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The University of Toledo

Project Kronos

Critical Design Review

01/12/2018

1 The University of Toledo Rocketry Club | Critical Design Review – Project Kronos

Contents 1. Summary of Critical Design Review ..................................................................................................................... 6

1.1 Team Summary ............................................................................................................................................... 6 1.2 Launch Vehicle Summary ............................................................................................................................... 6

Mass Summary ....................................................................................................................................... 6 Motor Selection ....................................................................................................................................... 6 Recovery Selection ................................................................................................................................. 7

1.3 Milestone Review Flysheet ............................................................................................................................. 8 1.4 Payload Summary ........................................................................................................................................... 9

2 Changes Made Since PDR ................................................................................................................................... 10 2.1 Vehicle Design Changes ............................................................................................................................... 10

Vehicle Changes ................................................................................................................................... 10 Recovery Changes ................................................................................................................................ 10

2.2 Payload Changes ........................................................................................................................................... 10 2.3 Project Plan Changes .................................................................................................................................... 11

Budget Changes .................................................................................................................................... 11 Educational Outreach Changes ............................................................................................................. 11

3 Vehicle Criteria ................................................................................................................................................... 12 3.1 Launch Vehicle Design ................................................................................................................................. 12

Mission Success Criteria ....................................................................................................................... 12 Vehicle Design Overview ..................................................................................................................... 16 Recovery Overview .............................................................................................................................. 18 Fin Design ............................................................................................................................................. 19 Fin Flutter Calculations......................................................................................................................... 19 Fin Mounting & Retention .................................................................................................................... 20 Recovery Bay ........................................................................................................................................ 22 Payload Deployment Bay ..................................................................................................................... 24 Motor Retention .................................................................................................................................... 26

Materials Selection................................................................................................................................ 27 Motor Selection ..................................................................................................................................... 28 Predicted Flight Analysis ...................................................................................................................... 29 Vehicle Mass Adjustment System (VMAS) ......................................................................................... 29

3.2 Subscale Flight Results ................................................................................................................................. 31 Vehicle Design ...................................................................................................................................... 31 Analysis of Flight .................................................................................................................................. 32 Derived Full Scale Predictions .............................................................................................................. 36

3.3 Recovery Subsystem ..................................................................................................................................... 36 Recovery System Overview .................................................................................................................. 36 Recovery Flight Plan............................................................................................................................. 37 Mechanical Recovery Mechanisms ...................................................................................................... 37 Electronics Bay Overview .................................................................................................................... 39

3.4 Mission Performance Predictions ................................................................................................................. 42 Key Flight Events Overview ................................................................................................................. 42 Flight Profile Simulations ..................................................................................................................... 43 Landing Kinetic Energy ........................................................................................................................ 44 Center of Pressure (CP) and Center of Gravity (CG) ........................................................................... 45 Stability Margin .................................................................................................................................... 46 Simulated Drift ..................................................................................................................................... 47 Hand Calculation vs OpenRocket Drift Distance Comparison ............................................................. 51 Motor Performance Predictions ............................................................................................................ 52

4 Safety ................................................................................................................................................................... 52 4.1 Launch Concerns and Operations Procedures ............................................................................................... 52


Safety & Operations Commitment Statement........................................................................................ 52 Procedures & Launch Concerns ........................................................................................................... 52

4.2 Environmental, Personnel and Mission Success FMEA's ............................................................................. 54 Hazard Level Ratings ............................................................................................................................ 54 Environmental Hazards Analysis & Mitigation .................................................................................... 56 Personnel Hazards Analysis & Mitigation ........................................................................................... 57 Mission Success Hazards & Mitigation ................................................................................................ 59

4.3 Failure Modes and Effects Analysis by Subsystem ...................................................................................... 62 Vehicle FMEA ....................................................................................................................................... 62 Recovery Bay FMEA ............................................................................................................................. 63 Propulsion FMEA ................................................................................................................................. 64 Payload Ejection System FMEA ........................................................................................................... 64 Electronics Bay and Rover Electronics FMEA ..................................................................................... 65 Recovery System FMEA ........................................................................................................................ 65

4.4 Personal Protective Equipment (PPE) Requirement Analysis ...................................................................... 66 Overview of Available PPE .................................................................................................................. 66 PPE Compliance ................................................................................................................................... 66

4.5 Compliance with NAR Safety Ordinances ................................................................................................... 66 4.6 Compliance with FAA Safety Ordinances .................................................................................................... 69 4.7 Procedural Compliance ................................................................................................................................. 70

Checklist Hierarchy & Sign-off ............................................................................................................ 70 4.8 Recovery Preparation Checklist .................................................................................................................... 71 4.9 Motor Preparation Checklist ......................................................................................................................... 73 4.10 VMAS Preparation Checklist ........................................................................................................................ 74 4.11 Launch Stand Setup Checklist ...................................................................................................................... 75 4.12 Pre-Flight Troubleshooting Checklist ........................................................................................................... 76 4.13 Post-Flight Inspection Checklist ................................................................................................................... 79 4.14 Post-Flight Vehicle Body Checklist .............................................................................................................. 80 4.15 Post-Flight Payload Mechanics Checklist ..................................................................................................... 81 4.16 Post Flight Electronics Checklist .................................................................................................................. 82

5 Payload Criteria ................................................................................................................................................... 83 5.1 System Overview .......................................................................................................................................... 83 5.2 Rover Design – Mechanical Systems ............................................................................................................ 83

Rover Body Design ............................................................................................................................... 83 Gear Wheel Design ............................................................................................................................... 86 Solar Panel Design ................................................................................................................................ 87 Orientation Independency ..................................................................................................................... 89

5.3 Rover Design – Electrical Systems ............................................................................................................... 90 Payload Electronics ............................................................................................................................... 90 Ground Control Operations ................................................................................................................... 94 Remote Frequency Compliance ............................................................................................................ 98

6 Project Plan .......................................................................................................................................................... 99 6.1 Comprehensive Testing Procedure ............................................................................................................... 99

Rover Deployment & Execution Testing .............................................................................................. 99 CO2 Ejection Testing .......................................................................................................................... 100 Remote Operations Testing ................................................................................................................. 101 Parachute Inflation Testing ................................................................................................................. 101 Static Ground Testing ......................................................................................................................... 102 Sub-Scale Vehicle Design Launch ...................................................................................................... 102 Parachute Shock Force ........................................................................................................................ 102 Full-Scale Vehicle Design Launch ..................................................................................................... 104

6.2 NASA SL Requirement Compliance Matrix .............................................................................................. 104 6.3 Team Derived Requirements ...................................................................................................................... 112


6.4 Educational Outreach .................................................................................................................................. 114 6.5 Budget ......................................................................................................................................................... 115

Changes from PDR to CDR ................................................................................................................ 115 Detailed Budget .................................................................................................................................. 115 Funding Plan ....................................................................................................................................... 118

6.6 Project Timeline .......................................................................................................................................... 119 7 Conclusion ......................................................................................................................................................... 120 8 Appendix A ....................................................................................................................................................... 120

8.1 Miscellaneous Drawings and Reference Material ....................................................................................... 120

Table of Tables Table 1: Vehicle Parameters .......................................................................................................................................6 Table 2: Vehicle Design Changes ............................................................................................................................10 Table 3: Recovery Design Changes .........................................................................................................................10 Table 4: Payload Design Changes ............................................................................................................................10 Table 5: Budget Changes ..........................................................................................................................................11 Table 6: Mission Success Criteria ............................................................................................................................12 Table 7: Pre-Flight Success Criteria .........................................................................................................................14 Table 8: During-Flight Success Criteria ...................................................................................................................15 Table 9: Post-Flight Success Criteria .......................................................................................................................15 Table 10: Key Flight Events Overview ....................................................................................................................42 Table 11: Kinetic Energy for Zero Separation Scenario Mass Distribution .............................................................44 Table 12: Kinetic Energy for Single Separation Scenario – Drogue Deployment Mass Distribution .....................45 Table 13: Kinetic Energy for Dual Separation Scenario – Normal Flight Mass Distribution ..................................45 Table 14: Basic Drift Calculations .............................................................................................................................0 Table 15: OpenRocket Drift Model ............................................................................................................................0 Table 16: Comparison of Hand Calculation and OpenRocket Drift Distances ........................................................51 Table 17: Personal Hazards Rating System Matrix ..................................................................................................54 Table 18: Mission Success Hazards Rating System Matrix .....................................................................................55 Table 19: Environmental Hazard Rating System Matrix .........................................................................................55 Table 20: Risk Magnitude Rating System Matrix ....................................................................................................56 Table 21: Environmental Hazards Analysis and Mitigation Matrix .........................................................................56 Table 22: Pernonnel Hazards Analysis and Mitigation Matrix ................................................................................57 Table 23: Mission Success Hazards and Mitigation Matrix .....................................................................................59 Table 24: Vehicle Subsystem FMEA .......................................................................................................................62 Table 25: Recovery Bay Subsystem FMEA .............................................................................................................63 Table 26: Propulsion Subsystem FMEA ..................................................................................................................64 Table 27: Payload Ejection System FMEA ..............................................................................................................64 Table 28: Electronics Bay and Rover Electronics FMEA ........................................................................................65 Table 29: Recovery System FMEA ..........................................................................................................................65 Table 30: NAR Safety Ordinance Compliance Matrix.............................................................................................66 Table 31: FFA Safety Ordinance Compliance Matrix ..............................................................................................69 Table 32: Rover Deployment & Execution Testing Passing Criteria .......................................................................99 Table 33: CO2 Ejection Testing Passing Criteria ...................................................................................................100 Table 34: Remote Operations Testing Passing Criteria ..........................................................................................101 Table 35: Parachute Inflation Testing Passing Criteria ..........................................................................................101 Table 36: Static Ground Testing Passing Criteria ..................................................................................................102 Table 37: Expected Best and Worst Case Scenario Data .......................................................................................103 Table 38: Expected Steady State Parachute Force .................................................................................................103 Table 39: Expected Max Parachute Force ..............................................................................................................104


Table 40: NASA SL Requirement Compliance Matrix ..........................................................................................104 Table 41: UT Rocketry Team Derived Requirements ............................................................................................112 Table 42: Itemized Team Budget ...........................................................................................................................115 Table 43: Team Funding Plan ................................................................................................................................118

Table of Figures Figure 1: Vehicle Sections ........................................................................................................................................16 Figure 2: Nosecone Depiction ..................................................................................................................................17 Figure 3: Airframe Depiction ...................................................................................................................................17 Figure 4: Forged Eye Bolt Depiction .......................................................................................................................18 Figure 5: Fin Design with Dimensions .....................................................................................................................19 Figure 6: Fin Flutter Calculations .............................................................................................................................20 Figure 7: Fin Mounting Diagram and Mounting Rig ...............................................................................................20 Figure 8: External Fin Fillet Design .........................................................................................................................21 Figure 9: Recovery Bay Sled Layout .......................................................................................................................23 Figure 10: PerfectFlite StrattoLoggerCF Altimeter Layout .....................................................................................23 Figure 11: Payload Ejection Bay CO2 Canister Integration .....................................................................................24 Figure 12: CO2 Ejection Canister Parts ...................................................................................................................25 Figure 13: CO2 Deployment Logic Block Diagram ................................................................................................25 Figure 14: Motor Mount Centering Ring Locations .................................................................................................26 Figure 15: AeroPack Motor Retainer .......................................................................................................................27 Figure 16: Ideal Predicted Flight Path ......................................................................................................................29 Figure 17: Depiction of the Vehicle Mass Adjustment System (VMAS) ................................................................30 Figure 18: Subscale Vehicle Design in OpenRocket ................................................................................................31 Figure 19: Simulated Subscale Altitude Plot ............................................................................................................33 Figure 20: Simulated Subscale Vertical Velocity Plot .............................................................................................33 Figure 21: Subscale Real-World Altitude Plot .........................................................................................................34 Figure 22: Subscale Real-World Vertical Velocity Plot...........................................................................................35 Figure 23: Recovery Flight Events ...........................................................................................................................37 Figure 24: SkyAngle Cert 3 Large 80 Depiction ......................................................................................................38 Figure 25: Electronics Bay Wiring Schematic .........................................................................................................41 Figure 26: Kronos Simulated Ideal Flight Profile ....................................................................................................43 Figure 27: CP & CG Representation without Motor ................................................................................................46 Figure 28: CP & CG Representation with Motor .....................................................................................................46 Figure 29: Dynamic Stability Margin Plot ...............................................................................................................47 Figure 30: K1000T-P 0 mph Drift Distance .............................................................................................................48 Figure 31: K1000T-P 5 mph Drift Distance .............................................................................................................48 Figure 32: K1000T-P 10 mph Drift Distance ...........................................................................................................49 Figure 33: K1000T-P 15 mph Drift Distance ...........................................................................................................50 Figure 34: K1000T-P 20 mph Drift Distance ...........................................................................................................51 Figure 35: Rover Integration Into Payload Bay ........................................................................................................84 Figure 36: Rover Base Dimensional Diagram ..........................................................................................................85 Figure 37: Gear Wheel Representation ....................................................................................................................86 Figure 38: McMaster-Carr Gear Diagram ................................................................................................................86 Figure 39: Rover Design with Deployed Solar Panels .............................................................................................87 Figure 40: Main Board Schematic ............................................................................................................................91 Figure 41: Rover Circuit Board – Front View ..........................................................................................................92 Figure 42: Rover Circuit Board – Back View ..........................................................................................................92 Figure 43: Ground Station Circuit Board – Front and Back .....................................................................................92 Figure 44: Ground Station Schematic ......................................................................................................................93 Figure 45: Command Station Logic Block Diagram ................................................................................................94 Figure 46: Antenna Simulation 1 Meter above Ground and in Free Space ..............................................................95


Figure 47: Smith Chart for Yagi-Uda Antenna ........................................................................................................96 Figure 48: Yagi-Uda Antenna Drawing ...................................................................................................................97 Figure 49: Project Timeline ....................................................................................................................................119


1. Summary of Critical Design Review

1.1 Team Summary

School Name: The University of Toledo

Location: 2801 West Bancroft Street

M.S. 105

Toledo, OH 43606

School Organization: The University of Toledo Rocketry Club

Project Title: Project Kronos

Important Personnel:

Team Mentor: Team Leader: Safety Officer:

Art Upton

[email protected]

(419) 290 - 8976

NAR# 26255 (L3 Certified)

Nathan Riethman

[email protected]

(937) 710 - 5213

NAR# 95938 (L1 Certified)

Victoria Raber

[email protected]

(419) 260 - 9235

1.2 Launch Vehicle Summary

Mass Summary

Throughout the design process, various CAE tools such as OpenRocket, SimScale, and Excel calculators were

utilized to develop a viable vehicle design. An overview of the design is provided below in Table 1.

Table 1: Vehicle Parameters

Length (in.) 87

Diameter (in.) 5

W/ Motor & W/O Motor Mass (lbs.) 25 / 19.3

Rail Size (in.) 1.5 x 96 (1515 Buttons)

Motor Selection AeroTech K1000T-P

Drogue/Main Recovery Parachutes (in.) 32 / 80

A length of 87in. was determined to be adequate in providing room for all sub-systems within the rocket. The

diameter of 5 in. was determined to provide enough room for the payload to be properly sized, stored, and

deployed. The diameter is also sufficient for the payload ejection system to be properly implemented and for all

recovery material to be properly stored and ejected.

Motor Selection

The motor, a solid-state AeroTech K1000T-P, was chosen from OpenRocket Simulations and determined that the

projected altitude is 5243ft. Though this is below the required height, it allows the rocket to stay below the

maximum allotted altitude of 5600ft for a possible 10% motor over performance. The motor meets all NAR,

TRA, and CAR specifications and does not expel medal shards. The K1000 has an expected impulse of 2,497 N•s

and an average thrust of 1,012N. The motor is 396mm long and 75mm in diameter. An expected maximum

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velocity of 647 ft/sec (0.575 Mach) will be reached after a 2.47 sec burn time. The team will use an 8-foot 1515

launch rail as an expected exit rail velocity of 68.1 ft/sec is achieved. This is above the minimum of 52 ft/sec. The

rocket will have a thrust-to-weight ratio of 9:1 which is above the minimum required ratio of 5:1.

Recovery Selection

The recovery is based upon three main sections: Drogue Parachute Section, Main Parachute Section, and the

Recovery Bay Section. The sections will be held together using forged eye bolts and quick links with the braided

nylon shock cord attaching the recovery bay to the main parachute section and the drogue chute section. A non-

slip knot will be used and epoxied in order to prevent slippage. The portions which will be separating will be

secured to the body using shear pins. The recovery bay will have two ejection charges which will separate the

main parachute bay and the drogue chute bay. One charge is the main ejection charge and the second charge will

act as a redundancy charge.


1.3 Milestone Review Flysheet


1.4 Payload Summary

The payload that was selected was the Deployable Rover. The current design is comprised of a gear wheeled

rover that will deploy from a dedicated payload bay. The rover will be deployed via a CO2 canister system and

geared wheels which will drive the rover out on a track. The rover will then travel 5-feet and deploy solar panels.

The team will receive remote information about the distance traveled and the power generated from the solar

panels.


Each of the geared wheels will be powered by an independent servo that will provide the torque and power

necessary to pull the rover along the gear rack that is located inside the rover. An independent battery will power

the system upon remote activation from the ground station. This battery will also be able to be recharged from the

solar panels that are being deployed.

2 Changes Made Since PDR

2.1 Vehicle Design Changes

Vehicle Changes

The following changes have been made to the vehicle since the Preliminary Design Review (PDR).

Table 2: Vehicle Design Changes

No. Change Justification

1 Lowered Predicted Payload Mass Upon further review of needed materials and sizing, the

mass could be lowered decreasing the total mass of the

vehicle.

2 Selected Final Fin Design From the proposed design alternatives, a final fin design that

improves stability and overall flight was chosen.

3 Selected Final Payload Deployment

Method

After reviewing design alternatives, an ejection system has

been selected that will provide a safe and reliable ejection of

the Payload Bay.

Recovery Changes

The following changes have been made to the recovery since the Preliminary Design Review (PDR).

Table 3: Recovery Design Changes


1 Finalized Drogue Parachute Size The Drogue Parachute Size was finalized at 32 inches in

Diameter in order to slow the rocket more before Main

Parachute Ejection and to provide a lower kinetic energy.

2.2 Payload Changes

The following changes have been made to the recovery since the Preliminary Design Review (PDR).

Table 4: Payload Design Changes


1 Changed Solar Panel Deployment

Method

To comply with NASA SL criteria for "Deployable Solar

Panel" the methodology for how the panel is to deploy have

been changed.


2.3 Project Plan Changes

Budget Changes

There have been many changes to the budget since the PDR. The main area that had significant changes made was

the electronics section, though the team also saw changes made in the following sections as well: recovery, body

hardware, and travel. The changes made in the electronics portion of the budget were due to needing to add a lot

of material so that the team would have everything necessary to properly construct all of the electronics items,

increasing the electronics section from needing to spend $30.79 to now needing to purchase $110.51 worth of

items. The changes in recovery and body hardware are smaller though. The portion of the budget for recovery will

increase from needing to spend $397.13 to purchasing $421.55 worth of materials. The body hardware budget

increases from $613.62 to spending $629.72. Finally, the last changes made to the budget for the team is for

travel. The team was unable to acquire hotel room reservations in the hotel the team had anticipated, causing the

budget to increase from spending $1,912.08 to spending $2,358.63 on travel.

Table 5: Budget Changes


1 Expanded the required materials in the

Electronics Portion of the Budget

This change was made in order to better represent the items

that the team will be purchasing. This will help the team

keep more accurate and reliable records.

2 Expanded the required materials in the

Recovery Hardware portion of the

Budget

This change will more accurately represent the needed

materials and the associated costs that will be incurred.

Educational Outreach Changes

Two events were added from the PDR to the CDR which were the engineering design competition and a Boy

Scout banquet. The University of Toledo hosted an engineering competition for high schools in the Toledo area.

In teams of four they built stomp rockets out of paper, paper clips, mail labels, and tin foil. They then launched

the rockets off of a launcher made of PVC. They stomped on a water bottle they were given. Their score was the

product of the distance and the mass of the rocket. The team staffed the event doing jobs such as recording the

distance and weight of each rocket. The event allowed the team to educate 160 youth.

The Boy Scout banquet was the Marnoc Lodge 2017 Winter Banquet. Marnoc Lodge is the local lodge for the

Akron area section of the Order of the Arrow. The Order of the Arrow is the National Honor Society of the Boy

Scouts of America. A team member brought last year’s competition rocket and talked about High Powered

Rocketry. The scouts got to build rockets out of paper and tape. The scouts were really impressed with the team

because in scouts the rockets they launch use A-B engines and are about one feet tall. The event allowed the

team to educate 210 youth and 20 adults.


