkheads

•Two eye bolts for shock chords

•Bulkheads protect electronics

Recovery Deployment Avionics


Stratologger SL100 (Primary)

9V

Stratologger SL100 (Secondary)

9V

Primary BP

Charge

Secondary BP Charge

Switch

Switch

Primary BP Charge

Secondary BP Charge

Drogue Parachute Bay Charge Fired at apogee

(5,280 ft)

Avionics Bay Main Parachute Bay Charge Fired at 600 ft

Line of Redundancy

Bulkheads Rocket Nose

*Secondary 130% of primary

Charge Fired 1 sec after apogee

Charge Fired at 550 ft

Lower Airframe

19

Lower Airframe Overview Requirements: • Reach an altitude of approximately one mile

• Maintain an acceptable stability margin of 2 calibers throughout ascent*

• Motor Requirements*

• Accommodate recovery, payload and motor


Fixed Fin (3 Places)

Fin Bracket (3 Places)

Centering Ring

Recovery Retention Assembly

Motor/Motor Casing

Payload* Payload Aft Bulkhead

Drogue/Shock Chord Envelope*

Aft Body Tube

Tail Cone/ Motor Retention

*See Recovery and Payload Section

Fin and Fin Brackets Fixed Fins:

• Primary

• Adjust CP for stability

• G10 Fiberglass Sheet

• Fabricated in house

• Fixed to Fin Bracket with ¼” bolts (4 Places)

Fin Bracket • Allows fins to be replaced easily

• Aluminum for strength and legacy

• Exploring 3D printing option

• Fixed to Airframe with ¼” bolts (8 Places)


Motor Retention-Tail Cone Design: • 3D Printed at UAHuntsville

Machine Shop • Reloadable motor casing • Acts as thrust plate and aft

centering ring

Load Path: • Boost Phase • Motor Case • Tail Cone Lip • Bolt holes • Body Tube

• Coast Phase • Snap Ring retains motor


Lip

Shoulder

Snap Ring

#10-32 Threaded inserts and bolt (3 Places)

Recovery Retention System


• Attaches drogue parachute to rocket body through forward motor closure

• 3.5’’ max diameter

• 3/8’’ aluminum all-thread rod

• Eyebolt fixed to rod with an aluminum coupling nut

• Rod fixed to forward motor closure through thread hole

• Passes through payload in line with the center of the rocket

• Drogue parachute attached to eyebolt

• Designed for easy installation between rocket flights

Aft Bulkhead


• Fixes payload to body

• Recovery retention rod passes through center hole

• 6” diameter

• 0.25” thick polycarbonate

• Fixed to body tube with four screws

• Fixed to payload with four screws

• Exploring option to place bulkhead forward and sharing bolt hole with rail button*

Motor Selection

Aerotech L140R-P • 75 mm diameter

• 10% mas increase requires an Aerotech L220G-18I

• Thrust curve per Open Rocket in Appendix


Flight Simulation


Flight Simulations performed in Open Rocket • Weather data observed for plausible launch date conditions

for flight predictions

• Stability off the rail: 2.18 • No wind conditions applied to this simulation

• 6% Ballast to account for mass creep *CP and CG off the rail

CP = 90.37”

CG = 76.88”

Flight Projection

18.6 sec Apogee, Drogue Deployment

3.3 sec Motor Burnout

74.0 sec Main Deployment (600 ft)

-100

100

300

500

700

900

1100

1300

1500

-1000

0

1000

2000

3000

4000

5000

6000

0 20 40 60 80 100 120

Ve

loci

ty/A

cce

lera

tio

n

Alt

itu

tde

(ft

)

Time(s)

Altitude Vertical Velocity (ft/s) Vertical Aceceleration (ft/s^2)

27

Trajectory Verification


• Hand calculations to verify Open Rocket results

• Thrust curve not available directly from Aerotech • RocketSim thrust curve

interpolated at consistent time steps for more accurate comparison

Stability Analysis


Static Stability Margin (off the rail): • Calculated with no

wind conditions

• 2.18

Static Stability Margin (at burnout) • 3.01

Launch Vehicle Verification and Test Plan


Payload

31

Roll Inducing Contraption (RIC) Overview

Objective To design a system that can mechanically induce/control the angular motion about the roll axis of a rocket, post motor burnout.

Requirements The RIC shall

• determine and monitor roll axis motion during flight • generate sufficient torque about the roll axis to both induce and control angular

motion

Considerations The RIC should

• not generate excessive losses to final rocket apogee • not create undesired precession in yaw or lift that effects rocket orientation

32

RIC Selection Subsystem Component Options

Controller • LabView Compatible

• MyRio, Arduino, etc..

Sensors • 9 DoF IMU, Integrated vs nonintegrated • Altimeter, or Pressure sensor

Controllable Fins • Shape/Sizing/Material Considerations

Servos • Holding torque requirements

Communication Method • Analog, SPI, IC2

Payload Housing • 3D Print, manufactured • Ensure forces generated are distributed properly

33

RIC Research and Theory


RIC Design Payload Sled 1

Servo 2

myRIO 3

IMU 4

Battery 5

Wing Connector 6

Wings 7

End Caps 8

7

8

1

6 2

5

4

3

35

RIC Fin Design

36

C

S

Fin Dimensions • C = 4” • S = 3” • T = 0.5” • Thickness = 0.25”

Attachment point positioned so that fins will return to neutral state with an angle of attack of 0˚ in case of servo power failure.

T

Recovery System

37

Recovery System


Drogue Parachute Deployment: • Deployment at apogee

• Fruity Chute CFC-18 (Cd=1.6)

• Shock Cords: 1 inch Nylon (50 ft)

• Connected between all-thread in lower airframe and avionics bay housing.

Main Parachute Deployment: • Deployment at 600 ft above

ground level

• SkyAngle CERT-3 X-Large (Cd=2.59)

• Shock Cords: 1 inch Nylon (50 ft)

• Connected between nose cone bulkhead and avionics bay housing.

http://fruitychutes.com/ http://SkyAngle_CERT3.llc.homestead.com

Recovery System


Drogue Parachute

Main Chute

Drogue Chute

• Kinetic Energy: 55.9 ft-lbf (more info in appendix) • Maximum landing distance from launch pad: 787 ft • Recovery Connections: Figure 8 knots and Quick-Links

Load Path (Ascending)


Drag & Weight

Thrust

1

2

3

4

5

Represents the force due to thrust.

Represents the force due to mass and drag.

• As is shown in the figure to the left, there are three forces acting on the rocket.

• Thrust is acting in the upward direction while drag and mass act opposite the thrust.

• In ascent, all components are in compression.

Load Path (Drogue and Main)


1

2

3

4

5

Represents the force due to drag from the drogue parachute

Represents the force due to mass of the descending components. 1

2

3

4

5

Drogue Parachute Main Parachute

• The load in 1, 2, and 3 are causing tension under Drogue and Main.

• The load in 4 and 5 is transferred through the all thread and down to the motor casing then back up the body tube.

Safety


CRW Safety Commitment


• The CRW Team believes that training and communication are the key fundamentals to a successful safety program

• The Safety Officer holds a weekly Safety Briefing to keep team members informed and educated on safety topics relevant to that week’s activities

• The CRW team will work together to produce comprehensive hazard and risk analysis and Standard Operating Procedures that will instill good work practices and ensure all mitigation options are verified

Safety Plan


• Hold weekly Safety Briefings with the entire CRW team

• Each sub-team will designate a Safety Representative to work with the Safety Officer • Aid in Hazard and failure mode analysis for their respective sub-section of the

rocket

• A Component Description Sheet will be created for each component used in the rocket • Analyze failure modes

• Track evolution of the component to aid in verification process

• CRW has identified the required success criteria and a method of verification for each (as outlined in the PDR report)

• A Test Plan has been created based on the verification of all identified success criteria (as outlined in the PDR report)

Safety Representatives


Safety Officer

Vivian B.