3 Vehicle Criteria

3.1 Launch Vehicle Design

Mission Success Criteria

In order to maintain a safe, successful flight, certain criteria, pre-flight, in-flight, and post-flight, must be met for

the launch to be considered a success. Beginning with pre-flight operations, all pre-flight checklists must be

successfully completed and all team leads must certify that their respective system has been properly prepared and

is flight ready. No damage that may induce a failure or assist in inducing a failure will be allowed unless the

damage has been adequately repaired. A successful loading of the launch pad will also be a pre-requisite to a

mission success.

Once the rocket has successfully passed all pre-flight checks and is loaded, the in-flight criteria will then be

checked. A successful motor ignition, a flight trajectory that is in accordance with the pre-planned path, a

successful deployment of both the drogue and main parachutes at their specified altitudes, and a safe landing are

all to be checked and verified during the flight. A system failure during the in-flight launch could lead to

catastrophic results, leading all prerequisite tasks to be more than adequately fulfilled in order to ensure a safe

flight.

Once on the ground, communication with the rover must be established in order to safely trigger the remote

payload ejection system and to initiate the rover. The rover must successfully leave the body, travel the minimum

distance of 5 feet, and deploy its solar panels. Once the solar panels have been deployed, the team will look to

receive data from the panels indicating a successful panel deployment and operation of the solar panels.

Finally, when the vehicle and rover are retrieved, all systems will receive a thorough look over to find any

damage, such as structural, cosmetic, or fatigue. If any damage is found it will be assessed and a corrective action

plan will be developed and implemented before a successive flight can occur.

After all of the above criteria has been met, the flight may be deemed a success. The above criteria is only a brief

overview of the entire system of flying a rocket. Each individual team will contribute to the overall success of the

rocket by successfully completing the tasks assigned and ensuring that each system is ready to perform as

intended.

Table 6: Mission Success Criteria

Requirement How the requirement will be fulfilled How to verify that the requirement is fulfilled

All subsystems must be accurately represented in simulations.

Simulations and tests in OpenRocket will use all known variables. The variables tested will be the same variables interacting with the rocket.

All masses and dimensions of components will be measured once the components are obtained, then they must match the OpenRocket model.


The rocket must assemble in a way that allows all subsystems to work as planned.

The distances from each component will be measured so that the components may be secured in the correct location.

After each component is installed and secured, it will be re-measured.

Minimize chances of system failure wherever possible.

Will have a minimum of two qualified team members attach each component after being briefed on the correct procedure beforehand.

Have the vehicle team leader confirm each part has been properly attached.

Maintain a straight flight path.

Properly attach the fins to the rocket body using a jig.

Measure the angle between each fin and use a level to make sure the fins are straight.

Properly attach the rocket to the launch pad.

Will follow all the steps on the setup launcher's checklist.

All the items on the setup launcher's checklist will be met and checked off.

Properly attach the igniter.

Will follow all the steps on the ignition installation check list.

All the items on the ignition installation check list will be met and checked off.

Motor must ignite safely.

Will measure and re-measure all of the mounts of the motor.

All the items on the motor preparation check list will be met and checked off.

The recovery system must properly release.

Will ensure switches are on the proper setting, has new batteries, and wires are attached to the proper terminals.

Will construct and complete the check list for the preflight recovery system.

Parachute must decrease the rocket to a safe landing velocity.

Will ensure the parachute and shock cords are properly attached to the rocket.

Will construct and complete the check list for recovery system assembly.

The rocket must be able to fly after refueling.

Will ensure the parachute properly deploys and be of the proper size to slow down the rocket to a safe velocity.

Will perform the proper calculations, double check the assembly of the recovery system, and a create a


working sub scale model.

Fins must stay attached and undamaged after landing.

Will add more epoxy than the minimum required quantity and use proper fin design.

Calculate the force experienced at landing and compare to the strength of the fin design.

Payload must remain stationary during the flight.

Will interlock the payload wheels to the inside of the body tube.

Construct and complete a check list for payload and body tube assembly.

Payload must properly deploy.

CO2 opening up the rocket nose cone to enable the payload to deploy.

Create and complete a check list for nose cone assembly.

Table 7: Pre-Flight Success Criteria


All systems will be in good, operational order

Team Leads will review their respective systems for damage.

A pre-flight checklist will be observed and followed.

The vehicle will show no signs of structural damage

Ensuring proper care of the rocket during transportation and after launch.

Proper padding will be used during transport and post flight damage inspections will be carried out.

All systems will be properly prepared for launch

All team leads ensuring that their respective systems are prepared for launch.

Each team lead will sign off after verifying their system is prepared for launch.

All team leads will ensure their sub-system is properly prepared and installed into the rocket

All team leads will verify that their respective system is prepared for launch

Each team lead will sign off after verifying their system is prepared for launch.

The recovery system will be properly prepared and armed

Team confirms all black power charges are prepared and parachutes are properly secured.

Recovery team double checks all charges and parachute for holes and tares that would compromise the safety of the launch.

Any means of body tube retention (shear pins, screws, etc) will be installed before flight

Team double checking all shear pins and screws before the launch begins

A preflight check of sheer pins and tightening of screws.


The rocket will be properly positioned on the launch stand

Teams ensure the stand is in the desired position for launch. Taking into account wind and terrain account.

The teams calculate for wind and check the stand to make sure it is not pointed at an angle.

The rocket will be prepped and armed for the minimum duration specified in the NASA SL Handbook

The payload and recovery system will be designed in accordance to the NASA SL guidelines

The required sub systems will be tested for compliance with the guidelines prior to launch.

Proper motor preparation and installation will be followed

Instructions that are provided with the motor will be followed and the motor will be securely installed with the proper motor retention method.

The propulsion team will ensure that all steps are followed and the team lead will sign off on all procedures.

Table 8: During-Flight Success Criteria


Rocket successfully leave launch stand

The safely and successfully achieves lift The rocket is safely flying in the sky.

Altimeters record altitude data

The electronics bay will be properly armed and prepared.

Altimeters are in the proper standby mode before the launch.

Payload systems deploy at specified times

The rover leaves the rocket once it reaches the ground.

After landing the rover roles 5 feet from the rocket and deploy solar panels.

Drogue chute deploys at apogee

The electronics bay will be properly prepared and the blast charges will be properly sized and prepped.

The recovery team will prepare the blast charges and electronics bay in accordance to pre-tested configurations.

Main chute deploys at 700ft

The electronics bay will be properly prepared and the blast charges will be properly sized and prepped.

The recovery team will prepare the blast charges and electronics bay in accordance to pre-tested configurations.

The rocket successfully lands without damage

During launch and recovery, the rocket stays in one piece and lands without external of internal damage.

There is no damage to the body tubes, payload, fins or electronics bay.

Table 9: Post-Flight Success Criteria


The rover successfully deployed and data is sent

The panels on the rover are deployed and a signal is sent

The data is showing up at the ground station and


back to the ground receiver

Back. Being recorded.

The rocket is recovered with no critical damage Incurred.

All prior flight preparation procedures are followed

The team leader will Verify all flight preparation lists are completed satisfactory

All material is recovered from the launch field

The rocket will land as intended and will not separate in an excessive manner

All parts are returned to The launch preparation site

Altimeters and energetic systems are Properly Disarmed after obtaining relevant data

Qualified members who fully understand these energetic systems will disarm and confirm with the team lead

The team lead will confirm that the systems have been properly disarmed

Vehicle Design Overview

The vehicle will be constructed primarily of fiberglass, aluminum, and plastic. Below in Figure 1 is an overview

of where each section is located within the rocket. This is divided into 7 sections: Nosecone, Payload Bay,

Payload Ejection Bay, Main Parachute Bay, Electronics Bay, Drogue Parachute Bay, and the Lower Body

Assembly.

Figure 1: Vehicle Sections

3.1.2.1 Selection Rationale

The design chosen is intended to keep safety and performance at the forefront of attention. The materials chosen

were selected due to their high strength to weight ratio and their ability to withstand high powered flight while

safely maintaining the ability to carry and deploy the rover payload.

Any metal used in the rocket was used sparingly and only in cases of increased strength. In all other cases, either a

larger quantity of material was used or another non-metal material was chosen.

The materials chosen come from a combination of experience within the field of rocketry and analysis by formal

calculations and FEA simulations. The results of these simulations were then used to develop and continue to

improve upon the vehicle. Simulations were also utilized in order to verify the material selection in some cases

where only experience was used in the selection.

Payload Ejection Bay


3.1.2.2 Nosecone Selection

The nosecone that will be utilized will be a 4:1 Ogive style nosecone. The nosecone will have a base diameter of

5 inches and a length of 20 inches. The selected material will be an aluminum tipped, fiberglass nosecone. This

nosecone was selected on the basis of both performance and strength. The 4:1 ratio keeps the nosecone at an

appropriate length while the fiberglass allows for a sufficiently strong and durable nosecone. The nosecone will

connect to the Payload Bay and be secured using screws. See Figure 2 for a representation of the nosecone that

will be used.

Figure 2: Nosecone Depiction

3.1.2.3 Airframe Selection

The rocket will be using G12 Wound Fiberglass tubing for the primary body design. The total length of the tubing

used is 67 inches. The tubing will have an outer diameter of 5 inches and a thickness of 0.079 inches. The tubing

used will be purchased from a trusted and reputable supplier in order to lower the risk of poor quality tubing being

supplied. See Figure 3 for a depiction of the body tubing.

Figure 3: Airframe Depiction

The final design of the rocket will utilize a single diameter of airframe, in comparison to the transitioned design

that was stated as a design alternative in the PDR. Having a streamlined, single diameter design allowed for the


rocket to take on a streamlined and simplified form as a transition is no longer required. This simplified form also

allowed for the simulation to become more accurate as the flight simulation software used, OpenRocket, must

generalize the rocket as a single diameter. Along with a better simulation, the overall aerodynamics of the rocket

improved by having a streamlined design by allowing a solid, uninterrupted fluid flow across the body. This will

improve the stability and reliability of the rocket.

Recovery Overview

Recovery is based on three key components: Parachutes, Shock Cords, and the Recovery Bay. Each plays a

critical role in securing the rocket and ensuring that a safe and effective recovery system is developed. Each of

these pieces is implemented in order to separate and hold together each of the three separating portions of the

rocket. Each section will be separated via ejection charges in the Electronics bay and will be tethered together

using tubular nylon shock cord. Parachutes will then deploy to slow the descent velocity of the rocket. More detail

about each system will be described in the sections below.

3.1.3.1 Recovery Retention

In order to properly secure the recovery system, items such as Quick Links, Welded Eye Bolts, and Bulkheads are

being utilized. All of the stated items are industry standard and are known to perform well and reliably. This has

been seen in previous year’s launches and in numerous documentations.

Welded Eye Bolts will be utilized to secure the shock cord to the body of the rocket. The eye bolts that will be

used are 3/8" Welded Steel Eye Bolts. At each point, the eye bolt, shown in Figure 4, will interface with either the

center of a bulk plate or in the side of a centering ring. The bolt will be secured using two washers and a nut that

will be sufficiently torqued. The nut and the washer will then be epoxied in order to secure the two in place.

Attached to these will be the quick links.

Figure 4: Forged Eye Bolt Depiction

The quick links that will be used are 1/4" steel quick links. The shock cord will be attached to the quick links via a

slip knot and epoxied to prevent slippage of the knot. This attachment of the shock cord is to allow easy removal

of the cord in case of repairs or modifications while still providing a reliable and safe method of retention. The

quick links will also provide a point for the parachutes to connect and, like the shock cord, will provide easy

access in the case of repair or replacement.


The highest forces that are expected are during parachute inflation and the resulting shock force that ensues. This

force will put substantial strain and shear stress on not only the bulk plates and centering rings but also on the

shock cord and the quick links that secure the cord to the body. These forces lead to the need of a more robust

design for critical components. For these components, a stronger material, coupled with a larger or more well-

built design will need to be used. The expected Parachute Shock Force has been described below in Section 6.1.7.

Fin Design

The fin design that will be used was determined from one of the design alternatives that was laid out in the PDR.

This design alternative allowed for the vehicle to have an acceptable margin of stability while proving to be able

to handle the stresses of high powered flight. The design and dimensions are shown below in Figure 5.

Figure 5: Fin Design with Dimensions

Fin Flutter Calculations

Fin flutter for the above fin design was calculated using a Fin Flutter Calculator that was designed in Excel. The

following items were required in order to determine the fin flutter at which point the fins would break. These

items include fin dimensions such as the Root Chord, Tip Chord and Semi Span, the altitude at which the rocket

reaches its maximum velocity, the thickness of the fins, and the shear modulus of the fiberglass used in the fins.

Upon analyzing the design, it was found that the fins are able to handle up to 1428 ft/sec or 1.293 Mach as a

maximum velocity. See Figure 6 for more detail. This is much less than the expected maximum velocity of 647

ft/sec or 0.575 mach. With the maximum speed being over double the expected maximum velocity, the team can

easily assume that the fin design will be able to handle the expected forces during the launch without experiencing

the breaking forces that fin flutter can create.


Figure 6: Fin Flutter Calculations

Fin Mounting & Retention

In order to ensure a secure mounting of the fins, a through-the-wall mounting approach will be used. This will not

only provide a better means for attaching the fins to the rocket but will also allow for the stresses during flight to

be better distributed and absorbed by the body, lessening the impact on the fin itself. In Figure 7, fin tabs will be

utilized in order to secure the fins to the motor tube, allowing for another point of glue contact and fillets to be

formed.

Figure 7: Fin Mounting Diagram and Mounting Rig

Another procedure that will be used is filleting both the inside and outside of the fins. A 3/8" fillet or greater is

desired and will provide as a redundant measure for securing the fins to the vehicle. This will not only help ensure

a well-formed fit, but also assist in distributing any shear forces experienced by the fin into the body of the rocket.

This will be beneficial during landing in preventing damage to the fins. In Figure 8, the proposed external fillet

design is shown.


Figure 8: External Fin Fillet Design

3.1.6.1 Material Selection

Fiberglass will be used as the material of choice for constructing the fins. Each of the fins will be made of 0.187-

inch-thick G12 Fiberglass. Fiberglass was chosen for the overall safety and strength that was provided given its

relative price and machinability. Fiberglass is also able to handle the expected fin flutter and shear forces that

come with high powered rocketry. These forces were calculated in Section 3.1.5 and it was found that the material

was more than capable of handling the expected forces during flight.

3.1.6.2 Fin Shape & Modifications

The final fin design selected was Fin Design #1 from the PDR. Upon inspecting the other options, this design lent

the best form, and machinability while still providing an above adequate stability margin for the rocket.

Modifications are planned to be made to the base fin design. These include the addition of a chamfer to the

leading edge, outboard edge, and trailing edge of the fin, and the addition of fillets once they are secured to the

rocket.

3.1.6.3 Mounting Methodology

The team will be using Through the Wall Construction to mount the fins to the main body tube, with both internal

and external fillets around the insertion. Through the Wall Construction is more effective than other mounting

options, mainly due to the several reassurances it offers. Firstly, with Through the Wall mounting, it becomes

impossible for the fin to bend without the body tube itself also bending, which is highly unlikely. Also, Through

the Wall mounting guarantees, as long as the slot is straight, that the fin will be seated in a straighter position on

the rocket, rather than the inaccuracies offered by other methods, such as solely securing the fin to the outside of

the rocket.


The fins will be mounted by first cutting slots into the airframe where the fins are to be mounted. These slots will

be the same thickness as the fin thickness. Aeropoxy will then be placed on the motor mount tube where the fin

will be connecting. The fin will initially be tacked to the epoxy until the epoxy sets. As the epoxy is setting, a fin

template will be holding the fin in place in order to ensure the fins are placed perpendicular to the airframe body.

Once the initial tacking epoxy has set, the process will be completed 3 more times to complete the 4-fin set. After

all 4 fins have been set, the internal meeting points will be filleted one at a time, allowing each to dry before

moving to the next set. After all internal fillets are set, the external fillets will be completed. Painters tape will be

placed around the maximum fillet width on the airframe to limit the amount of excess epoxy that will be on the

vehicle body. This will assist in developing a nicer finish. Again, each fillet must be fully set before moving to the

next fillet.

Recovery Bay

The Recovery Bay, or E-Bay, is the heart of the recovery system, dictating when ejection charges are to go off

and recording flight characteristics such as altitude, velocity, and acceleration. This portion will be located

between the two parachute bays.

The E-Bay will be made from a tube coupler that is designed to fit into the inner diameter of the main airframe. It

will contain two stepped bulkheads that will form a seal on either end of the coupler and be secured using two

threaded rods that will run through the length of the tube. The rods will be tightened using a washer and a nut on

both ends. On the outside of the tube coupler, a 1-inch portion of airframe will be secured in order to house the

arming switch. A hole will also be drilled in this section to allow for air pressure adjustment for the altimeters.

Inside of the E-Bay, the threaded rods will support the Electronics Sled. On the sled, two Stratologger CF

altimeters will be present. One will be the primary altimeter and the second being a redundant altimeter. These

will be powered using two 9V batteries. These batteries will be secured to the sled using two zip-ties per battery.

Figure 9 below illustrates the layout for the recovery sled.


Figure 9: Recovery Bay Sled Layout

On the outside of each of the stepped bulkheads, a forged eyebolt will be secured. This will attach the shock cord

and parachute to the E-Bay with a quick link. This will also help transmit much of the shock force that is

experienced during ejection through the E-Bay. The outside of the bulkhead will also have two blasting caps and

two 4 to 4 terminal blocks. The blasting caps and the terminal blocks will be connected via the schematic below.

Figure 10: PerfectFlite StrattoLoggerCF Altimeter Layout


Payload Deployment Bay

The Payload Deployment Bay will be constructed from G12 Filament Wound Fiberglass airframe coupler with an

outer diameter equal to the inner diameter of the airframe. This portion will house the CO2 deployment system

and the mass management ballast system. This coupler will be attached to the Payload Bay with four screws. The

coupler assembly will be constructed in a comparable manner to the recovery bay, allowing access to the CO2

canister and the Vehicle Mass Adjustment System. The coupler will have two removable bulkheads that will be

retained and tensioned with steel rods that will run through the length of the coupler and be secured on the ends

with a nut on each rod. There will also be a forged eye bolt on the bulkhead that mates into the Main Parachute

Bay. This will allow the shock cord to attach via a quick link. The CO2 deployment system is described below in

Section 3.1.8.1. The below image, Figure 11, illustrates how the CO2 canister will be integrated into the Payload

Deployment Bay.

Figure 11: Payload Ejection Bay CO2 Canister Integration

The Payload Deployment System will be attached to the Payload Bay and the Main Parachute Bay via 4 screws in

each section. These screws will allow the bay to be removable from the rocket while still allowing sufficient

strength and rigidity during flight.

3.1.8.1 CO2 Deployment System

In order to allow the Rover to deploy from the rocket, the nosecone will be ejected using CO2. The canister will

be a Peregrine 8g canister manufactured by Tinder Rocketry, shown in Figure 12 below. The canister will be

located in a coupler at the rear of the payload bay where the "Mount and Cap" will mate with the bulkhead. A turn

switch will be accessible to the exterior of the rocket which will serve as the arming switch for the ejection

system. The rover will receive the signal to deploy the rocket, activating the e-match to ignite a small black

powder charge which will propel the canister into a pin to puncture the throat of the canister. The pressure caused

by the CO2 release will eject the nose cone from the payload and ensure that it lands safely out of the path of the

rover for deployment.


Figure 12: CO2 Ejection Canister Parts

The amount of CO2 that is needed for the system was sized by using information provided on the manufacturer's

website. The manufacturer states that "whatever the quantity of Black Powder that you have used in your rocket,

measured in grams, multiply that by 5 to get the equivalent grams of CO2 needed for the same deployment

pressure". From this methodology, it was calculated that a minimum of 1.5g of black powder would be needed to

shear 4x 2-56 shear pins. From this, it can be determined that a 7.5g canister would be needed to equate the same

charge. Thus, from available supplies, an 8g canister will be needed to shear the 4 shear pins that are securing the

nosecone.

Figure 13: CO2 Deployment Logic Block Diagram


Motor Retention

In order to secure the K1000 Motor during flight, two main methods will be used to ensure proper retention. The

two methods are the Motor mount and the motor retainer which are described in the sections below.

3.1.9.1 Motor Mount

The motor mount will be made from 75mm diameter G12 Fiberglass tubing and will have a length of 16 inches.

The tube will be supported in three places by fiberglass centering rinds. Each of these rings will assist in

supporting and centering the rocket. Figure 14 illustrates the location of each of these centering rings.

Figure 14: Motor Mount Centering Ring Locations

The motor mount will be constructed outside of the rocket and periodically test fit in order to ensure a proper fit.