Payload

Safety Rep Chris B.

Lower

Airframe Rep Jacob E.

Upper

Airframe Rep Harpreet S.

Safety Briefings • Weekly safety briefings focused on material pertinent to project phase

Team Training

• Periodic reviews of test procedures and work place environments


Launch and Assembly Procedures


• The Test Plan and Verification Processes will be used to optimize the final design, assembly, and launch procedures

• Final rocket assembly procedures have been developed to fit the design concept

• Any changes to the design that require updating the assembly or launch procedures will be coordinated through the team safety officer

• Simulated runs of all procedures will take place at least one week prior to any launch

Information on Website For the convenience of all team members, the following items will be located on the CRW team website:

• Material Safety Data Sheets

• Operators Manuals

• CRW Safety Regulations

• Safety Briefing slides

• Standard Operating Procedures

The Safety Officer will work to keep this information relevant and up to date


Educational Engagement


Preliminary Schedule


Event Date Type of Engagemnt Anticipated Number of

Individuals Impacted

UAH Discovery Days October 29th Outreach: Direct Interaction 200

Girl's Science & Engineering Day November 5th Education: Direct Interaction 400

UAH Discovery Days November 19th Outreach: Direct Interaction 200

Society of Women Engineers: First

LEGO League QualifierJan-17 Education: Direct Interaction 250

Science Olympiad Feb-17 Education: Direct Interaction 50

Boys & Girls Club Mar-17 Education: Direct Interaction 25

James Clemens High School Feb-17 Education: Direct Interaction 1250

Bob Jones High School Feb-17 Education: Direct Interaction 1250

UAH Engineering Organization

PresentationsVaries Education: Direct Interaction 100

Additive Manufacturing Program Varies Education: Direct Interaction 25

Total Impacted 3750

Educational Engagement Opportunities Coming Up:


Girl’s Science & Engineering Day • UAH/US ARMY Sponsored Event

• Girls 3rd through 5th grade from Huntsville area

• 400+ Participants

• 10+ CRW Volunteers

• 80 Direct Educational Interactions

UAH Discovery Days • October 29th & November 19th • UAH Sponsored • Prospected UAH engineering students • 100+ students per event • 5 Volunteers for CRW • ~100 Direct Outreach Interactions per

event

CRW at UAH Discovery Days

Project Management


Project Budget Summary


Upper Airframe $1,063.70

Recovery $1,189.00

Lower Airframe $1,902.98

Payload $1,509.90

General $270.96

Upper Airframe $372.04

Lower Airframe $193.76

Payload -

$750.00

$7,252.34

Sub Scale Budget

Miscellaneous, Taxes,& Shipping Charges

Total

Budget Summary

Full Scale Budget

Project Schedule – Fall 2016


Project Schedule – Spring 2017


Questions?


Appendix


Recovery Charge Sizing PV = nRT

P = Target Pressure for ejection 12.5-15 psi

V = Volume

n= mass * (454 g/lbm)

R = Ideal Gas Constant 266 (in-lbf/lbm)

T = Temperature of combustion 3307 Rankine

Using four 40 lb shear pins

Type: 4F


Aerotech L1420R Thrust Curve


-22

28

78

128

178

228

278

328

378

428

70

270

470

670

870

1070

1270

1470

1670

1870

0 0.5 1 1.5 2 2.5 3 3.5

Thru

st (

lbf)

Thru

st (

N)

Time(s)

Fly Sheet


Vehicle Properties Motor Properties

Total Length (in) 119 Motor Designation Aerotech L1420R-P

Diameter (in) 6.17 Max/Average Thrust (lb) 373.23/323.80

Gross Lift Off Weigh (lb) 46 Total Impulse (lbf-s) 1038.17

Airframe Material G12 Fiberglass Mass Before/After Burn 10.1/5.64

Fin Material G10 Fiberglass Liftoff Thrust (lb) 346.4

Coupler Length 14" Motor Retention Tail Cone/Snap Ring

Stability Analysis Ascent Analysis

Center of Pressure (in from nose) 90.374 Maximum Veloxity (ft/s) 628.72 ft/s

Center of Gravity (in from nose) 76.883 Maximum Mach Number 0.57

Static Stability Margin 3.04 Maximum Acceleration (ft/s^2) 1494.7 ft/s^2

Static Stability Margin (off launch rail) 2.18 Target Apogee (From Simulations) 5283.2 ft

Thrust-to-Weight Ratio 6.87 Stable Velocity (ft/s) 59.42 ft/s

Rail Size and Length (in) 1515, 96 in. Distance to Stable Velocity (ft) 96 ft

Rail Exit Velocity 59.42

Fly Sheet cont.


Recovery System Properties Recovery System Properties

Dogue Parachute Main Parachute

Manufacturer/Model Fruity Chutes/CFC-18 Manufacturer/Model SkyAngle/CERT-3 XLarge

Size (ft^2) 1.7 Size (ft^2) 89

Altitude at Deployment (ft) 5280 Altitude at Deployment (ft) 600

Velocity at Deployment (ft/s) 0 Velocity at Deployment (ft/s) 83.4

Terminal Velocity (ft/s) 83.4 Terminal Velocity (ft/s) 12.47

Recovery Harness Material Nylon Recovery Harness Material Nylon

Harness Size/Thickness (in) 1 Harness Size/Thickness (in) 1

Recovery Harness Length (ft) 50 Recovery Harness Length (ft) 50

Harness/Airframe Interfaces

The shock cord that is utilized for the drogue chute has two connection points, one to the

bulkhead under the nose cone and one to the upper end of the avionics bay.

Harness/Airframe Interfaces

The shock cord that is utilized for the main chute has two connection points, one to the lower section of the avionics bay and

one to the all thread which is connected to the motor casing.

Kinetic Enerfy of Each

Section (Ft-lbs)

Upper Airframe

Lower Airframe

N/A N/A Kinetic

Enerfy of Each

Section (Ft-lbs)

Nose Cone Upper

Airframe Lower

Airframe N/A

1173.45 2499.47 10.5 21.07 55.92

Recovery Electronics Recovery Electronics

Altimeter(s)/Timer(s) (Make/Model) PerfectFlite Stratologger SL100

Rocket Locators (Make/Model)

XBee transmitter with Antenova GPS chip

Redundancy Plan Dual, independent system Transmitting Frequencies ***Required by CDR***

Black Powder Mass Drogue Chute (grams) 1.45

Pad Stay Time (Launch Configuration)

Indefinite with pull pin installed, unknown with pin removed (hours)

Black Powder Mass Main Chute (grams) 2.48

Fly Sheet cont.


Payload

Payload 1

Overview

The overall goal of this project is to design a payload system that will mechanically induce and control the angular velocity about the roll axis of a rocket. This is to be done without causing excessive drag or instability due to secondary control surfaces positioned aft of the center of gravity.

Test Plans, Status, and Results

Ejection Charge Tests

Test Plans: Ground Tests to confirm proper ejection and appropriate charge sizing Status: To be conducted post-assembly

Results: N\A

Sub-scale Test Flights

Test Plans: Sub scale vehicle will be flown to verify overall vehicle design, fin design, fin mounting design, and motor size.

Status: To be conducted in November/December Results: N\A

Full-scale Test Flights

Test Plans: Testing critical recovery systems, payload function, and flight simulations Status: To be conducted post-sub scale launch

Results: N\A

Descent Rates and Energies


•Expected descent speed under main parachute is 12.47 ft/s

•Expected descent speed under drogue parachute is 83.4 ft/s

•Kinetic energy of heaviest section (Lower Airframe) at this velocity is 55.9 ft-lbf

•Drift calculations were done with 5 to 20 mph winds in Open Rocket and it was determined that the 5 mph wind speed yields the largest distance from launch with a value of 787 ft.

nasa sl preliminary design reviewchargerrocketworks.files.wordpress.com/...presentation summary...

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