During construction, each centering ring will be tacked to the motor mount tube to initially set all of the rings in

place. Once all are in place, each ring will receive a fillet on both sides of the mating edge. This will ensure the

fillets are properly secured and are able to withstand the forces of high powered flight. Once the fillets have been

formed, the mount will be epoxied in place. Then, the outer mating edges, which connect to the airframe, will

receive a fillet as well.

On the fore centering ring, a forged eye bolt will be added in order to secure the shock cord with a quick link. The

eye bolt will be placed in the center of the centering ring edge and secured using two washers and a nut. The nut

will also be epoxied to prevent slippage. This will be performed before the motor mount is epoxied to the

airframe.

3.1.9.2 Motor Retainer

The motor retainer that will be used is an AeroPack motor retainer. This retainer works on the principle of screw

compression and will allow the team to be able to securely compress the motor casing into the motor mount. This

motor retainer is an aluminum design, leading the retainer to be able to withstand the heat of the motor exhaust.


All materials around the motor exhaust are also non-combustible under normal flight circumstances and will

either melt or break apart before a fire can happen. The retainer will be secured to the body using epoxy and

screws provided with the retainer. Figure 15 shows the motor retainer that will be used in the vehicle.

Figure 15: AeroPack Motor Retainer

Materials Selection

The vehicle is comprised mostly of G12 wound fiberglass, which makes up the body tubes, couplers, nosecone,

and the fins. G12 fiberglass was chosen over other types of fiberglass because G12 fiberglass parts are massed

produced which brings down their price. The reason why G12 fiberglass was chosen over phenolic tubing is

because fiberglass has a greater strength to weight ratio than phenolic tubing. Even though G12 fiberglass parts

are more expensive than phenolic tubing parts, a lighter rocket means a less powerful motor is required, which

will lower the cost of the rocket. In addition, the fiberglass is less susceptible to dents if it is bumped or dropped

in transport. Another reason why phenolic tubing was not used was because it runs the risk of becoming deformed

if it gets wet even if it is painted. While carbon fiber has a greater strength to weight ratio than G12 fiberglass, the

increase price of carbon fiber parts is more than the amount of money that would be saved by switching to a less

powerful motor. In addition, the University of Toledo rocketry club has experience working with G12 fiberglass,

but does not have experience working with carbon fiber.

The vehicle uses steel for structural support and as a ballista weight in the forms of washers, nuts, forge eye bolts,

and threaded rods. The use of steel was minimized in order to decrease the shrapnel in the case of an explosion.

Even though the introduction of steel creates a potential hazard, the increase in structural support of the rocket

will result in a safer launch. By increasing structural support of the rocket, the risk of a part breaking off is

reduced. In addition, the introduction of a ballista weight will increase the stability margin which will reduce the

risk of the rocket flying off course. The reason for the increase in the stability margin is the shifting of the center

of gravity upwards which increases the distance between it and the center of pressure.

The vehicle uses plywood to create the sled in the recovery bay. The sled only has to hold the components of the

recovery bay; therefore, a cheaper material could be used even if it is weaker. While the University of Toledo


rocketry club would usually apply weather resist coat to any wooden part, it is not necessary this time since the

sled will stay inside the rocket at all times. In addition, constructing the sled out of plywood will save time

allowing more time to be spent on other parts of the rocket.

The vehicle uses Kevlar for the blast shield and for the shock cord of the drogue parachute, since Kevlar can

withstand a large amount stress. Even though Kevlar is more expensive than the other material, it is much safer

which is a top concern. In addition to Kevlar’s high tension breaking strength, knots tied with Kevlar are less

likely to come undone than most other rope materials, since Kevlar fibers grip to each other and have a high

coefficient of friction.

The vehicle uses nylon for both the recovery system and the payload bay. Both the main and drogue parachute

will be comprised of nylon and will be woven in a rip-stop pattern to minimize the risk of the parachutes

malfunctioning. In addition, nylon fabric can be easily folded to fit in the rocket, but still open up and expand

quickly. Nylon was chosen for the gears and gear rack of the rover because nylon is durable enough for multiple

deployments, is lightweight, and easily available. Wood was considered but was not chosen since it chips much

easier, which could lead to the rover dislodging from the track. Steel wheels were also considered but was not

chosen since the increased weight would result in an increase in rotational inertia. With the terrain of the launch in

mind, it was decided that the increase in rotational inertia is too risky because it would hinder the rover’s ability to

get out of low patches. Nylon shear pins are used to connect the nose cone to the body tube, because nylon shear

pins are strong enough to hold the rocket together during the flight but weak enough to break when the CO2

canister fires.

Motor Selection

The motor utilized to power the rocket will be an Aerotech K1000T-P. This motor was chosen after careful

selection from simulations ran using OpenRocket. The process utilized in this selection was based on the success

of the flight and most importantly safety. The Aerotech K1000T-P also meets all requirements and standards set

by NASA and UT Rocketry.

The Aerotech K1000T-P is a solid-state class K motor approved by NAR, TRA, and CAR. The motor is 396 mm

in length and 75 mm in diameter which is within tolerance of the vehicle design. This motor will add a weight of

90.8 ounces to the tail of the rocket increasing stability. For safety consideration and NASA requirements, this

motor does not expel metal shards. The simulations in OpenRocket show that the Aerotech K1000T-P will have a

thrust-to-weight (TTW) ratio of 9:1 which exceeds the 5:1 TTW ratio set by NASA. There will be an impulse of

2,497 N*s and an average thrust of 1,012 N with a max thrust of 1,140 N. With the total weight and design of the

rocket along with burn time of 2.47 seconds being considered, a maximum altitude that will be achieved is be

5,223 ft. This puts the rocket within 57 ft of the 5,280 ft target altitude and stay below the 5,600 ft limit when a

10% over performance is taken into account. The peak velocity of the rocket will be 645 ft/s which is the

equivalent of 0.575 Mach which is below the speed of sound ensuring a safe flight of the rocket. The simulations

also show that the rocket will have an exit rail velocity of 70.7 ft/s on an 8 ft 1515 rail exceeding the minimum

velocity requirement of 52 ft/s.


Predicted Flight Analysis

In order to understand what a perfect flight would be, certain criteria need to be met during the flight and after the

flight. During the flight, certain key criteria need to be met as shown below in Figure 16. This figure comes from

an OpenRocket simulation where all key components are activated, deployed, and are performing as specified.

Figure 16: Ideal Predicted Flight Path

In order for this flight to be considered a success, 4 key in-flight items need to occur. They are as followed:

1. Successful Liftoff

2. Drogue Parachute Ejection

3. Main Parachute Ejection

4. Successful Landing

Vehicle Mass Adjustment System (VMAS)

The Vehicle Mass Adjustment System (VMAS) is a means for stabilizing and standardizing the overall mass of

the rocket. This mass is used to help ensure that the total mass of the rocket will be the same regardless of outside

variables that may influence the mass of the rocket such as the amount of paint or epoxy used, overestimated or

underestimated masses, and an overall margin of error when calculating the mass of the rocket. The goal of

VMAS is to be able to have accurate, and reproducible results while maintaining a constant rocket weight during

takeoff.


3.1.13.1 System Overview

The VMAS system will be located in the Payload Ejection Bay as it will allow easy access for modification and

provide a stable and reliable point of mass adjustment. This will be accomplished by mounting washers to the

inside of a bulkhead. These washers will be placed on the forged eye bolt and will be secured down using two

nuts. Both nuts will be thoroughly tightened in order to prevent the slippage. Two nuts will be used in order to

provide a redundant connection as this section is a load bearing section during the recovery stages. Below, in

Figure 17, a depiction of the VMAS is shown.

Figure 17: Depiction of the Vehicle Mass Adjustment System (VMAS)

The mass of the VMAS system will be determined by the vehicle's mass without a motor. By taking the mass of

the rocket without the motor, the variance of the mass of the motor is not taken into account. The team decided to

not take the mass of the motor into account as the overall mass of the motor may have some representation of the

total power output it may have. This, then, would allow the rocket to still maintain a relatively constant height

even though the overall mass may not be perfectly in line with the predicted total mass. Once the mass of the

rocket has been determined without the motor, the appropriate amount of mass will be added in order to bring the

weight up to the desired total of 19.3lbs. If the mass is over this amount, the team will not add any mass and will

have to suffer a degradation in altitude.

3.1.13.2 Materials Selection

Materials used in the VMAS are primarily metal washers and metal nuts. Metal was chosen as it provided a

reliable means of adjusting the mass as standard off-the-shelf metal washers can be used. The same applies to the

nuts that will be used to secure the system. It was proposed that plastic washers be used to assist in adhering to a


minimum amount of metal being used. Though, it was found that the mass density of the plastic could not

compete with the metal in effectively adjusting the mass.

3.2 Subscale Flight Results

The purpose of the subscale flight is to prove the validity of the full-scale design using real world testing and

performance data. This was accomplished by designing, building, and flying a sub scale model that will

accurately represent the full-scale design on a smaller scale. In order to meet the above criteria, the team decided

to use a LOC IRIS 3.10" Kit and flew the rocket on an AeroTech DMS H100 motor. This provided the team with

an appropriate representation of a high-powered launch in a subscale form. The design of the subscale and the

results are discussed in detail below.

Vehicle Design

The vehicle design, as stated above, is based on a LOC IRIS 3.10" Kit that was purchased commercially. This kit

provided a good representation of the rocket due to its similar form factor and fin shape. The kit that was used

came with all the necessary components to build and prepare for launch. These included 3.10" Phenolic Tubing

with a 38mm phenolic tubing motor mount, wood centering rings and bulkheads, 1/4" wood fins with through-

the-wall mounting fin tabs, a 150-inch-long elastic shock cord and a 36-inch diameter parachute.

The vehicle was constructed using similar techniques to the full scale to help solidify the methodology to build

the full-scale rocket. These techniques included filleting the inside and outside fin connecting edges, filleting the

edges of centering rings on the motor mount tube and the connection points on the airframe, connecting the shock

cord using a quick link and eye bolt, and using an AeroPack Motor Retainer to verify the retention success.

Below, Figure 18 shows the vehicle design in OpenRocket.

Figure 18: Subscale Vehicle Design in OpenRocket

3.2.1.1 Vehicle Similarity

Similarity between the subscale and the full-scale rocket was determined based upon the following criteria: Fin

Design, Airframe Design, Nosecone Design, Relative Mass Location, and surface finish.

Fin Design was kept constant as it would allow for an appropriate analysis of how the fins will affect the stability

of the rocket as a whole. If the smaller subscale fin design could not keep the rocket on a stable flight, the design

would have no chance of keeping the full-scale design on a stable flight path. The mounting methodology was


also kept similar with through-the-wall mounting used as well. Keeping this methodology the same allowed for an

analysis on how to properly place fins with through-the-wall mounting and helps solidify a wise practice.

The Airframe Design was a key factor to keep constant as changing this will affect the overall flight dynamics of

the rocket. From an aerodynamics perspective, the fluid flow over the body can be expected to be the same as the

full-scale design as both rockets have a streamlined, single-diameter design.

In order to show how the nosecone will pierce the air, the design on the nosecone was kept the same. By differing

the shape of the nosecone, different drag coefficients could have affected the performance of the rocket. Thus,

keeping the same nosecone shape will allow for an accurate representation in this aspect.

Relative mass location was an essential part in predicting the overall stability of the full-scale rocket. By having

the overall mass distribution match that of the full-scale, the sub scale can exhibit flight in a similar manner,

validating that the mass distribution in the full-scale will produce a flyable rocket.

Finally, having a similar surface finish would allow the rocket to exhibit a similar coefficient of drag as to what is

expected on the full-scale rocket. A smooth surface finish produced by spray-paint and a clear coat is expected on

the full scale and was simulated on the subscale in order to match what is expected.

Some items were not as essential to the overall flight and were not kept constant. These variables are as followed:

Motor Performance and the recovery system.

Both the performance of the motor and the recovery system are key items within the overall dynamics of rocket

flight, but for the case of the subscale launch, proved to not be as important as other aspects. The motor

performance did not need to be kept constant as it can vary between launch to launch. The recovery system was

also not as important to keep constant due to the fact that a dual deployment system was not implemented. This

completely changes the entire dynamic of the recovery system and having only a single deployment system will

change the overall recovery outcome.

Analysis of Flight

The flight was recorded using an AltusMetrum TeleGPS. This provided the team with the altitude and the vertical

velocity of the rocket. Both of these values are critical to launch safety and prediction and can help show what

might be expected with the full-scale rocket. Below, an analysis of the simulation and the real-world data is

expanded upon and the possible sources of error and their causes are also expanded upon.

3.2.2.1 Predicted vs Actual Flight Data

When the model of the subscale is designed in OpenRocket, an idealized model is formed. This model is then

adjusted with other factors such as weather and the launch angle. During the launch, a wind speed of 6 mph was

recorded and the launch angle was given as no angle. These will be held constant when comparing the data with

both the simulation and the recorded real-world data. Below in Figures 19 and 20 is an analysis of the Simulation

Data.


Figure 19: Simulated Subscale Altitude Plot

.

In Figure 19, the simulated apogee and flight path of the rocket is shown. The OpenRocket simulation put the

idealized apogee at 1352ft and a total flight time of 61sec. There were no flight abnormalities such as a thermal or

a high variance in wind.

Figure 20: Simulated Subscale Vertical Velocity Plot

In Figure 20, the vertical velocity is shown. This, again, shows an idealized version of the flight path. This is

especially seen in the negative velocity after the Parachute Ejection. The descent is always at a constant rate and

does not account for any variance in air density, weather effects, or changes in parachute shape as the rocket

descends.


The real-world data shows a more accurate picture of the type flight that can be expected. In the Real-world flight,

key flight characteristics such as a non-idealized thrust curve, varying parachute descent rates, and weather effects

can all be seen. These, though not shown in a simulation, should always be considered when comparing real-

world data to simulated data. Below, in Figures 21 and 22, the Subscale flight data is shown.

Figure 21: Subscale Real-World Altitude Plot

In Figure 21, the real-world subscale flight data is shown. This data depicts what can be seen during a real-world

launch. The largest differences come from a few main points. The first difference comes from the motor thrust

curve. In a simulation it is idealized and always the same. The real-world model will have variation, which can be

seen in the figure. The curve is not a perfect, smooth curve as in the simulation. There is also a variation in the

total thrust as the apogee obtained was lower than the simulated apogee. This difference in thrust also related to a

change in total impulse as the maximum velocity was also higher than what was expected. This, in conjunction,

means that the real-world motor burned quicker but with less force than the simulated motor. Another key item

that cannot be shown in the simulation is the thermal that the parachute hit. This thermal can both negatively

affect total flight time by keeping the parachute in the air longer, but also by increasing drift distance. Both of

these items can drastically change a system that is time or distance based.


Figure 22: Subscale Real-World Vertical Velocity Plot

In Figure 22, the vertical velocity of the subscale is shown. The vertical velocity shows many similar points that

the simulation also shows. These include Motor Burnout, which takes on the same form as in the simulation,

indication that the rocket is coasting in a comparable manner, the parachute ejection is also similar as it also

shows that the negative velocity was decreased and began to take on a more uniform descent pattern. Though, two

key items that are not shown are the thermal and the non-constant descent rate. The thermal can be seen as the

velocity ticks above the 0 line on the graph. This indicates that the descent velocity at one time was zero and the

descent of the parachute has slowed to a stop, essentially hanging in the air. This uptick above the 0 line on the

graph is also seen a little later but this can be attributed to the fact that the parachute is approaching the ground

and any updrafts or changes in near surface winds can affect this steady descent. Another item that is inconsistent

with the simulation is the non-constant descent rate of the parachute. This comes from changes in winds, local air

density, and total parachute inflation. When an average of the parachute descent rate is taken, the average comes

out to be similar to the advertised descent rate of the parachute, indicating that the parachute inflated properly and

was working as intended.

3.2.2.2 Error Discussion

In both the Real-world data and the simulation data, error can occur. This error comes from factors that may be

out of human control, instrumentation limits, or lack of control when recording. Some of the factors that are out of

human control involve the weather. Since the localized wind speed, wind direction, and air density cannot be

controlled, real-world data will experience these changes as seen with the subscale hitting a thermal on the way

down. These can be mitigated by adjusting flight angles and flight times to avoid certain circumstances, though

they cannot be entirely mitigated.


Instrumentation limits come from a lack of precision when measuring high speeds. This can contribute to data

with approximations and smoothing error. This is something that instrumentation with greater capabilities will be

able to mitigate but, unless sufficient funding is put forth, cannot be entirely mitigated.

Finally, lack of control when performing the experiments can come from not recording the correct data or not

knowing what to look for when interpreting data. This can lead to simulations not matching their real-world

counterparts, assuming the simulation can properly simulate the real-world.

Derived Full Scale Predictions

From the full-scale data, certain assumptions can be made. From this data, the team has been able to conclude that

drift distance may have a larger range than estimated. This came from the analysis of the thermal that the

parachute hit. From this, the team will add a small thermal factor that will help in creating a more real-world

dataset.

It can also be concluded that the mass placement in the rocket is correct and that the flight will be stable. This was

validated based upon the successful flight and will allow the full-scale model to be built in a similar manner.

3.3 Recovery Subsystem

A dual-deployment recovery system will be utilized on the rocket. The recovery system is comprised of two main

sections: a Drogue Parachute and a Main Parachute. These sections will deploy from a black powder charge that

is located in the recovery bay. Each section will release their parachute and be tethered together using a nylon

shock cord. More about each section is described below.

Recovery System Overview

Two distinct parachutes will be used to safely recover the rocket: a drogue parachute and a main parachute. The

drogue chute that will be used is a SkyAngle 32" Parachute. The main parachute that will be used is a SkyAngle

Cert 3 Large 80" Parachute. Each of these parachutes will be tethered to a portion of the rocket via a quick link

attached to a forged eye bolt. Each section will be ejected using black powder charges that are located on the

outside of the recovery bay.


Recovery Flight Plan

Figure 23: Recovery Flight Events

In Figure 23 above, the two key flight events are shown in an idealized flight pattern. For optimal recovery, a 32-

inch drogue parachute will deploy at Apogee to slow the overall descent of the rocket until the main parachute

ejection. The main parachute ejection will occur at 700ft and will be triggered once the altimeters read that the

rocket has reached 700ft on descent.

Mechanical Recovery Mechanisms

Mechanical Recovery Mechanisms takes an in-depth look at all portions of the recovery system that are

mechanically based in either slowing the rocket or holding sections together in a mechanical fashion. These

systems may be reliant on an electrical system to engage the mechanical system, such as in the case of parachute

ejection.

3.3.3.1 Drogue Parachute

The SkyAngle 32 Parachute will be a 32-inch drogue chute with 4 mil-spec tubular nylon shroud lines rated at

950lbs. The shroud lines have a length of 32 inches and are connected using a metal swivel ring. This will allow

for easy connection to the quick link and assist in preventing the lines from tangling. The parachute as a surface


area of 11.2 ft2 and a tested coefficient of drag of 1.14. Deployment is expected to occur at 5,223 ft which is the

apogee of the rocket's flight path. This parachute is able to withstand the total shock forces that are generated

during various deployment stages. See Section 6.1.7 for an overview of the parachute shock force calculations.

3.3.3.2 Main Parachute

The SkyAngle Cert 3 Large 80 Parachute has a diameter of 80 inches and 4 mil-spec 5/8" tubular nylon shroud

lines that are rated at 2,250lbs. The shroud lines also have a length of 80" and are connected with a 3/4" welded

ring and swivel attachment. This swivel, much like in the drogue, will assist in preventing the cords from

tangling. The parachute has a surface area of 57 ft2 and has a tested coefficient of drag of 1.26. Deployment is

expected to occur at 700 ft and will be initiated via the altimeter. Figure 24 below illustrates the type of SkyAngle

Parachute that will be used for the Main Parachute.

Figure 24: SkyAngle Cert 3 Large 80 Depiction

3.3.3.3 Shock Cords

A 25 ft, 1/2" tubular Kevlar shock cord is utilized for this vehicle. The shock cord will be tied with a non-slip knot

on both ends which will be epoxied to prevent slippage. These knots will be tied onto a quick link in order to

assist in attaching or removing the shock cords from each section. A 25ft shock cord will be placed in each

Parachute bay for a total shock cord length of 50ft. The shock cord will be nicely folded when prepared for use in

order to prevent tangling when the ejection charge forces the shock cord out of the parachute bay.

3.3.3.4 Eye Bolts and Quick Links

A 1/4" Quick Link for easy installation and removal of both the drogue and main parachutes will be utilized in

order to assist in making a more serviceable and easy to use rocket. The Eye bolts used will be 3/8” Forged Steel

Eye Bolts. These will be secured to their respective bulkhead using two washers and a nut. The washers and nut

will also be epoxied in order to prevent slackening of the nut and to prevent slippage caused by sudden shock

forces during flight.


The quick links that will be used will be 1/4" steel quick links. These will be standard off the shelf quick links that

can be purchased at any standard hardware store. These will be securing either a shock cord or a parachute to their

respective forged eye bolt. These quick links will also be able to be securely tightened using a 1/4" wrench.

3.3.3.5 Bulkheads

The team will be using G12 Fiberglass Bulkheads with a thickness of 1/8”. These bulkheads will be secured to

their respective coupler using epoxy and epoxy fillets around the outside mating edges. On bulkheads that will be

experiencing large forces and are only to be glued into the body, a thin layer of epoxy will also cover the bulkhead

in order to prevent cracking. These bulkheads will be used in many cases, such as in the electronics bay and the

payload ejection bay, to hold the forged eye bolt that the shock cord will attach to. In these cases, the forged eye

bolt will pass through the center of the bulkhead.

Electronics Bay Overview

The electronics bay is, in essence, the heart of the recovery system. This section is built into the middle of the two

parachute bays and is responsible for holding not only the black powder ejection charges, but for recording flight

data and statistics. The electronics bay is designed with redundant systems and is able to ensure that ejection

charges and flight data is properly recorded and executed. This section is built into an airframe tube coupler and

will have two stepped bulkheads attached on either side. These bulkheads will be secured together using two

threaded rods that will run through the length of the coupler. A nut on each end will secure the bulkheads in place

and provide a locking force for the system. Inside, a wooden sled will house the altimeters and batteries that are

responsible for the systems electronic needs. On the outside of the bay, a contact based arming switch will be used

in order to arm and disarm the system. The Electronics Bay is designed to be able to be armed and in standby

mode for 1 hour. The system will also be designed so that any wind gusts will have minimal impact on the system

to prevent causing a possible ‘false take-off” which would trip the altimeter into beginning to record data. In the

sections below, more detail about each system is presented.

3.3.4.1 Altimeters

The Electronics Bay will house 2 StrattologerCF Altimeters that will be powered by two 9V batteries. These

altimeters will be secured to the sled using standoff pins and will be wired to be armed and disarmed using the

contact switches. One altimeter will be marked as the official altimeter for scoring purposes and the other will be

marked for redundancy purposes. Each altimeter will be capable of setting off a blast charge. The first main

altimeter will set off the charge at the exact specified time. For the drogue parachute, this will occur at apogee and

for the main parachute, this will occur at 700ft. The redundancy altimeters will set off the backup charges 50ft

after each of the main charges are set to go off. This will provide each system enough time to fully eject before

the backup charge is set off.

Before each flight, the altimeters will also be checked to ensure that the proper boot sequence can be run through

and that the altimeter can enter standby mode. If an altimeter cannot enter standby mode, troubleshooting will

begin as necessary.


3.3.4.2 Blast Caps

The blast caps that are used in the electronics bay are located on the outside of each of the bulkheads. Two of

these will be placed apart from each other and will be connected to a 4 by 4 terminal block. The terminal block is

wired into the altimeter system. Each blast cap is designed to hold up to 4g of black powder. For the main charge,

2g of black powder will be used while in the backup, 3g of black powder will be used. The backup charge is

intended to have a larger black powder volume in order to help mitigate the chance that the total volume of gas

produced by the 2g of black powder was not enough to separate and shear the shear pins holding the parachute

section in contact with the electronics bay. Once the black powder has been placed into the blasting cap, each cap

will be covered with masking tape in order to hold the powder in place while still allowing for the powder to

freely ignite. After each use of the blast caps, all residue will be cleaned away in order to prevent contaminants

from building up that may inhibit the performance of the black powder.

3.3.4.3 System Redundancy and Safety

The recovery system utilizes two StratologgerCF Altimeters. Each altimeter is powered by its own 9V battery.

Each flight, new batteries will be used to ensure they have a charge rather than risking a launch with faulty, used,

low amperage batteries. Along with replacing the batteries, the wires from the altimeters to the charges will also

be replaced after each launch to ensure continuity.

The altimeters are activated by a pair of exterior screws which are then tightened on the pad in order to close the

circuit. The primary altimeter is programmed to activate when the rocket reaches apogee. At this point, the

altimeter sends a charge to ignite a charge cap filled with two grams of black powder, utilizing e-matches taped to

the top of the charge cap with masking tape. The force will then separate the lower end of the rocket, releasing the

drogue parachute. The backup altimeter will set off a similar charge shortly after in case the primary altimeter or

blast cap malfunctioned.

The main parachute is released at the programmed altitude of 700 feet AGL with a one second delay in case issues

arise from the primary ignition system. The nose cone includes a TeleGPS tracking unit that transmits live flight

data to the ground control via HAM band radio. The data is saved onto the TeleGPS which is then downloaded to

locate the rocket's impact location as well as to validate data collected by alternate sensors onboard.

3.3.4.4 GPS Tracking

The rocket will be located using an AltusMetrum TeleGPS locator. This device tracks the rocket using GPS

satellites and stores this data onboard. Live data is also transmitted by the device using HAM band radio at

434.550 MHz. This signal is received by a ground station antenna and the TeleGPS software displays the position

of the rocket superimposed on a satellite map of the area, along with the current velocity and altitude of the

rocket. This system will be crucial in tracking the rocket through the duration of the flight.

3.3.4.5 Electronics Bay Wiring Schematic & Logic

Below, in Figure 25, is the proposed writing layout for the Electronics Bay,


Figure 25: Electronics Bay Wiring Schematic

The logic of the controller is based upon a two altimeter setup with one main altimeter responsible for two

ejection charges and a backup altimeter responsible for two backup charges. Each output terminal is labeled above

and will be referenced below in brackets.

To start, each altimeter will be wired into a contact switch from port [B] to port [B_Gn] that is located on the

outside of the rocket body. This will allow the recovery bay to be activated from the outside of the rocket. Once

the contact switch is engaged, the battery cell which is connected on terminals [A] and [A_Gn] will become live

and activate the altimeter’s boot sequence. During flight, when an altimeter reads that the proper altitude has been

obtained for ejection, each altimeter will send a current out through terminal [D] or [C] depending on whether or

not the Drogue Parachute Ejection Charge or the Main Parachute Ejection Charge is being fired. Each wire is then

connected to a terminal block and then to a Blasting Cap with an integrated E-Match. For example, Port [C] on

the Main Altimeter is connected to Port [1] with the Main Ejection Terminal Block. Port [1] then connects to Port

[8] on the same block. This connects the E-Match into circuit with the return wiring being connected into Port [7]

and then to Port [2] on the Terminal Block. Finally, the wiring returns to Port [C_Gn] on the main altimeter to

complete the circuit. There is also a dedicated terminal for Data Transfer which will be used to program the

altimeter on when to fire each ejection charge.


3.4 Mission Performance Predictions

Key Flight Events Overview

Key flight events are events that are deemed to be important to the overall success of the rocket. These events will

prove to be stepping stones along the duration of the flight and many of which will prove to be prerequisites for

future events. In Table 10 below, the key events are laid out and the criteria for how the team will identify them is

given.

Table 10: Key Flight Events Overview

Event How to Fulfill Event How to Verify Event

Takeoff from launch pad Ensure all sub systems are properly

installed, primarily the motor and

igniter are of key importance.

Successfully leaving the launch

pad and attaining a vertical ascent.

Motor Burnout Ensure that the motor has been

properly built and installed into the

rocket.

Motor performs successfully and is

of acceptable burn time and thrust.

Drogue Parachute Deployment Ensure that all recovery systems

are armed, prepared, and installed

properly.

Drogue parachute event at apogee

successfully occurs and the drogue

parachute fully deploys.

Main Parachute Deployment Ensure that all recovery systems

are armed, prepared, and installed

properly.

Main parachute event at 700ft

above the ground occurs

successfully and the main

parachute fully deploys.

Landing The rocket successfully lands by

not coming in ballistic or having

any portion of the rocket come in

ballistic if the rocket becomes fully

separated between stages.

Visually inspect and watch the

rocket to ensure that the system

comes down with all portions

intact and under control.

Ejection of the Nosecone Remote triggering of the internal

CO2 canister that is within the

rocket.

The nosecone separates

Rover Deployment Ensure the rover is properly armed

and can be remotely triggered to

begin exiting from the payload bay.

The rover successfully leaves the

payload bay and begins traveling

the required 5ft.

Payload Success Design the rover to successfully

travel 5ft in one direction and

deploy solar panels. Data is to be

sent back to the ground station

indicating the distance traveled and

solar panel output

The ground station will receive

data indicating distance traveled

and the solar panel output. These

will serve as the initial verification.

Upon retrieving the rover, a visual

inspection will also be taken.


Flight Profile Simulations

All simulations of the rocket’s performance were performed in OpenRocket. The simulations that were performed

in OpenRocket are based upon the most accurate mass predictions that can be made. These predictions come from

estimating the mass of each component based off of provided weights and measurements that are given by

manufacturers.

Weather and launch conditions are another key factor that is attempted to be maintained during launch

simulations. These include controlling for the following: Wind speed, Temperature, Pressure, Latitude,

Longitude, and Altitude. All of these factors can be crucial in getting accurate simulation data.

Below, are various scenarios and criteria that will be used in order to verify and predict the performance of the

rocket under certain conditions and launch scenarios.

3.4.2.1 Vehicle Flight Data

Figure 26: Kronos Simulated Ideal Flight Profile

The above simulation data showcases what an ideal flight profile for the rocket would be under zero wind

conditions. An altitude of 5223ft is expected to be reached after a maximum vertical velocity of 647 ft/sec. There

will be two ejection charges with each releasing their own parachute.


3.4.2.2 Simulation Error & Prevention

A simulation is not always a perfect representation of what will occur in real life. As seen in the subscale flight

data, the simulation cannot predict certain weather phenomena such as thermals and does not account in variance

of parachute descent rate due to local variations in wind speed, wind direction, and air density. These can lead to

portions of the simulation to be off.

In the above simulated perfect flight under zero wind conditions, this is an overly idealized flight. A zero wind

condition is generally not present and any addition of wind can affect the drift distance. Wind can also affect the

overall flight trajectory due to weather cocking. In the case of weather cocking, the initial flight angle may be

used in order to compensate.

Landing Kinetic Energy

In order to calculate the total landing energy of each system, the Kinetic energy equation was used. When

developing each scenario, the velocity at each key point was taken from OpenRocket and used. OpenRocket

provided the means to develop and check the total velocity that each section would be experiencing. Below, the

landing scenarios for a zero separation, if no parachutes were to deploy, a single separation, if only the drogue or

main parachute were to deploy at their specified times, or a dual separation, what would happen under normal

flight, is explored. It is kept constant that the total mass of the rocket will be 10.2 kg. This mass comes from the

mass of the rocket without a motor plus the weight of the empty motor.

3.4.3.1 Kinetic Energy for Zero Separation Scenario

For the zero separation scenario, it will be assumed that no recovery parachutes have been deployed and the

rocket is falling ballistic towards the Earth. In this case, the terminal velocity of the rocket must be used when the

landing energy is calculated. Table 11 below outlines the masses used.

Table 11: Kinetic Energy for Zero Separation Scenario Mass Distribution

Mass Location Mass [kg]

Nosecone 0.493

Payload Bay 3.240

Main Parachute Bay 1.710

Electronics Bay 0.899

Lower Body Tube 2.470

Empty Motor w/ Casing 1.390

Total 10.202

The terminal velocity of the rocket was determined in OpenRocket. The terminal velocity that was given was 118

ft/sec or 35.966 m/sec.

Given the following equation, the kinetic energy in joules was calculated.

Sect

ion

1


𝐾𝐸 =1

2𝑚𝑣2

𝐾𝐸 = 1

2(10.202)(35.966)2

𝐾𝐸 = 6598.415 𝐽

𝐾𝐸 = 6598.415 ∗ 0.7376 = 4866.739 𝐿𝑏𝑓

From the above equation, it can be determined that the total kinetic landing energy for the entire rocket given

none of the recovery parachutes deploy is 4866.739 Lbf. At this landing force, substantial damage to the rocket

can be expected, primarily damaging the nosecone and payload bay. Damage will also be dealt to the rover which

will become inoperable.

3.4.3.2 Kinetic Energy for Single Separation Scenario – Drogue Deployment

This calculation is the same calculation as the Drogue Parachute Kinetic Energy for each section that is given in

the Flysheet.

For the single separation, it is assumed that only the drogue parachute is going to deploy at apogee and the vehicle

will fall in two, connected sections. These sections will have the same combined mass of 10.2 kg, but each section

will have a mass as described in Table 12 below.

Table 12: Kinetic Energy for Single Separation Scenario – Drogue Deployment Mass Distribution

Mass Location

Mass [kg]

Section

Masses [kg]

Nosecone 0.493

Payload Bay 3.240

Main Parachute Bay 1.710

Electronics Bay 0.899 6.342


Empty Motor w/ Casing 1.390 3.860

Total 10.202

The terminal velocity of each section was determined in OpenRocket to be 55.94 ft/sec or 17.05 m/s. This was

then used in the same kinetic energy equation as shown above in Section 3.4.3.1. Calculations are shown below.

Section 1

𝐾𝐸 =1

2𝑚𝑣2

𝐾𝐸 = 1

2(6.342)(17.05)2

𝐾𝐸 = 921.818 𝐽

𝐾𝐸 = 921.818 ∗ 0.7376 = 679.898 𝐿𝑏𝑓

Section 2

𝐾𝐸 =1

2𝑚𝑣2

𝐾𝐸 = 1

2(3.860)(17.05)2

𝐾𝐸 = 561.056 𝐽

𝐾𝐸 = 561.056 ∗ 0.7376 = 413.814 𝐿𝑏𝑓

Sect

ion

1

Sect

ion

2


From these calculations, it can be determined that Section 1 will have a kinetic energy of 679.898 Lbf and Section

2 will have a kinetic energy of 413.814 Lbf.

3.4.3.3 Kinetic Energy for Dual Separation Scenario – Normal Flight

For the dual separation, it is assumed that both parachutes will deploy at their intended altitudes and the vehicle

will fall in three, connected sections. These sections will have the same combined mass of 10.2 kg, but each

section will have a mass as described in Table 13 below.

Table 13: Kinetic Energy for Dual Separation Scenario – Normal Flight Mass Distribution

Mass Location

Mass [kg]

Section

Masses [kg]

Nosecone 0.493

Payload Bay 3.240

Main Parachute Bay 1.710 5.443

Electronics Bay 0.899 0.899


Empty Motor w/ Casing 1.390 3.860

Total 10.202

The terminal velocity of each section was determined in OpenRocket to be 19.40 ft/sec or 5.91 m/s. This was then

used in the same kinetic energy equation as shown above in Section 3.4.3.1. Calculations are shown below.

Section 1

𝐾𝐸 =1

2𝑚𝑣2

𝐾𝐸 = 1

2(5.443)(5.91)2

𝐾𝐸 = 95.153 𝐽

𝐾𝐸 = 95.153 ∗ 0.7376

= 70.181 𝐿𝑏𝑓

Section 2

𝐾𝐸 =1

2𝑚𝑣2

𝐾𝐸 = 1

2(0.899)(5.91)2

𝐾𝐸 = 15.716 𝐽

𝐾𝐸 = 15.716 ∗ 0.7376

= 11.592 𝐿𝑏𝑓

Section 3

𝐾𝐸 =1

2𝑚𝑣2

𝐾𝐸 = 1

2(3.860)(5.91)2

𝐾𝐸 = 67.480 𝐽

𝐾𝐸 = 67.480 ∗ 0.7376

= 49.771 𝐿𝑏𝑓

From these calculations, it can be determined that Section 1 will have a kinetic energy of 70.181 Lbf and Section

2 will have a kinetic energy of 11.592 Lbf and Section 3 will have a kinetic energy of 49.771 Lbf.

Center of Pressure (CP) and Center of Gravity (CG)

To determine both the Center of Pressure (CP) and Center of Gravity (CG), each location is determined from the

tip of the nosecone. From this reference point, the CP is located at 65.91 inches and is represented by the red dot.

The CG without the motor is located at 55.15 inches and with the motor, the CG is located at 65.91 inches. Figure

Sect

ion

1

Sect

ion

2

Sect

ion

3


27 below shows a physical representation of both the CP and CG on the rocket without the motor and Figure 28

shows a physical representation with the motor.

Figure 27: CP & CG Representation without Motor

Figure 28: CP & CG Representation with Motor

Stability Margin

The rocket has a stability margin of 2.15 caliber with the selected motor and a stability margin of 3.56 caliber

without the motor. The stability margin is above the required 2 calibers as set forth in the NASA SL Handbook

and Guidelines. During the flight, the stability margin will max out at approximately 2.75 caliber during the

motor burn out. Below, both the static and dynamic margins will be expanded upon.

3.4.5.1 Stability Statement

The current goal of the club is to keep a minimum stability of 2.0 caliber with a desired goal of 2.5 to 3.0 caliber.

This goal is met when a motor is not included with the rocket. When no motor is included, a stability margin of

3.56 caliber is expected. This falls above the NASA minimum requirement and above the goal set by the club.

Once the motor is included, the stability drops to 2.16 caliber. This does not fall within the desired goal but does

fall above the minimum stability of 2.0 caliber. In each scenario, the rocket is projected to make a stable flight

that adhered to practice and guidelines that have been set forth.

3.4.5.2 Static Stability Margin

The current static stability margin of the rocket is 2.15 caliber. When determining the stability of the rocket, the

static stability is used as a quick glance in determining how stable a rocket will be directly off the launch pad.

This quick glance does not take into account changes in vehicle mass throughout the flight that primarily come

from changes in motor weight. This change in stability margin due to the change in weight will be explored in

Section 3.4.5.3


3.4.5.3 Dynamic Stability Margin

The Dynamic stability margin takes into account the change in mass of the rocket throughout the flight. This

change in mass comes from the rocket losing mass as the motor burns. Below, in Figure 29, the dynamic stability

margin is shown. This margin was calculated using OpenRocket. The Dynamic Margin, after motor burnout,

becomes 2.75 caliber and maintains this caliber throughout the rest of the flight.

Figure 29: Dynamic Stability Margin Plot

Simulated Drift

In order to determine how far the rocket will drift during the specified wind conditions of 0, 5, 10, 15, and 20

MPH Crosswinds, two methods will be utilized. The first method is a basic drift model where solely the parachute

descent rate, predicted altitude, and wind speed are taken into account. The second method is derived from the

OpenRocket Model Predictions for total drift distance. Both models are expanded upon in the sections below.

3.4.6.1 Basic Drift Model

The basic drift model is based on the simplest form of parachute descent. In order to determine the total descent,

the projected altitude of 5223 ft is used as the maximum altitude. From this maximum altitude, the descent rate of

the drogue parachute, which was pulled from the manufacturer’s documentation, was used to calculate the time to

go from apogee to 700 ft. Then, at 700 ft the descent rate of the main parachute, which was also pulled from the

manufacturers documentation, was used to determine the time from 700 ft to landing. These two times were then

added together and multiplied with the wind velocity to get the total drift distance at each wind speed. Below are

the written equations that were used to determine the distances.

𝑡𝐷𝑟𝑜𝑔𝑢𝑒 = 5223 − 700

𝐷𝑟𝑜𝑔𝑢𝑒 𝐷𝑒𝑠𝑐𝑒𝑛𝑡 𝑅𝑎𝑡𝑒

𝑡𝐷𝑟𝑜𝑔𝑢𝑒 = 5223 − 700

55.46

𝑡𝐷𝑟𝑜𝑔𝑢𝑒 = 81.55 𝑆𝑒𝑐

𝑡𝑀𝑎𝑖𝑛 = 700 − 0

𝑀𝑎𝑖𝑛 𝐷𝑒𝑠𝑐𝑒𝑛𝑡 𝑅𝑎𝑡𝑒

𝑡𝑀𝑎𝑖𝑛 = 700

20.05

𝑡𝑀𝑎𝑖𝑛 = 34.91

𝑡𝑇𝑜𝑡𝑎𝑙 = 𝑡𝐷𝑟𝑜𝑔𝑢𝑒 + 𝑡𝑀𝑎𝑖𝑛

𝑡𝑇𝑜𝑡𝑎𝑙 = 81.55 + 34.91

𝑡𝑇𝑜𝑡𝑎𝑙 = 116.46 𝑆𝑒𝑐

𝐷𝑟𝑖𝑓𝑡 = (𝑡𝑇𝑜𝑡𝑎𝑙)(𝑣𝑊𝑖𝑛𝑑)

After performing the above calculations, the above drift equation was used to determine the following drift

distances. They are represented in Table 14 below.

Table 14: Basic Drift Calculations

Wind Speed [mph] Drift Distance [feet]

0 0

5 582.30

10 1164.60

15 1746.90

20 2329.20

3.4.6.2 OpenRocket Drift Model

For each of the required wind speeds, the most recent OpenRocket model was used to simulate the total drift of

the rocket. Each simulations involved launching straight up with a 90 degree crosswind of varying velocity.

Below is a summarized table of the OpenRocket drift calculations.

Table 15: OpenRocket Drift Model

Wind Speed [mph] Drift Distance [feet]

0 7.80

5 518.75

10 1011.81

15 1680.82

20 2296.97


Figure 30: K1000T-P 0 mph Drift Distance

With a simulated crosswind of zero mph and zero standard deviation in wind velocity, the response lateral drift

for the current model and expected motor is less than 8 feet from the launch rod position when modeled as

launching vertical at a ninety-degree angle to the ground



With a simulated crosswind of 5 mph and zero standard deviation in wind velocity, the response lateral drift for

the current model and expected motor is approaching 475 feet from the launch rod position when modeled as

launching vertical at a ninety-degree angle to the ground.



the current model and expected motor is approximately 1050 feet from the launch rod position when modeled as


This drift distance is approaching the maximum drift distance, but still maintains a value of less than the

maximum 2500 feet drift distance by a large margin.




the current model and expected motor is approximately 1550 feet from the launch rod position when modeled as


This simulated crosswind is 75% of the maximum wind allowable for safe launch conditions and maintains a drift

distance of a 60.0% of the maximum drift distance allowable for calculations.




the current model and expected motor is less than 2232 feet from the launch rod position when modeled as


The maximum allowable drift in the most severe allowable conditions is a modeled 2500 feet at 20 mph when

modeled as the above does. The most severe conditions simulate a response of 89.3% the maximum allowable

drift, which still gives the team a margin of error for launch day conditions and launch angle while maintaining an

acceptable minimal drift distance.

Hand Calculation vs OpenRocket Drift Distance Comparison

In every case, the hand calculations were higher in the total distance. This is more than likely the case because of

the simplified nature of the calculation. Below, in Table 16, is a comparison of each of the drift distances.

Table 16: Comparison of Hand Calculation and OpenRocket Drift Distances

Wind Speed [mph] Hand Calculation

Drift Distance [feet]

OpenRocket Calculation

Drift Distance [feet]

Difference between

Methods [feet]

0 0 7.8 7.8

5 582.3 518.75 63.55

10 1164.6 1011.81 152.79

15 1746.90 1680.82 66.08

20 2329.20 2296.97 32.23


Motor Performance Predictions

The chosen motor will be an Aerotech K1000T-P, due to its success in OpenRocket simulations, its meeting of

NASA standards, and, most importantly, its safety. The Aerotech K1000T-P is 396 mm in length and 75 mm in

diameter, within tolerance of the vehicle design, and also adds a weight of 90.8 ounces to the tail of the rocket,

subsequently increasing stability. The motor will have an average thrust of 1,012 N with a max thrust of 1,140 N,

ultimately resulting in a maximum altitude of 5,223 ft. This altitude places the rocket within 57 ft of the 5,280 ft

target altitude and stay below the 5,600 ft limit.

3.4.8.1 Nominal Performance (±0%)

With a nominal performance the Rocket will have an average thrust of 1,012N and reach apogee at 5,223ft. This

is 57 feet below the target altitude but is safely below the 5,600 ft allotted altitude. This would keep all other

characteristics such as thrust at takeoff, total drift distance, and descent time constant.

3.4.8.2 Overperformance (+7%)

If the motor over performs by 7% the average thrust of the rocket would be 1,083 N and reach apogee around

5,589 ft. This would shift the thrust-to-weight ratio to 10:1 this is double the minimum required ratio. This not

only places the rocket's apogee 309 ft above the desired altitude but also 11 ft below the maximum height

allowed. An overperformance of 7% would also increase initial thrust at takeoff, total drift distance, and descent

time.

3.4.8.3 Underperformance (-7%)

If the motor underperforms by 7%, the average thrust of the rocket would be 941 N and reach apogee around

5,066 ft. This would decrease the thrust-to-weight ratio to 8:1 this is still well above the minimum required ratio

of 5:1. This is places apogee at 214 ft below the target altitude. An underperformance of 7% would also decrease

initial thrust at takeoff, total drift distance and decent time.

4 Safety

4.1 Launch Concerns and Operations Procedures

Safety & Operations Commitment Statement

The team’s highest ranked criteria for mission success is safety. The safety plan and results outlined below

summarizes the approach to ensure zero safety incidents. Victoria Raber is serving as the designated safety officer

for the duration of the USLI competition and has ensured the safety plan is known and followed by all members

of the University of Toledo Rocketry Club and bystanders.

Procedures & Launch Concerns

To ensure safety of the team and the success of the launch, safety protocols are in place to prevent and minimize

harm to anyone involved. These protocols are described below in the form of checklists to ensure the safety of the

operation.


4.1.2.1 Vehicle Construction

When building the vehicle, all team members must adhere to the predefined rules and terms that have been set

forth by the safety officer, team leads, and

To construct the vehicle the team will be cutting and drilling fiberglass which requires thick gloves, eye

protection, long sleeves and pants and closed toed shoes to prevent cuts and other injuries. Then when

everything is cut and drilled the members can switch to latex or latex alternative gloves to protect their

skin from more carbon fiber laced epoxy. The members may need to switch back to thick gloves to cut

couplers, but to assemble some forged eyebolts, which will be two washers and a nut all epoxied together,

the members will need to wear those latex or latex alternative gloves, especially when epoxying in parts

like the motor mount and casing and retainer. The vehicle team will also make sure to screw in parts like

the motor retainer which may require the thicker gloves again just in case of issues with the drill and

screwdrivers.

4.1.2.2 Fin Mounting Procedure

The fins will be mounted using carbon fiber laced epoxy, a through-the-wall method that attaches the fins

to the motor tube using fin tabs, from which the fins will be filleted. In this procedure the safety team will

provide thick latex or latex alternative gloves to protect the skin from the epoxy, and then when the epoxy

dries it will need to be sanded down for extra smoothness and aerodynamics so the safety team will

disperse filter masks to prevent dust from being breathed in. At all times through these builds all members

will be required to wear safety glasses, closed to shoes and long pants and long sleeves.

4.1.2.3 Payload Construction

To construct the payload, most of the body will be 3-D printed which will not require a large amount of

safety precautions as these parts will be made to order from a local supplier. To put the payload together,

the payload construction team will need small screws and some electrical safety gear which will include

rubber, insulated gloves in case of shock. Some parts will require epoxy, therefore rubber/latex gloves

will also be needed.

4.1.2.4 Recovery Bay Construction

The recovery bay will need some screws to be drilled and screwed in to ensure the main parachute is

attached securely so the recovery bay construction members will need the thick gloves and eyewear.

There are also modified forged eyebolts that will need to be attached but these will not need to be epoxied

so that the team can remove the washers and nuts after launch. This is also where the recovery team will

be attaching some quick links and forged eyebolts for the shock cord to be attached. The shock cord will

be tied in a non-slipping knot and epoxied for extra safety. The nose cone will have 4 shear pins and

another quick link for the drogue parachute to deploy.

4.1.2.5 Recovery System Procedure

The recovery system has an extra step to overcome because the parachutes need to be loaded properly

upon launch day. If the parachute folder loads the parachute improperly then the parachute may not open


and slow the descent enough for a safe recovery. Therefore the parachute folder needs to be experienced

and double checked upon launch day. This will be watched over by the president since he has the most

experience with parachute folding.

4.2 Environmental, Personnel and Mission Success FMEA's

Environmental, Personnel, and Mission Success FMEA’s are designed to take a comprehensive and in-

depth look at the methods of failure and prevention that may be related to the environment, personnel on the team,

and failures that can ultimately impact the overall mission success. In the sections below, an analysis of the

potential problems and the mitigations is presented along with an explanation of the rating system we used.

Hazard Level Ratings

4.2.1.1 Personnel Hazard Rating System

Table 17: Personal Hazards Rating System Matrix

Severity - (S) Frequency - (F) Description:

Fatality (F) (5)

Frequent (F) (5)

This event will be likely to occur in

normal operation.

80%-100% chance of occurring

Medical Attention (MA) (4)

Reasonably Probable (RP) (4)

This event will not be unusual to

occur in normal operation.

60%- 80% chance of occurring

Serious Incident (SI) (3)

Occasional (O) (3)

This event is unlikely to occur in

normal operation.


First Aid (FA) (2)

Remote (RE) (2)

This event will only result from an

unforeseen event.


No Injury (NI) (1)

Extremely Improbable (EI) (1)

This event is one so unlikely that it

is not anticipated to

occur during the entire operation.



4.2.1.2 Mission Success Hazard Rating System

Table 18: Mission Success Hazards Rating System Matrix


Total loss of vehicle (TL) (5)

Frequent (F) (5)

This event will be likely to occur

in normal operation.


Severe damage to vehicle (DV)

(4) Reasonably Probable (RP) (4)

This event will not be unusual

to occur in normal operation.


Repair required (RR) (3)

Occasional (O) (3)


normal operation.


Superficial Damage (SD) (2)

Remote (RE) (2)

This event will only result from

an unforeseen event.


No Damage (ND) (1)


This event is one so unlikely

that it is not anticipated to

occur during the entire

operation.


4.2.1.3 Environmental Hazard Rating System

Table 19: Environmental Hazard Rating System Matrix


Fatality (F) (5)

Frequent (F) (5)

This event will be likely to occur in

normal operation.


Medical Attention (MA) (4)

Reasonably Probable (RP) (4)

This event will not be unusual to

occur in normal operation.


Serious Incident (SI) (3)

Occasional (O) (3)


normal operation.


First Aid (FA) (2)

Remote (RE) (2)

This event will only result from an

unforeseen event.


No Injury (NI) (1)


This event is one so unlikely that it

is not anticipated to

occur during the entire operation.



4.2.1.4 Risk Magnitude Rating System

As an example below is the Personnel Risk Magnitude grid. The numbers are the same for each different rating

system but the initials (F, MA, SI, FA, NI) change depending on what is being referenced, personnel hazards

versus mission success hazards, versus environmental hazards.

Table 20: Risk Magnitude Rating System Matrix

F: 5 RP: 4 O: 3 RE: 2 EI: 1 Risk Magnitude:

F: 5 25 20 15 10 5 Risk Magnitude (RM) =

Severity * Likelihood MA: 4 20 16 12 8 4

SI: 3 15 12 9 6 3 High

FA: 2 10 8 6 4 2 Medium

NI: 1 5 4 3 2 1 Low

Environmental Hazards Analysis & Mitigation

To ensure the safety of the environment these hazards are expected and their mitigation plans follow next to each

potential hazard.

Table 21: Environmental Hazards Analysis and Mitigation Matrix

S LRisk

Mag

Urgenc

yS L

Risk

Mag

Urgenc

y

LitteringLitter from the

Team or Rocket Debris

Cause harm to

humans, vegetation or

wildlife.

2 5 10 Medium 2 1 2 Low

Fire Electronics or Motor Fire.

Burn vegetation,

release potentially toxic

fumes, may spread

and destroy property,

damage personnel, or

damage the

environments or

buildings.

5 3 15 High 3 1 3 Low

Rocket Motor Explosion Fragments of the RocketDamage to property,

environment, or people.5 2 10 Medium 5 1 5 Low

Battery Leaking Battery Acid

Battery acid could harm

the environment,

personnel, and objects

in the area.

3 2 6 Low 2 1 2 Low

Excess Drift Rocket Lost

Rocket damages an

uncontrolled

environment,

personnel, wildlife, or

property in the area.

3 3 9 Medium 3 1 3 Low

Recovery System

FailureBallistic Rocket

Rocket damages an

uncontrolled

environment,

personnel, wildlife, or

property in the area.

5 4 20 High 5 1 5 Low

Tree Landing Landing in Tree

Cause damage to tree,

potential safety risk to

remove.

2 3 6 Low 2 2 4 Low

Controlled and

Uncontrolled Explosions

Excessive Explosions can

Destroy Vehicle

Small parts of fiberglass

will litter the

environment, potentially

damaging wildlife.

5 4 20 High 2 2 4 Low

Main Parachute Fails to

Deploy

Rocket Impacts Ground at

High Speeds. Shatters

Fiberglass Body Tube and Fins

Fragments of the

rocket could hit humans

and litter launch area.

May disturb vegetation

or strike animal.


Rocket LandingRocket Lands on Wildlife or

Spectator

Large mass of rocket

can cause pain and

possible death to small

wildlife. Could possibly

injure or kill spectators

and personnel. Heavy

damage to environment

and objects in the area.

5 2 10 Medium 4 1 4 Low

Toxic Chemicals Leak Fuel or Battery Acid LeakPoison ground water,

ponds or streams.3 2 6 Low 2 1 2 Low

Payload Electrical FireBatteries, Wiring, or Board

Catch Fire

Payload will not

function.3 2 6 Low 1 1 1 Low

Fire caused by Ballistic

Crash

Lithium Battery becomes

Punctured and Potentially

Ignites a Fire

Damage to

environment nearby. 3 2 6 Low

2 1 2 Low

Motor burn Impact with Flying Object

Flying object changes

rocket's trajectory. 3 2 6 Low 3 1 3 Low

Hazard Hazard EffectControlled RiskUncontrolled Risk

Activity/Event Existing Controls

The enclosure and rocket

wall will partially protect

the flammable

Check skies before

launching.

Provide trash/recycling

recepticles. Fasten items

that may blow away.

Keep fire extinguisher on

hand. Clear launch area

of debris. Follow correct

fire prevention protocols.

Follow recovery bay

system checklist. Use

onboard GPS to track

rocket.

Follow procedural

checklists before launch.

Proper protective clothing

Inspect all used and new

batteries. Never use a

battery that appears

damaged or fails any

Follow recovery bay

system checklist. Report

any issues to Recovery

Team Lead. Ensure

backup altimeter is

Point launch rail in proper

direction according to

wind.

Experienced parachute

packer will practice and

fold the parachute on

launch date.

Use correct amount of

blackpowder, ground test

electronics.

Electrical components

provided extra

Ensure that rocket's

landing speed is within

NAR code. Use an air

horn to warn spectators

of rocket landing.

Since the airframe is

fiberglass, the small


Personnel Hazards Analysis & Mitigation

To ensure the safety of personnel, these hazards are expected and their mitigation plans follow next to each

potential hazard.

Table 22: Pernonnel Hazards Analysis and Mitigation Matrix

Rocket LandingRocket Lands on Wildlife or

Spectator

Large mass of rocket

can cause pain and

possible death to small

wildlife. Could possibly

injure or kill spectators

and personnel. Heavy

damage to environment

and objects in the area.

5 2 10 Medium 4 1 4 Low

Toxic Chemicals Leak Fuel or Battery Acid LeakPoison ground water,

ponds or streams.3 2 6 Low 2 1 2 Low

Payload Electrical FireBatteries, Wiring, or Board

Catch Fire

Payload will not

function.3 2 6 Low 1 1 1 Low

Fire caused by Ballistic

Crash

Lithium Battery becomes

Punctured and Potentially

Ignites a Fire

Damage to

environment nearby. 3 2 6 Low

2 1 2 Low

Motor burn Impact with Flying Object

Flying object changes

rocket's trajectory. 3 2 6 Low 3 1 3 Low

The enclosure and rocket

wall will partially protect

the flammable

Check skies before

launching.

Electrical components

provided extra

Ensure that rocket's

landing speed is within

NAR code. Use an air

horn to warn spectators

of rocket landing.

Since the airframe is

fiberglass, the small

S LRisk

Mag

Urgenc

yS L

Risk

Mag

Urgenc

y

Sanding Fumed Silica

Small, Airborne, Hazardous

Particles, Carcenogenic

Material

Damage to lungs. 5 5 25 High 3 1 3 Low

Sanding Body Tubes Fiberglass SplinterFiberglass entering skin

causing extreme pain.2 4 8 Medium 2 1 2 Low

DrillingMaterial being Drilled may

Enter Eyes

Damage to eye(s), possible

blindness.4 3 12 Medium 4 1 4 Low

Soldering BurnsBurns cause pain, and

possible time off.3 3 9 Medium 3 2 6 Low

Cutting FiberglassFiberglass Splinters, Small

Particles

Cutting fiberglass may

cause fiberglass splinters,

and release small particles

that may be hazardous if

inhaled. Can cause splinters

and possible lung damage.

3 4 12 Medium 3 2 6 Low

Using EpoxyPossible burns, epoxy may

dry on skin.

The epoxy being used dries

at high temperatures. Dried

epoxy does not come out

of clothing and does not

come off of skin easily.


Testing Electronics Bay

Electric shock may occur

while testing. Fire may

start due to improper

testing.

Burns or fires. 3 3 9 Medium 3 2 6 Low

Testing Payload

Electronic components

may become hot or start

a fire.

Burns or fires. 3 3 9 Medium 3 2 6 Low

Using Blackpowder Black Powder

Highly flammable and ignites

easily, can cause burns,

shrapnel entering skin.

4 3 12 Medium 4 1 4 Low

Using a Hacksaw HacksawsCould puncture or lacerate

skin.4 3 12 Medium 4 1 4 Low

Battery Leakage Battery Acid

Can cause severe burns

when in contact with skin or

eyes.

3 2 6 Low 3 2 6 Low

Exposed to Fumes

Fumes from motor,

epoxy, fiberglass, or other

objects. could make a

team member sick, or

affected from gases.

Fumes from motor, epoxy,

fiberglass, or other objects.

could make a team

member sick, or affected

from gases.


Fire

The exhaust of the motor

is at a very high

temperature and may

cause dry vegetation to

ignite. Electronics cause a

fire while launch. Fire starts

during construction of

rocket.

Flames could cause burns.

Fumes from burnt fiberglass

should not be inhaled. A

fire during construction could

grow and burn other parts

of the construction area.


Premature Rocket

LaunchIgniter Installation

Could prematurely start

motor which could cause

burns.

5 2 10 Medium 5 1 5 Low

Rocket Fails to LaunchRocket Ignites during

RecoveryBurns. 5 2 10 Medium 5 1 5 Low

Activity/ Event Hazard

Wear gloves and use

extra caution.

Wear gloves and use

extra caution.

Controlled Risk

Wear safety glasses.

Hazard EffectUncontrolled Risk

Wear face mask and

gloves when cutting

fiberglass.

Wear gloves and use

extra caution.

Existing Controls

Wear thick gloves.

Wear face mask to

prevent fume silica

from entering lungs.

Follow the NAR code.

Wait sixty seconds

Use extreme caution,

and keep black powder

away from ignition

sources.

Wear gloves and use

extra caution.

Wear gloves and use

clamp to hold piece

Wear hand and eye

protection when

handling batteries.

Team members who

are exposed to fumes

will be required to wear

masks, as well as

required take frequent

The safety team will

clear the launch sight

of

any dry vegetation

and

ensure the launch rail

has an exhaust shield.

If fiberglass is burned

Keep all electrical

devices away from

igniter as it is going


Fire

The exhaust of the motor

is at a very high

temperature and may

cause dry vegetation to

ignite. Electronics cause a

fire while launch. Fire starts

during construction of

rocket.

Flames could cause burns.

Fumes from burnt fiberglass

should not be inhaled. A

fire during construction could

grow and burn other parts

of the construction area.


Premature Rocket

LaunchIgniter Installation

Could prematurely start

motor which could cause

burns.

5 2 10 Medium 5 1 5 Low

Rocket Fails to LaunchRocket Ignites during

RecoveryBurns. 5 2 10 Medium 5 1 5 Low

Motor IgnitionCatastrophe At Take Off

(CATO).

Shrapnel flying into

spectators and team

members. Fires from motor

failure. Remaining parts of

rocket falling out of control.

5 2 10 Medium 5 1 5 Low

Motor Ignition Launch lug failure.

Launch lugs fail to keep

rocket straight. If too

extreme, rocket may

become pointed at

spectators.

5 2 10 Medium 5 1 5 Low

Touchdown Rocket lands on spectator.

Rocket may cause

concussion, broken bones,

or cuts.

4 4 16 High 4 1 4 Low

TouchdownRocket lands on power

line.

If an attempt to recover is

not done by a professional

then electric shock is

possible.

5 2 10 Medium 5 1 5 Low

Writing PartiesHigh temperatures in

computer labs.

Temperatures may cause

dehydration and possible

fainting.

2 3 6 Low 2 2 4 Low

Launch EventsHigh temperatures at

venue.

Team members may

become dehydrated and

become sick.


Launch Events Cold temperatures.Team members may

experience frostbite.3 3 9 Medium 3 2 6 Low

Launch Events Rain.Team members may

become drenched in water3 3 9 Medium 3 2 6 Low

Launch Events Fog.Launch fails due to poor

viability3 3 9 Medium 3 2 6 Low

Launch Events Ice / snow.

Team members may slip

and fall or develop

hypothermia.


Education

Children start a fight, not

pay attention, or

purposefully try to hurt

someone.

Children could hurt each

other or themselves. 4 2 8 Medium 4 1 4 Low

EducationEducation subscale goes

ballistic.

Subscale rocket will impact

ground at very high speeds.5 2 10 Medium 5 1 5 Low

Education Education CATO`s Rocket is uncontrolled and

very dangerous.5 2 10 Medium 5 1 5 Low

EducationChild has an allergic

reaction.

If an allergic reaction occurs

child may have to be sent

to the hospital.

5 3 15 High 5 1 5 Low

Allergic reaction

A team member may

have an allergy to a

building material, or a

food allergy at the

event.

Member may have to be

seek medical attention.2 4 8 Medium 2 3 6 Low

Burns

Ejection charges, motor

burn, and electronics can

get hot.

If a team member touches

a hot object they may have

severe burns.


CutsKnives, drills and other

sharp objects are used.

Minor cuts could require

special care. Deep cuts

require going to the hospital.

4 3 12 Medium 4 1 4 Low

Safety team will inform

team members to

dress for the weather.

The safety and

recovery teams will

inform the team where

Wear gloves when

cutting, be trained and

use caution. The

Safety Team will be

Safety will wait until the

backup day to launch


team members to


team members to

Follow the NAR code.

Wait sixty seconds


team members of

water and snacks

Ensure launch lugs are

straight and will not fall

out easily.

Inspect motor for

problems when

purchased. Buy from

trusted motor

providers.


ensure that

professionals recover

the rocket in the event

Control flight path so

rocket is not above

spectators. Have air

Members are

encouraged to take

breaks and stay

Test fly subscale

before launching at

education events.

Constant vigilance and

keep children under

control at all times.

Test fly subscale

before launching at


account for any

allergies and alert the

person(s) when that

material is being used

or an allergen is near.

Do not let children

touch rockets. Watch

materials used like


clear the launch sight

of

any dry vegetation

and

ensure the launch rail

has an exhaust shield.

If fiberglass is burned

Keep all electrical

devices away from

igniter as it is going


Mission Success Hazards & Mitigation

To ensure mission success with maximum safety, these hazards are expected and their mitigation plans will

follow next to each potential hazard.

Table 23: Mission Success Hazards and Mitigation Matrix

Electric shock

When wires are live, the

risk of electrical shock

exists.

If shock is severe, team

member may have to seek

medical attention.


Car accidentDuring travel a car

accident occurs.

If serious, members may

have to go to hospital.4 2 8 Medium 4 1 4 Low

Travel injuries

Accidents when loading or

unloading vehicles. Injure team members. 3 26 Low

1 11 Low

Recovery

Electronics Bay Misfires

During Recovery

Misfire may cause burns or

cuts. 5 210 Medium

5 15 Low

Drive carefully and

follow all traffic laws.

Make sure no live

wires are touched

after batteries are

Team members will

wear proper safety

Test Electronics.

Before recovery

S L Risk Mag Urgency S L Risk Mag Urgency

Motor Motor Failure causes CATO

Rocket is destroyed,

unable to complete

mission criteria.

5 2 10 Medium 5 1 5 Low

VehicleVehicle Body Breaks During

Flight

Rocket is destroyed,

unable to complete

mission criteria.

5 2 10 Medium 5 1 5 Low

Launch RailLaunch Buttons do not fit Rail,

or Disconnect from Rocket

Rocket comes loose from

rail, unable to launch,

unable to complete

mission criteria.


Motor MountCentering Rings Fail During

Launch

Motor and motor casing

will fly through rocket and

destroy insides of rocket

causing parts to fail,

unable to complete

mission criteria.

5 2 10 Medium 5 1 5 Low

Motor Mount Motor Casing FailureMotor CATO mission

failure.5 2 10 Medium 5 1 5 Low

CoastingRocket Impacts Object

Midflight

Impact alters flight profile.

NAR requirements unmet,

unable to complete

mission criteria.

3 2 6 Low 2 1 2 Low

Coasting

Drag from Fins Separates

Rocket after Burnout, but

before Apogee

Launch will be a disaster,

severe damage to rocket.

Rocket design fails, unable

to complete mission

criteria.

3 2 6 Low 3 1 3 Low

Coasting Fins ShearMission fails, rocket is

recoverable.3 2 6 Low 3 1 3 Low

ApogeeAltimeter Fails to Fire at

Apogee

Drogue parachute fails to

deploy, rocket falls ballistic,

unable to complete

mission criteria.

5 3 15 High 5 1 5 Low

Apogee E-match Fails to Ignite

Parachutes do not deploy,

rocket goes ballistic,

unable to complete

mission criteria.

5 2 10 Medium 3 1 3 Low

Apogee

E-match Insecure, Black

Powder doesn't Recieve

Charge


rocket goes ballistic,

unable to complete

mission criteria.

5 3 15 High 3 1 3 Low

Apogee

Batteries Fail to Provide

Enough Electricity to Altimeters

or E-Matches.

E-matches do not ignite,

parachutes do not deploy

leading to damage to the

rocket, unable to complete

mission criteria.

5 3 15 High 3 1 3 Low

ApogeeDrogue Parachute Fails to Fully

Deploy

Rocket enters a ballistic

trajectory. Rocket is

destroyed on impact or

when the main parachute

is deployed, unable to

complete mission criteria.

5 3 15 High 3 1 3 Low

Apogee Shear Pins Fail to Break

Shear pins fail to break at

the proper times, causing

the parachutes to fail to

deploy, damaging rocket,

unable to complete

mission criteria.

5 2 10 Medium 2 1 2 Low

Apogee Excess Black Powder

Rocket does not separate,

goes ballistic, unable to


5 3 15 High 5 1 5 Low

Apogee Insufficient Black Powder




5 3 15 High 5 1 5 Low

ApogeeShock cords are not Properly

Installed

Parts of rocket fall

uncontrolled without a

parachute, unable to


5 3 15 High 5 1 5 Low

ApogeeMain Parachute Deploys

Prematurely

Greatly increases drift

distance. Potential to go

out of bounds, unable to


4 3 12 Medium 4 1 4 Low

ApogeeExcess Masking Tape Covering

Black Powder Charges

Black powder charges do

not separate rocket, goes

ballistic, unable to


5 3 15 High 5 1 5 Low

Descent on DrogueRocket Impacts Object Upon

Descent

Drogue chute rips, or

becomes tangled. Falls at

high speed which will affect

the deployment of the

main parachute, unable to



Descent on Drogue Electrical Fire

Electronics Bay and/or

Payload electronics have a

major problem and ignite,

unable to complete

mission criteria.


Rocket Descends to 700 ft.

on DrogueAltimeter Fails to Fire

Main parachute does not

deploy. Rocket falls under

drogue only, damaging


mission criteria.

4 3 12 Medium 4 1 4 Low


on Drogue

Main Parachute Fails to Fully

Deploy

Rocket lands at high

velocity, potentially

damaging rocket, unable

to complete mission

criteria.

4 3 12 Medium 3 1 3 Low

Hazard EffectHazardActivity/Event

Experienced recovery

team members will pack

parachutes. Altimeters

and other components

set up as described.

Uncontrolled Risk Controlled Risk

Structural considerations

in development of the

vehicle body make sure

Use and implementation

of a motor from a known

production line with a

Safety team will test

motor retainer for

Sky will be confirmed clear

before launching rocket.

Existing Controls

Body team uses stress

analysis to confirm that

motor mount is secure.

Launch buttons fit a 1515

rail, are attached firmly to

rocket body and have

been tested.

E-matches have been

tested and flown on

previous flights.

Redundant altimeters

The Vehicle team will

calculate how strong the

fins have to be.

The Vehicle team will

calculate how strong the

Secondary altimeter

backing up drogue

deployment.

E-matches are taped into

position with masking

tape. E-match leads are

trimmed to prevent

New batteries are used

for every flight and are

tested beforehand.

Recovery will test,

measure, and use the

appropriate amount of

blackpowder, 2g for main,

Shear pins have been

tested and flown on

previous flights.

Experience recovery team

members will pack




Recovery team will double

check connection, and

inspect shock cords for

damage before launch.

Test electronics.

Recovery will test,




Secondary altimeter

backing up main

parachute deployment.


check the skies before

launch for flying objects.

Test electronics.

Recovery team only uses

one layer of masking

tape.






5 3 15 High 5 1 5 Low

Apogee Insufficient Black Powder




5 3 15 High 5 1 5 Low

ApogeeShock cords are not Properly

Installed





5 3 15 High 5 1 5 Low

ApogeeMain Parachute Deploys

Prematurely

Greatly increases drift

distance. Potential to go

out of bounds, unable to


4 3 12 Medium 4 1 4 Low

ApogeeExcess Masking Tape Covering



not separate rocket, goes

ballistic, unable to


5 3 15 High 5 1 5 Low

Descent on DrogueRocket Impacts Object Upon

Descent

Drogue chute rips, or

becomes tangled. Falls at

high speed which will affect

the deployment of the

main parachute, unable to



Descent on Drogue Electrical Fire

Electronics Bay and/or

Payload electronics have a

major problem and ignite,

unable to complete

mission criteria.



on DrogueAltimeter Fails to Fire

Main parachute does not

deploy. Rocket falls under

drogue only, damaging


mission criteria.

4 3 12 Medium 4 1 4 Low


on Drogue

Main Parachute Fails to Fully

Deploy

Rocket lands at high

velocity, potentially


to complete mission

criteria.

4 3 12 Medium 3 1 3 Low


on DrogueE-match Fails to Ignite



to complete mission

criteria.

5 2 10 Medium 3 1 3 Low


on Drogue

E-match Insecure, Black

Powder doesn't Recieve

Charge



to complete mission

criteria.

4 3 12 Medium 3 1 3 Low


on DrogueShear Pins Fail to Break

Shear pins fail to break at

the proper time.



to complete mission

criteria.



on DrogueExcess Black Powder

Black powder explosion

shaders the fiberglass

body tube, unable to


5 3 15 High 5 1 5 Low


on DrogueInsufficient Black Powder

Rocket does not separate.

Impacts the ground while

only on ground parachute,

unable to complete

mission criteria.

5 3 15 High 5 1 5 Low


on Drogue

Shock cords Improperly

Installed or Fail





5 3 15 High 5 1 5 Low


on Drogue

Excess Masking Tape Covering



not separate rocket.

Rocket lands with high

kinetic energy, unable to


5 3 15 High 5 1 5 Low

Touchdown Rocket Lands in Water

Electronics in the rocket will

be ruined, unable to


5 3 15 High 5 1 5 Low

Touchdown Rocket Lands on Power Lines

Rocket will be stuck on

power lines for extended

period of time. Electronics

will lose data due to loss of

power, unable to complete

mission criteria.


Travel damageRocket Loading or

Transportation Damage

Rocket unable to fly or

require repairs. Mission

Failure if the rocket cannot

be repaired.

3 2 6 Low 1 1 1 Low

E-matches are taped into

position with masking

tape. E-match leads are

trimmed to prevent

Shear pins have been

tested and flown on

previous flights.

Recovery will test,




backup 3g.

Recovery will test,






tape.

Experienced recovery

team members will pack




E-matches have been

tested and flown on

previous flights.

Redundant altimeters





Recovery will test,








Test electronics.

Recovery will test,




Secondary altimeter

backing up main

parachute deployment.


check the skies before

launch for flying objects.

Test electronics.



tape.

Inspect launch field. If

there is a large pond,

river, or puddle then No-

Change flight path op

avoid power lines. If

power lines can not be

avoided then No-Fly.

Rocket will be stored

securely during travel.


Touchdown Rocket Lands on Power Lines

Rocket will be stuck on

power lines for extended

period of time. Electronics

will lose data due to loss of

power, unable to complete

mission criteria.


Travel damageRocket Loading or

Transportation Damage

Rocket unable to fly or

require repairs. Mission

Failure if the rocket cannot

be repaired.

3 2 6 Low 1 1 1 Low

Miswiring of Arming Switches Switches Fail Launch Day

Have to rewired in field, if

not possible then the

launch will be scrapped,

unable to complete

mission criteria.


GPS Contact Lost Rocket LostMission failed if rocket is

not found.5 3 15 High 5 1 5 Low

Mathematical ErrorIncorrect Conversion or Wrong

Units

Numbers for important

values may be off. If

errors are critical, could

cause a mission failure.

5 4 20 High 5 1 5 Low

Drogue Parachute is BurntEjection Charge Burns Drogue

Parachute

When rocket descends to

700 feet the rocket may

have too much kinetic

energy to correctly deploy

the main parachute,

unable to complete

mission criteria.

4 3 12 Medium 4 1 4 Low

Main Parachute is BurntEjection Charge Burns Main

Parachute

If the main parachute is

burnt, then upon landing

the rocket will have a high

kinetic energy. Possible

high damage, unable to

satisfy mission criteria.

4 3 12 Medium 4 1 4 Low

Theft of Equipment. Parts or Tools are Stolen

If part of tool is

mandatory and

unreplaceable, mission

fails.

5 3 15 High 5 1 5 Low

Motor or Casing is

Unavailable

Motor or Motor Casing is

Unavailable by Launch Site

Retailer

If not available, mission is

failed.5 3 15 High 5 1 5 Low

Section of Rocket InsecureLarge Part of Rocket Falls

Without a ParachuteMission failed. 5 2 10 Medium 5 1 5 Low

Rocket Descends on Drogue

Parachute

High Touchdown Impact

SpeedMission failed. 4 2 8 Medium 4 1 4 Low

Rocket Fails to Separate at

Apogee and Impacts Ground

at Extremely High Speeds

Rocket becomes Ballistic Mission failed. 5 2 10 Medium 5 1 5 Low

Environmental Impact on

RocketInsecure Launch Pad

Rocket will not fly straight

up, resulting in loss of

altitude, possible mission

failure.

3 2 6 Low 3 1 3 Low


RocketSnow or Freezing Rain

Ice build up on ventilation

holes. Altimeters do not

detect apogee and rocket

goes ballistic, mission

failure.

3 1 3 Low 3 1 3 Low


RocketRain

Electronic damage

resulting in possibility of

rocket going ballistic,

mission failure.

3 2 6 Low 3 1 3 Low


RocketHigh Winds

Wind cocking and

excessive drift may cause

loss of altitude and

possible loss of rocket,

unable to satisfy mission

criteria


Environmental Impacts on

RocketHigh Temperature

Fiberglass may melt or

become weaker.

Electronics my overheat

and malfunction. Electronic

malfunction could lead to

rocket going ballistic.

Weakened fiberglass could

lead to complete mission

failure.

3 2 6 Low 3 1 3 Low

Descent on Drogue

Parachute Rocket Impacts Object Midair

Drogue parachute may

become tangled causing

the rocket to fall at a high

speed. Flying object my

become unable to fly and

high ground at high

speeds, unable to satisfy

mission criteria 3 2 6 Low 3 1 3 Low

Check skies before

launching.

No-Fly if rain does not

dissapate.

No-Fly if ice is forming on

rocket.

Use a plywood board to

prevent sinkage. No-Fly if

launch pad is not level.

GPS in nosecone. No-Fly if

wind is greater than 20

MPH.

Limit exposure to sunlight.

Team lead of each team

will double check any

conversions that take

place.

Parachute will be

inspected by the recovery

and safety teams.

Nomex will be used in

between the parachute

and ejection charge.

Recovery team checks

Electronics Bay.

The team will be

observant of all tools and

parts. The work space

will be locked at all times

The team will confirm with

retailers on site about

stock.

Recovery team checks

Electronics Bay.

Recovery team double

checks connections.

Parachute will be

inspected by the recovery

and safety teams.

Nomex will be used in

between the parachute

and ejection charge.

Charge GPS and check to

make sure that GPS is

Change flight path op

avoid power lines. If

power lines can not be

avoided then No-Fly.

Test electronics.

Rocket will be stored

securely during travel.


4.3 Failure Modes and Effects Analysis by Subsystem

Vehicle FMEA

The chart below describes the potential hazards and the steps to minimize the chance of occurrence and damage

from these events.

Table 24: Vehicle Subsystem FMEA

Descent on Drogue

ParachuteRocket Impacts Object Midair

Drogue parachute may

become tangled causing

the rocket to fall at a high

speed. Flying object my

become unable to fly and

high ground at high

speeds, unable to satisfy

mission criteria

3 2 6 Low 3 1 3 LowCheck skies before

launching.

S LRisk

MagUrgency S L Risk Mag Urgency

Liftoff Centering Rings InsecureMotor Movement in Body

Destroys Internals.5 3 15 High 5 1 5 Low

Liftoff Centering Rings FailMotor Movement in Body

Destroys Internals.5 2 10 Medium 5 1 5 Low

Liftoff Airframe Fails Under Stress

Airframe Breaks, can cause

parts to Fall

and Potentially Injure

Personnel or Environment.

5 3 15 High 5 1 5 Low

Exiting Rail Rail Buttons Shear

Instability Tilts Vehicle at

Launch

Potentially Endangering


5 4 20 High 5 1 5 Low

Exiting Rail Rail Buttons Not Aligned


Launch



5 3 15 High 5 1 5 Low

Exiting Rail Fins Not AlignedVehicle Spins and Potentially

Endangers Personnel.4 3 12 Medium 4 1 4 Low

Exiting Rail High Friction with Rail


Launch



5 3 15 High 5 1 5 Low

Stability High Aerodynamic ForcesHigher Stress Could Cause

Vehicle Failure.3 3 9 Medium 3 1 3 Low

Stability Fin Flutter and Shear

Stability would be

unpredictable and

flight path could become a

danger for

Personnel and Environment.

4 3 12 Medium 4 1 4 Low

ApogeeBlack Powder Charge

Prematurely Detonates

Vehicle Separates upon

Ascent causing CATO.5 3 15 High 5 1 5 Low

Motor burn Motor Retainer Failed

Motor may explode, or

make rocket take a unsafe

trajectory.

5 3 15 High 5 1 5 Low

Motor RetentionMotor Retainer Improperly

Loaded

Motor Casing Separates

from Vehicle,

Mission Failure and

Endangers


5 3 15 High 5 1 5 Low

Motor RetentionMotor Retainer Improper

Thread Alignment


from Vehicle,

Mission Failure and

Endangers


5 3 15 High 5 1 5 Low

Motor Retention Motor Retainer Incorrect Size


from Vehicle,

Mission Failure and

Endangers


5 3 15 High 5 1 5 Low

LandingDescent Velocity higher than

Expected

Vehicle Breaks Upon

Landing, Mission Failure,

Potential to Endanger


5 3 15 High 5 1 5 Low

Motor BurnoutRocket separates due to

drag from fins

Rocket will separate while

moving at high speeds and

may cause the rocket to

break apart and parts to fall

uncontrollably.

5 3 15 High 5 1 5 Low

Coasting Fins rip off

Parts of the fins that have

fell off fall to at high speeds.

Rocket may lose control

after fins are sheared off.


RecoveryMotor Casing High

TemperatureBurns. 2 3 6 Low 2 1 2 Low

Activity/Event

Controlled Risk

Existing Controls

Uncontrolled Risk

Hazard Hazard Effect

Vehicle and Propulsion

team double check that

the motor retainer,

centering rings, and

casing are all correct sizes

and types to ensure the

most secure fit.

Ensure that the main and

drogue parachute can

safely stop the rocket

even at max velocity.

Design fins to reduce

drag, and ensure when

attaching the fins that the

fins are installed correctly.

Wait before recovering

the motor to ensure cool

down time.



the motor retainer,




most secure fit.



the motor retainer,




most secure fit.






teams calculate the

maxiumum stress possible

and ensure the centering

rings can withstand the

Calculate maxiumum

stress. Design and

construct the airframe to

withstand maximum

Use correct rail buttons,

follow instructions for

launch.

Have two people double

check construction.

By using two separate

terminals on the altimeter,

the charge won't reach

the black powder until the

altimeter reaches the

Design fins to prevent fin

flutter and design the fins

strong enough not to

shear. Have vehicle team

members calculate fin

flutter and ensure fins are

constructed in a manner

that maximizes stability.

Use correct rail buttons,

follow instructions for

launch.

Have two of the vehicle

team members double

check fin angles and

placement during

Follow instructions from

launch pad instructors.

Calculate the Aerodynamic

forces, do not fly in

adverse conditions,

ensure that vehicle design



the motor retainer,




Recovery Bay FMEA


from these events.

Table 25: Recovery Bay Subsystem FMEA

Motor RetentionMotor Retainer Improperly

Loaded


from Vehicle,

Mission Failure and

Endangers


5 3 15 High 5 1 5 Low

Motor RetentionMotor Retainer Improper

Thread Alignment


from Vehicle,

Mission Failure and

Endangers


5 3 15 High 5 1 5 Low

Motor Retention Motor Retainer Incorrect Size


from Vehicle,

Mission Failure and

Endangers


5 3 15 High 5 1 5 Low

LandingDescent Velocity higher than

Expected

Vehicle Breaks Upon

Landing, Mission Failure,

Potential to Endanger


5 3 15 High 5 1 5 Low

Motor BurnoutRocket separates due to

drag from fins

Rocket will separate while

moving at high speeds and

may cause the rocket to

break apart and parts to fall

uncontrollably.

5 3 15 High 5 1 5 Low

Coasting Fins rip off

Parts of the fins that have

fell off fall to at high speeds.

Rocket may lose control

after fins are sheared off.


RecoveryMotor Casing High

TemperatureBurns. 2 3 6 Low 2 1 2 Low



the motor retainer,




most secure fit.

Ensure that the main and

drogue parachute can

safely stop the rocket

even at max velocity.





Wait before recovering

the motor to ensure cool

down time.



the motor retainer,




most secure fit.



the motor retainer,




most secure fit.





S L

Risk

Mag

Urgenc

y S L Risk Mag Urgency


Fiberglass body tube

breaks apart and pieces

fall uncontrollably. 4 2 8 Medium 4 1 4 Low

Apogee

Shock Cord Installation or

Failure

Large and heavy parts of

rocket fall uncontrollably. 5 2 10 Medium 5 1 5 Low

Apogee Drogue Parachute Failure

Rocket falls at high

speeds which may

interrupt deployment of

main parachute. 4 2 8 Medium 4 1 4 Low

Rocket descends to

700 ft. Main Parachute Failure

Rocket impacts the

ground at a high speed. 4 3 12 Medium 4 1 4 Low

Rocket descends to

700 ft.

Insufficient Black Powder

Causes Main Parachute to

Fail

Rocket impacts the

ground at a high speed. 4 2 8 Medium 4 1 4 Low

Rocket descends to

700 ft.

Damage to Main parachute

or Deployment System.


rocket fall uncontrollably. 4 3 12 Medium 4 1 4 Low

Rocket descends to

700 ft. Excess Black Powder

Breaks apart the

fiberglass and shrapnel

falls uncontrollably. 3 3 9 Medium 3 1 3 Low

Uncontrolled Risk

Recovery team will

double check the

Test, measure, and use

the appropriate amount

of blackpowder, 2g for

Activity/Event Hazard Hazard Effect Existing Controls

Controlled Risk




The recovery team will

double check shock cord


folder will practice and

fold parachute on launch

date.

Have an experienced

parachute folder practice

Test Electronics Bay,

calculate appropriate

amount of blackpowder.


Propulsion FMEA

To ensure a safe and successful launch the propulsion team has tested the motor through Open Rocket, a simulator

that helps calculate the possibilities for launches. The rocket will be launched from an 8-foot launch rail to ensure

the rocket launches in a safe direction and with maximum stability. The chart below describes the potential

hazards and the steps to minimize the chance of occurrence and damage from these events.

Table 26: Propulsion Subsystem FMEA

Payload Ejection System FMEA


from these events.

Table 27: Payload Ejection System FMEA

S L Risk Mag Urgency S L Risk Mag Urgency

Motor RetensionMotor Retainer Improperly

Loaded

Motor Casing Separates from

Vehicle,

Mission Failure and Endangers


3 4 12 Medium 3 1 3 Low

Motor BurnMotor Casing Ignites

Fiberglass

Burnt fiberglass is hazardous

to breathe in. Fires may cause

structural damage. Burnt

parts of rocket may fall off on

descent.


Exiting Rail Motor Power Insufficient


Launch



5 3 15 High 5 1 5 Low

Liftoff Faulty MotorCatastrophic Motor Failure

Destroys Launch Vehicle.5 3 15 High 5 1 5 Low

Ignition Defective Igniter

Motor Fails to Ignite, Delays

Launch,

Potential to Ignite as

Personnel Approach

and could cause Injury.

3 2 6 Low 3 1 3 Low

Ignition Loose Connection to Igniter


Launch,


Personnel Approach


3 2 6 Low 3 1 3 Low

Ignition Igniter Inserted Improperly


Launch,


Personnel Approach


3 2 6 Low 3 1 3 Low

Motor burn Motor Retainer Failure

Motor may explode, or make

rocket take a unsafe

trajectory.

5 2 10 Medium 5 1 5 LowPropulsion Team reviews

motor casing before use.

Inspect motor for

problems when

purchased. Buy trusted

motor providers. Check

motor casing for

Existing Controls

Test the motor mount

and casing so the motor

casing does not fall out.

Propulsion team

calculates how much

thrust is needed for

clearance of the rail. Buy

Buy a tested and

comercial motor.

Replace the igniter after a

safe waiting period.

After a safe waiting

period, recheck

connections then retry

launch.

After a safe waiting

period, check igniter

installation.

Controlled RiskActivity/Event Hazard Hazard Effect

Uncontrolled Risk

S L

Risk

Mag Urgency S L Risk Mag Urgency

CO2 ejection Potential Fire Burns 5 1 5 Low 5 1 5 Low

CO2 ejection Pressurized Container Becoming PuncturedExplosion, shrapnel could

cause lacerations or burns4 2 8 Medium 4 1 4 Low

CO2 ejection Overly PressurizedExplosion, shrapnel could

cause lacerations or burns4 1 4 Low 4 1 4 Low

LiPO battery OverchargedPossible fire and electric

damage4 2 8 Medium 4 1 4 Low

LiPO battery Over discharged Possible fire and electric

damage4 1 4 Low 4 1 4 Low

Gears Pinch points Possible pinch and slight pain 2 2 4 Low 2 1 2 Low

Existing Controls

Uncontrolled Risk

Lipo charge/discharge

protector

Warning labels

Contained within

protective casing

Contained within

protective casing

Contained within

protective casing

Lipo charge/discharge

protector

Activity/Event Hazard Hazard Effect

Controlled Risk


Electronics Bay and Rover Electronics FMEA


from these events.

Table 28: Electronics Bay and Rover Electronics FMEA

Recovery System FMEA

To ensure the safety of the recovery of the rocket, the chart below describes the potential hazards and the

steps to minimize the chance of occurrence and damage from these potential events.

Table 29: Recovery System FMEA

S LRisk

MagUrgency S L

Risk

MagUrgency

Motor Burn Electronics Bay Misfires

Rocket will separate

while motor is burning,

which may cause rocket

to break apart and fall

uncontrollably.

5 2 10 Medium 5 1 5 Low

CoastingPayload or Electronics

Bay Starts a Fire

Burnt fiberglass is

hazardous to breathe in.

Fires may cause

structural and electrical

damage that may be

critical to the project.

5 3 15 High 5 1 5 Low

ApogeeElectronics Bay Does

Not Detect Apogee

The rocket does not

break apart and will

impact the ground and

very unsafe speeds.

5 3 15 High 5 1 5 Low

ApogeeE-Matches Fail to Ignite

Black Powder

Rocket does not

separate and impacts

ground at high speeds.

5 3 15 High 5 1 5 Low

Descent on Drogue

Parachute

Fire in Electronics Bay

or payload electronics

Burnt fiberglass is

unsafe to breathe. May

cause structural damage

and separation resulting

in parts falling

uncontrollably. Damage

to main parachute or

deployment system.

4 3 12 Medium 4 1 4 Low

Rocket Descends to

700 ft.

Electronics Bay Fails to

Deploy Main Parachute

Rocket impacts the

ground at a high speed.4 3 12 Medium 4 1 4 Low

Rocket Descent on

Main ParachuteElectronic Fire

Burnt fiberglass is

unsafe to breathe. May

cause structural damage

and separation resulting

in parts falling

uncontrollably.

4 3 12 Medium 4 1 4 Low

RecoveryElectronics Bay Misfires

During Recovery

Misfire may cause burns

or cuts.5 2 10 Medium 5 1 5 Low

Test Electronics. Before

recovery attempt is


purchase altimeters

from trustworthy

manufacturers.

Controlled Risk

Existing Controls

Uncontrolled Risk

HazardActivity/Event

Install a backup

altimeter. Test

Electronics Bay.

Test Electronics Bay and

Payload Bays.

Test Electronics.

Test Electronics.

Test Electronics.

Test Matches for

continuity before

installing. Test

Hazard Effect

S LRisk

MagUrgency S L Risk Mag Urgency


Fiberglass body tube

breaks apart and pieces

fall uncontrollably.


ApogeeShock Cord Installation or

Failure


rocket fall uncontrollably.5 2 10 Medium 5 1 5 Low

Apogee Drogue Parachute Failure

Rocket falls at high

speeds which may

interrupt deployment of

main parachute.


Rocket descends to

700 ft.Main Parachute Failure

Rocket impacts the


Rocket descends to

700 ft.



Fail

Rocket impacts the


Rocket descends to

700 ft.





Rocket descends to

700 ft.Excess Black Powder

Breaks apart the


falls uncontrollably.


Uncontrolled Risk

Recovery team will

double check the




Activity/Event Hazard Hazard Effect Existing ControlsControlled Risk




The recovery team will

double check shock cord


folder will practice and

fold parachute on launch

date.

Have an experienced

parachute folder practice





4.4 Personal Protective Equipment (PPE) Requirement Analysis

Overview of Available PPE

The team has face masks available at all times in case of dust, shards, or fumes that could be breathed in. The

team also has a gas mask in case of fumes. Then, the team has multiple types of gloves available at all times.

There are thick gloves to handle tools and anything that could shatter or splinter, and there are rubber gloves in

multiple sizes to ensure proper fit to keep chemicals from damaging skin. There are multiple types of safety

glasses, some designed to fit around glasses to ensure that those with glasses still have adequate safety while

maintaining visual clarity. The safety team also recommends not wearing contacts during build times to prevent

any mishaps with contacts getting cut or lost that could damage the eyes. The safety team also requires closed

toed shoes in the work area at all times, along with thick long pants and sleeves with tight cuffs. Just in case of

accidents the safety officer also keeps a first aid kit in their car for when the team has events not in the teams

designated work area. At the work area, the team has multiple first aid kits available, along with fire extinguishers

and fire blankets and an overhead fire suppression system.

PPE Compliance

To ensure proper Personal Protection Equipment Use during construction of the rocket the Safety Officer was

present during the builds and verbally reminded those constructing the subscale and the personal certification

rockets to use gloves when handling epoxy, safety glasses at all times, and proper protective clothing and closed

toed shoes were worn. The safety officer is required to attend all builds and constructions to ensure safe handling

of materials and to ensure proper use of tools and correct procedures for construction.

4.5 Compliance with NAR Safety Ordinances

To ensure compliance with the National Association of Rocketry and to ensure safety the team will comply with

the rules set by NAR. These rules will be known and followed by every member of the team. Should any member

break one of the rules, the executive board of the University of Toledo Rocketry Club will decide on the

consequences.

The rules are as follows:

Table 30: NAR Safety Ordinance Compliance Matrix

NAR Requirement How the team will fulfill the requirement

I will only fly high power rockets or possess high

power rocket motors that are within the scope of

my user certification and required licensing.

Only those who have been certified L2 or higher will

handle the motor and launch the rocket.

Rocket descends to

700 ft.



Fail

Rocket impacts the


Rocket descends to

700 ft.





Rocket descends to

700 ft.Excess Black Powder

Breaks apart the


falls uncontrollably.


Recovery team will

double check the








I will use only lightweight materials such as paper,

wood, rubber, plastic, fiberglass, or when

necessary ductile metal, for the construction of my

rocket.

The body of the rocket is made of fiberglass, any other

material used in the rocket is lightweight as well.

I will use only certified, commercially made

rocket motors, and will not tamper with these

motors or use them for any purposes except those

recommended by the manufacturer. I will not

allow smoking, open flames, nor heat sources

within 25 feet of these motors.

The motor will be bought from certified dealers at the

NASA Student Launch Event. The safety officer and

those with high enough clearance to handle the motor

will ensure that there are no sparks or flames or heat

sources near the motor at all times.

I will launch my rockets with an electrical launch

system, and with electrical motor igniters that are

installed in the motor only after my rocket is at

the launch pad or in a designated prepping area.

My launch system will have a safety interlock that

is in series with the launch switch that is not

installed until my rocket is ready for launch, and

will use a launch switch that returns to the “off”

position when released. The function of onboard

energetics and firing circuits will be inhibited

except when my rocket is in the launching

position.

The rocket is equipped with an electrical launch

system the igniter will not be installed until arrival at

the launch. There will be no currents running until the

rocket is ready to launch.

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 seconds

after the last launch attempt before allowing

anyone to approach the rocket.

In cases where the rocket fails to launch the team will

follow the instructions of the range safety officers.

I will use a 5-second countdown before launch. I

will ensure that a means is available to warn

participants and spectators in the event of a

problem. I will ensure that no person is closer to

the launch pad than allowed by the accompanying

Minimum Distance Table. When arming onboard

energetics and firing circuits I will ensure that no

person is at the pad except safety personnel and

those required for arming and disarming

operations. I will check the stability of my rocket

before flight and will not fly it if it cannot be

determined to be stable. When conducting a

The team and spectators will be following the

instructions of the range safety officers and will

maintain the minimum distance and keep spectators

back so that only required personnel will be around

the rocket.


simultaneous launch of more than one high power

rocket I will observe the additional requirements

of NFPA 1127.

I will launch my rocket from a stable device that

provides rigid guidance until the rocket has

attained a speed that ensures a stable flight, and

that is pointed to within 20 degrees of vertical. If

the wind speed exceeds 5 miles per hour I will use

a launcher length that permits the rocket to attain

a safe velocity before separation from the

launcher. I will use a blast deflector to prevent the

motor’s exhaust from hitting the ground. I will

ensure that dry grass is cleared around each

launch pad in accordance with the accompanying

Minimum Distance table, and will increase this

distance by a factor of 1.5 and clear that area of

all combustible material if the rocket motor being

launched uses titanium sponge in the propellant.

The team will only launch in safe conditions, under

guidance from the range safety officers.

My rocket will not contain any combination of

motors that total more than 40,960 N-sec (9208

pound-seconds) of total impulse. My rocket will

not weigh more at liftoff than one-third of the

certified average thrust of the high power rocket

motor(s) intended to be ignited at launch.

Flight Safety. I will not launch my rocket at

targets, into clouds, near airplanes, nor on

trajectories that take it directly over the heads of

spectators or beyond the boundaries of the launch

site, and will not put any flammable or explosive

payload in my rocket. I will not launch my rockets

if wind speeds exceed 20 miles per hour. I will

comply with Federal Aviation Administration

airspace regulations when flying, and will ensure

that my rocket will not exceed any applicable

altitude limit in effect at that launch site.

I will launch my rocket outdoors, in an open area

where trees, power lines, occupied buildings, and

persons not involved in the launch do not present

a hazard, and that is at least as large on its

smallest dimension as one-half of the maximum

The propulsion team will choose the correct motor for

the rocket. The team will only launch in safe

conditions, under guidance from the range safety

officers


altitude to which rockets are allowed to be flown

at that site or 1500 feet, whichever is greater, or

1000 feet for rockets with a combined total

impulse of less than 160 N-sec, a total liftoff

weight of less than 1500 grams, and a maximum

expected altitude of less than 610 meters (2000

feet).

My launcher will be 1500 feet from any occupied

building or from any public highway on which

traffic flow exceeds 10 vehicles per hour, not

including traffic flow related to the launch. It will

also be no closer than the appropriate Minimum

Personnel Distance from the accompanying table

from any boundary of the launch site.

I will use a recovery system such as a parachute in

my rocket so that all parts of my rocket return

safely and undamaged and can be flown again,

and I will use only flame-resistant or fireproof

recovery system wadding in my rocket.

The recovery team has equipped the rocket with a

drogue parachute to slow the descent at apogee, then

the main parachute will deploy at 700 ft. to the ground

to slow it to a gentle land.

I will not attempt to recover my rocket from

power lines, tall trees, or other dangerous places,

fly it under conditions where it is likely to recover

in spectator areas or outside the launch site, nor

attempt to catch it as it approaches the ground.

The team will not attempt dangerous recoveries.

4.6 Compliance with FAA Safety Ordinances

To ensure safety and proper protocol through the Federal Aviation Administration the team will build

protocols for safe flying around their requirements. These requirements and the teams plan to ensure those

requirements are met are in the table below.

Table 31: FFA Safety Ordinance Compliance Matrix

FAA Requirement Team Plan for Compliance

Rockets may not be flown in controlled airspace

(which is extensive in the U.S. even at low altitudes

and includes all airspace above 14,500 feet), within

5 miles of the boundary of any airport, into cloud

cover greater than 50% or visibility less than 5

miles, within 1500 feet of any person or property

not associated with the operation, or between

sunset and sunrise.

The team will only fly in NAR approved locations, by

the locations requirements. These NAR locations are

also FAA approved.


The NAR safety codes and the NFPA Codes both

require that rockets be launched from a distance

by an electrical system that meets specific design

requirements. Ignition of motors by a fuse lit by a

hand- held flame is prohibited, and in fact both

NFPA Codes prohibit the sale or use of such fuses.

The rocket uses the NAR approved electrical system

and therefore meets FAA's requirements.

All persons in the launch area are required to be

aware of each launch in advance (this means a PA

system or other loud signal, especially for high-

power ranges), and all (including photographers)

must be a specified minimum distance from the

pad prior to launch.

The range safety officers on NAR approved launch

points use megaphones or a PA or air horns to ensure

all personnel in the area are aware of launches and

those range safety officers also maintain the minimum

safe distance by using caution tape and have extra

officers on hand to remind participants of the rules.

4.7 Procedural Compliance

Checklist Hierarchy & Sign-off

To ensure the proper personnel are informed of all safety checks, the president and vice president will

have to sign off on all checklists along with either the team lead or the safety officer for each specific

subsystem. Below is a peek at the forms the team leads, president and vice president will use to ensure

each step is taken and double checked.


4.8 Recovery Preparation Checklist

The University of Toledo Rocketry Club – Recovery Preparation Checklist

Preparer:__________________________________ Date:_______________

This checklist is to ensure that all components of the recovery system are sound and ready for flight. All items are

to be in proper working condition. Failure to take action on non-operational items can result in damage or injury.

Any items not prepared must be prepared before launch!

Pre-Flight Inspection

Inspect all Forged Eye Bolts for damage (Main Parachute Bay, Electronics Bay, Drogue Parachute Bay)

Inspect Eye Bolt Bulkheads for damage (Main Parachute Bay, Electronics Bay, Drogue Parachute Bay)

Inspect Quick Links for Damage (Main Parachute Bay, Electronics bay, Drogue Parachute Bay)

Ensure Quick Links can close securely and screw latch is not loose

Inspect shock cord for fraying, ripping, or burns

Inspect shock cord & Quick Link connection points to ensure epoxy and knot is secure

Inspect Drogue Parachute shroud lines for burns, tears, or fraying

Inspect Drogue Parachute Canopy for burns, tears, or holes that might compromise flight

Inspect Drogue Parachute swivel link for bending or cracks in metal

Inspect Main Parachute shroud lines for burns, tears, or fraying

Inspect Main Parachute Canopy for burns, tears or holes that might compromise flight

Inspect Main Parachute swivel link for bending or cracks in metal

Inspect the Kevlar parachute blast sheets (x2) for burns or tears

Inspect Electronics Bay Battery Charge (Must be at Minimum 75% of original charge)

Inspect Electronics Bay Altimeters (Must be able to enter ready state)

Inspect Electronics Bay Wiring for damaged, loose, or disconnected wires

Inspect Blast Caps for damage

Inspect Arming Switches for Damage


Pre-Flight Installation and Assembly

Ensure all Quick Links are securely attached to their respective Forged Eye Bolt

Ensure Electronics Bay Blasting caps have the proper amount of Black Powder (2g main, 3g backup)

Ensure Electronics Bay Blasting caps have been properly sealed to prevent black powder leakage

Ensure all nuts on the Electronics Bay’s threaded rods are tightened and secure

Ensure the drogue parachute is properly folded before use

Ensure the main parachute is properly folded before use

Ensure the drogue parachute is attached to the aft portion of the electronics bay

Ensure the Main Parachute is attached to the fore portion of the electronics bay

Ensure Kevlar Parachute Blast Sheets are installed with knot

Ensure the shock cord is properly folded before installation

Ensure parachutes are properly inserted as to not be restricted upon exit

Ensure Electronics Bay is properly inserted into the Drogue Parachute Bay

Ensure Electronics Bay is properly inserted into the Main Parachute Bay

Sign-Off:

Recovery Team Lead:

Vice President:

President:

Comments:


4.9 Motor Preparation Checklist

The University of Toledo Rocketry Club – Motor Preparation Checklist

Preparer:__________________________________ Date:_______________

This checklist is to ensure that all components of the recovery system are sound and ready for flight. All items are



* Instructions to assemble the motor are provided with the kit. Motor must be assembled by qualified personnel.


Inspect that the motor casing is clean and free of debris

Inspect that the motor casing is free of damage

Inspect that the motor mount is free of damage

Inspect that the motor retainer is properly adhered to the rocket

Inspect that the motor kit has all required components for assembly

Inspect that all needed tools are present and ready to be used


Assemble motor in motor casing according to the provided instructions*

Ensure all portions of the motor assembly have been followed*

Insert motor casing with finished motor into motor mount

Ensure motor retainer is properly tightened to secure motor

Ensure Motor Igniter is NOT installed in the motor

Sign-Off:

Propulsion Team Lead:

Vice President:

President:

Comments:


4.10 VMAS Preparation Checklist

The University of Toledo Rocketry Club – VMAS Preparation Checklist

Preparer:__________________________________ Date:_______________

This checklist is to ensure that all components of the VMAS system are sound and ready for flight. All items are




Inspect the retaining bulkhead in the payload deployment bay for cracks or breakage

Inspect the forged eye bolt for signs of wear or breakage

Inspect the retaining nuts to ensure no signs of stretching have occurred

Inspect the retaining rods to ensure that the threads have not been compromised

Inspect the washers for cleanliness and debris


Weigh out the proper mass in washers that is needed based on OpenRocket Simulation data

Place the forged eye bolt through the bulkhead centering ring with the appropriate mass of washers

Ensure that a small washer has been placed on the outer side of the bulkhead in between the forged eye

bolt and bulkhead

Place on, then hand tighten, then torque the two retaining nuts to prevent slippage of the mass washers

Ensure that all portions of the VMAS are properly secured down and can be assembled within the system

Sign-Off:

Vehicle Team Lead:

Vice President:

President:

Comments:


4.11 Launch Stand Setup Checklist

The University of Toledo Rocketry Club – Launch Stand Setup Checklist

Preparer:__________________________________ Date:_______________

This checklist is to ensure that all components of the launch system are sound and ready for flight. All items are to

be in proper working condition. Failure to take action on non-operational items can result in damage or injury.


Tools needed:

Screwdriver flat head and Phillips head


Ensure Launch Lugs are Engaged

Raise Rail to desired angle, based on wind speed and direction

Tighten bolts to lock rail into place

Confirm active surfaces are locked at zero degrees. If active services are off angle disengage and fix

payload.

Check continuity of E-Matches

Ensure GPS software has GPS lock and map view loaded

Inform Launch Control Officer that rocket is ready to launch

Pre-Flight Assembly

Lower Launch Rail

Slide Rocket onto Launch Rail

Ensure Launch Lugs are Engaged

Raise Rail to desired angle, based on wind speed and direction

Tighten bolts to lock rail into place

Engage the payload with rotary switch and screwdriver

Confirm active surfaces are locked at zero degrees. If active services are off angle disengage and fix

payload.

Activate first Altimeter with screwdriver

Listen for three beeps to signify continuity of E-Matches

Repeat for Second Altimeter

Sign-Off:

Vice President:_______________________________________________

President:_______________________________________________

Comments:


4.12 Pre-Flight Troubleshooting Checklist

The University of Toledo Rocketry Club – Troubleshooting Form

This form is to ensure that any common issues are resolved to prepare for flight. All items are to be in proper

working condition. Failure to take action on non-operational items can result in damage or injury. Any items not

prepared must be prepared before launch!

Issues Solutions

Shear pins are loose Add or replace electrical tape over shear

pins

Altimeters are failing e-match continuity

test

Remove electrical connections between

altimeters and E-matches and recycle to

Recovery Checklist

Altimeters failing to signal Replace the 9V battery and check the other

altimeter.

Altimeters signal incorrect deployment

parameters

Reset altimeters. If problem persists,

connect to ground control computer and

reprogram proper parameters. Notify

Recovery Team Lead.

Loose battery connections Add electrical tape and zip ties until the

batteries are securely fashioned.

Payload will not turn on Change Batteries

Ensure continuity between battery and

electronics

Investigate wire harness

Damaged control surface Replace damaged control fin and inspect

others for damage. Ensure the shaft is not

bent.

Parachute not packing properly Remove parachute and re-roll, being

mindful of tightness of roll

Bent/damaged control surface shaft Replace damaged shaft and inspect the

alignment of the other shafts.

Shock cable shows tearing or damage Replace damaged shock cable and inspect

all other shock cable

Epoxy shows signs of cracking or damage Add more epoxy and inspect all other

epoxy sites. Inform mentors and team


members. Adequate time is needed for

epoxy to cure.

Bolt or screw found loose Tighten bolt or screw. Add Loctite as

needed. Inspect other bolts and screws.

Bolt or screw missing Replace bolt or screw with spare. Notify

other members to ensure adequate spares

are available.

Motor not firing Replace the e-match and check connections

Shock cord shows damage/tears. Replace damaged shock cord with new

shock cord of equal length.

Quick Link not properly securing Replace the damaged quick link with a new

one. Inspect the other quick links for signs

of damage.

Control surface gearbox not turning Add lubricant and hand spin to ensure free

movement.

GPS unit not communicating with ground

control

Cycle the GPS power and reattempt

communication.

Check ground station antenna connection

Microcontroller/payload control board not

logging/reading data properly

Cycle power

Replace with backup board

Rocket coupling does not fit properly Add/remove masking tape to ensure

proper fit

Masking tape/ electrical tape not adhering

properly

Clean off surface that is being taped.

Control surfaces loose on shafts Check set screw tightness

Replace the control surface with one of the

available backups

Add epoxy to solidify the link

Replace the shaft

Check other control surfaces

Wet black powder Store black powder in a dry environment

Obtain dry black powder

Delay flight until black powder is dried

Shock cord tangled/snagged Untangle and inspect for damage

Bolts, nuts or screws broken or damaged Remove and replace the damaged

component

Nomex blanket damaged/torn Replace the nomex blanket and inspect

parachutes

Inspect other nomex blanket and parachute

Inspect interior of rocket for any burrs or

foreign materials


Detect any foreign or unfamiliar noises will

assembling or transporting the rocket

Inspect for any loose or damaged

components or foreign materials

Motor retainer loose or threads stripped Retap threads

Tighten screws

Loose or damaged launch lugs Tighten or replace as needed

Inspect other launch lug

Launch rail not locking into place Tighten

Inform RSO and LCO

Servo not turning Inspect pulse width modulation output

from control module

Test with backup board

Replace with backup servo

Loose rotary (enabler) switch Tighten nut

Replace with backup switch

epoxy in place

Ground control laptop not activating Charge battery

Use secondary laptop

Altimeter/GPS not linking to computer (for

data extraction)

Inspect cable

Comments:


4.13 Post-Flight Inspection Checklist

The University of Toledo Rocketry Club – Post-Flight Inspection Checklist

Preparer:__________________________________ Date:_______________

This checklist is to ensure that all components of the rocket have survived the flight. All items are to be in proper

working condition. Failure to take action on non-operational items can result in damage or injury.

Post-Flight Inspection

Insert flat head screwdriver to turn off Altimeters.

Insert screwdriver to turn off payload.

Open payload ejection bay and inspect CO2 compartment for damage.

Disconnect Quick Links.

Inspect Parachutes for burns or damage.

Inspect Shock Cords for burns or damage.

Remove Motor when cool.

Inspect Motor mount for damage.

Inspect Fins for damage.

Check for “Zipper” damage along body.

Connect Altimeters to computer to download flight data.

Disassemble the payload area.

Remove SD card from electronics payload.

Insert SD card from electronics into PC and retrieve the collected data from SD card.

Sign-Off:

Vice President:

President:

Comments:


4.14 Post-Flight Vehicle Body Checklist

The University of Toledo Rocketry Club – Post-Flight Vehicle Body Inspection

Checklist

Preparer:__________________________________ Date:_______________




Ensure that the motor is still retained by the motor retainer

Inspect that the fins have not sustained damage upon landing

Inspect the fin fillets to ensure that no cracks have formed

Inspect the Lower Body Tube to ensure that no damage is present

Inspect the electronics bay outside for any damage

Inspect the main parachute bay outside for any damage

Inspect the outside of the payload ejection bay for damage

Inspect the outside of the payload bay for damage

Inspect the nosecone for damage

Inspect the shock cords for burns, tears, or any other forms of damage

Inspect the forged eye bolts to ensure that no signs of fatigue or damage have occurred

Clean the outer surface of the rocket to inspect for damage

Sign-Off:

Vice President:

President:

Comments:


4.15 Post-Flight Payload Mechanics Checklist

The University of Toledo Rocketry Club – Post-Flight Payload Mechanics Checklist

Preparer:__________________________________ Date:_______________




Ensure that all portions of the rover body are free of damage, cracks, and damaging wear

Inspect the gear wheels to ensure that all teeth are in operable condition

Inspect the solar panels to ensure that no damage has been done do the solar cell

Clean the solar panels of any debris that may inhibit operability

Ensure that all on-board components are securely fastened

Ensure that Wheel Balls are securely fastened

Inspect for damage on the Wheel Balls

Inspect for damage on the locking mechanism

Inspect servos for damage and general wear and tear

Clean the rover of any foreign matter that may have been picked up during use

Ensure all terminals are free of debris and have not been bent or otherwise compromised

Sign-Off:

Vice President:

President:

Comments:


4.16 Post Flight Electronics Checklist

The University of Toledo Rocketry Club – Electronics Setup Checklist

Preparer:__________________________________ Date:_______________

This checklist is to ensure that all components of the Electronic system are sound and ready for flight. All items

are to be in proper working condition. Failure to take action on non-operational items can result in damage or

injury. Any items not prepared must be prepared before launch!

Tools needed:

Philips screwdriver


Rover board is secure to the rover

Battery is properly mounted

SD card is formatted and in the mainboard

All connection are properly secure

Pre-Flight Assembly

Connect Servos

Insert SD card

Secure mainboard to rover chassis

Connect battery

Ensure Status LED is blinking

Sign-Off:

Vice President:_______________________________________________

President:_______________________________________________

Comments:


5 Payload Criteria

5.1 System Overview

The payload will be a four-gear wheeled rover that will deploy itself from the rocket after landing and the nose

cone has been ejected. A CO2 ejection system will be utilized to safely eject the nose cone from the rocket while

also making sure it lands safely out of the path of the rover. The rover will then self-deploy, driving itself out of

the rocket and driving a minimum of five feet to reach the minimum required distance. At that point, the rover

will deploy folding solar panels, creating a total exposed surface area of 6.837 square inches of solar panel

surface.

5.2 Rover Design – Mechanical Systems

Rover Body Design

The rover will utilize four Adafruit continuous rotation micro servos in order to give power to each of the four

wheels independently. These servos will be able to rotate at a maximum speed of 130 RPM. When no load is

applied, the servos will draw 120 mA of current and the servo will stall out when it is using 650 mA of current. At

6 volts, the servos will produce 20.86 oz/in of torque as a maximum. Each servo is 1.2" x 1.2" x 0.5" and weighs

0.159 ounces. They will all be attached to the rover base via the mounting holes on the servos and machine

screws. A small amount of epoxy will be added to ensure a completely stable attachment to the rover.

Each of the servos will be attached to a gear made of nylon that will act as the wheels when driving outside of the

rocket, and act as a way to extract the rover from the rocket after landing. The gears themselves are 2.25" in

diameter and 5/16" wide. They have a pitch of 16 and have 36 teeth. They will mesh with a 5/16" wide rack of the

same pitch that will be mounted to a 3D printed base attached to the inner diameter of the payload tube. All gears

on the rover and rocket utilize a 14 ½" pressure angle that maximizes contact between the mating teeth for smooth

operation during gear on gear power transmission.

The rover base will be 3D printed on a stereolithographic printer to allow for complex and smooth parts that a

regular fused deposition modeling printer cannot offer the team. The base has cutouts and mounting points to

allow for easy attachment of the various components of the rover. There is also a T channel on the bottom of the

rover base to attach the rover to the payload base and to keep the rover secure during flight.

Finally, the rover will have 3D printed parts attached to holes in the gear wheels. These 3D printed parts, called

wheel balls, will ensure that even if the rover exist the rocket on its side, it will not be able to balance on the large

flat surfaces on the wheels gears, and instead be forced to tip either side allowing the rover to drive away after

settling on the ground.

5.2.1.1 Materials Selection – Rover Body

The material used for the rover body will be comprised of resin from a resin 3D printer. The team will be 3D

printing the entire body of the rover. The reason for printing the body is that it will provide a quality finish on the


parts as well as allow the team to print overhangs and other very specific shapes that the team needs for the body

of the rover. This will also make for easier construction of the rover body.

5.2.1.2 Construction Techniques

The payload bay uses similar construction techniques to other sections of the vehicle, namely the recovery bay.

The CO2 canister section is constructed similar to the recovery bay, using a coupler section and two bulkheads

attached with two threaded rods. This is then screwed into the payload bay section, and then connected with shear

pins to the main parachute compartment of the rocket.

The rover body and connected systems are primarily SLA 3D printed resin parts. As explained in the materials

selection section, this allows for high quality smooth prints, which is important due to the design of sliding solar

panels, while also allowing the printing of a complex rover body, which would not be as possible with a more

traditional FDM printer. The supports inside the payload bay are FDM printed parts, as the tolerances are not as

critical as those inside of the rover.

3D printed parts that are permanently attached to the payload bay or to the rover body are done so with epoxy,

allowing the system to hold up to the rigors of launch. It is important the rover and related systems remained fixed

during flight for stability and safety.

5.2.1.3 Component Placement

Figure 35: Rover Integration into Payload Bay

The payload bay is arranged, from aft to forward, the CO2 ejection canister, the rover and rover assembly, and

then the nose cone. The CO2 canister section is screwed into the payload bay tube, and attached to the main

parachute compartment with four nylon shear pins. The rover rack and pinion setup is then attached with epoxy to

the inside of the payload bay compartment, with the rover positioned in such a way where the gear wheels are

engaged into the rack and pinion. Forward of the rover assembly is the nosecone, which is attached with four


nylon shear pins. This allows for the nosecone to be deployed by the ejection system when commanded after

landing.

5.2.1.4 Dimensional Design – Rover Body

The rover body is a custom made and 3D printed component that has the necessary channels and mounting holes

necessary to allow for the proper attachment of our solar panels, servos, gears, and any other electronics. The

rough dimensions are 3” wide, 6” long, and 0.9” tall. In the center of the rover body is a hole that will be used for

the mounting of solar panels. This hole measures 1.654” by 1.378” and is 0.25” thick. This allows the rover to

hold the whole of the main body solar panels within the rover itself and allows it to be sunken down into the rover

allowing the solar panel carriers above to be undisturbed by the panel below. There is also a T-channel that the

rover will use to secure itself to the inside of the payload bay during launch. This T-channel will prevent the rover

gears from moving off the track, ensuring the rover wheels will be able to bring the rover out regardless of

orientation. This T-channel will be 0.2” at its widest point and be 0.2” deep. It will extend 0.6” out below the

main rover body, giving us proper clearance for electronics and other components on the base of the rover. There

is also an insert for our ultra-nano servo that will be deploying the solar panels. That insert measurers 1.2” wide

and 1.0” long allowing for a perfect slot to hold and mount the servo, with the included mounting holes lined up

to the mounting bracket on the servo. There are also four holes through the main body of the rover meant to house

the racks that will carry out the solar panels. The measure 0.15” by 0.2375” and are used to house the racks that

will move the solar panel carriers. These racks are 0.125” by 0.125” so there is plenty of wiggle room for

construction inconsistencies.

Figure 36: Rover Base Dimensional Diagram


Gear Wheel Design

The critical design continues to utilize the gear wheel design that was described in the Preliminary Design

Review. The wheels are nylon gears attached directly to continuous servos. The servos will drive a rack and

pinion system in which the wheels act as the pinions and are meshed to two sets of gear racks attached to the base

of the payload bay. This ensures there is sufficient traction while the rover is within the payload bay, enabling the

rover to drive itself out of the payload bay on its own power. Though gears are not traditional tires, due to the size

of the gears and the teeth on them, it was determined they will provide sufficient traction on the terrain at the

launch field.

Figure 37: Gear Wheel Representation

5.2.2.1 Dimensional Design – Gear Wheels

The dimensions of the gears that will be utilized in the rover are four 2.25" diameter large gears with a 5/16"

width. They have a pitch of 16 and 36 teeth. The team went with gears of this dimension as it allows the team to

utilize more space within the payload bay for the body of the rover. This also allows the gears to mesh with a rack

of the same width and pitch that will be mounted to a 3D printed base attached to the inner diameter of the

payload tube.

Figure 38: McMaster-Carr Gear Diagram


5.2.2.2 Materials Selection – Gear Wheels

The gears that will be used for the wheels of the rover will be made of nylon with a diameter of 2.25" with 36

teeth. The team selected these gears as the wheels for the rover as the team determined they would provide

sufficient traction on the terrain of the field while also being able to withstand and overcome any obstacles that is

presented to the rover. They also allow for the team to utilize one system for driving and for self-deployment.

Nylon specifically is a good plastic for the team to use because of their light weight, keeping the overall weight of

the rover low, and because the nylon gears will mesh better with the racks compared to 3D printed ABS gears.

Solar Panel Design

The solar panel design selected for the Critical Design Review was a sliding solar panel design, which is

comprised of solar panels on sliding trays that extend from the sides of the rover. An ultra-nano servo drives

mirrored rack and pinions to extend the solar panels. The solar panel trays are fixed to the rack of the rack and

pinions, and will be extended in unison by the single gear. This system has a lower profile than other solar panel

designs, which allows for higher ground clearance for the rover. This design also allows for the largest change in

exposed solar panel surface area. The solar panels being deployed by the rack and pinion means there is a positive

mechanical system deploying the panels, as compared to a passive spring system. See Figure 39.

Figure 39: Rover Design with Deployed Solar Panels

5.2.3.1 Deployment Methodology

The critical design utilizes a CO2 canister to eject the nose cone from the payload bay, allowing the rover to

deploy itself from the payload bay. The CO2 canister is a Peregrine 8g canister manufactured by Tinder Rocketry.

The Peregrine CO2 canister is intended for use in high powered rocketry recovery bays, so it is already suited for

the rigors of flight. Using a commercially available system reduces design complexity and the risk of a custom-


built system. Canisters come pressurized from the vendor, and are single use, so their pressurization history is

only the initial fill.

The canister will be located in a coupler at the rear of the payload bay. A turn switch will be accessible to the

exterior of the rocket and will serve as the arming switch for the ejection system, per NASA's requirements. This

is a similar layout to what is used in the recovery bay of the rocket, this allows the team to ensure the energetics

will not activate before the vehicle is safe on the pad. The rover will receive the signal to deploy the rocket and

activate the e-match inside of the CO2 canister assembly. The method in which the payload subsystem receives

and handles the signal is described in Section 5.3.2.1. The electronic match will ignite a small black powder

charge, which will propel the canister into a pin that will puncture the throat of the canister. The pressure caused

by the CO2 release will eject the nose cone from the payload bay. The nose cone will be attached to the body tube

of the payload bay by nylon shear pins, a similar construction to the recovery system. This ensures that the nose

cone will be safely out of the path of the rover during deployment and when driving on the terrain.

As described in Section 5.2.2, the design of the rover wheels and payload bay provide the means for the rover to

deploy itself after landing. The wheels of the rover are gear shaped, allowing the rover to mesh in with a rack of

gear teeth at the base of the payload bay, this essentially creates a rack and pinion system for the rover to use to

drive itself out of the payload bay. A T-shaped slot in the payload bay allows the rover to remain meshed with the

gear rack independent of orientation after landing. The orientation independent design is justified as well. The

gear rack extends along the length of the payload bay which provides positive traction with the gear wheels until

the front rover wheels are free from the vehicle and can engage with the terrain at the landing site. Additionally,

this rack and pinion design provides the retention required to ensure the rover cannot move during the launch

phase of the mission. The detailed verification of this NASA requirement is described in Section 5.2.1.4

5.2.3.2 Dimensional Design – Solar Panels

The dimensional design of the solar panels will be measuring at 1.378" x 1.654" x 0.079". This will be one large

panel in each section for ease of installation and added simplicity of the construction of the rover solar panel

system. These panels output 223mW of power max at 6.3 V and 50mA. It is a monocrystalline panel produced by

IXYS Solar as part of their IXOLAR series of small solar panels. It will be bought through DigiKey as they offer

good savings when buying in bulk, along with quick shipping.

Two of the solar panels will be directly mounted to the rover body and will not actively move during the solar

panel deployment process. The other four solar panels will be mounted to solar panel carriers which will allow the

rover to deploy the solar panels out of the sides of the rover. The panels’ carriers will be moved into their

extended position with an ultra-nano servo. This servo offers 11.11 oz/in of torque at a speed of 0.1sec/60. It is

also a very small servo, thus the name, at 0.73\"x0631" x0.275". That allows the servo to fit well into the small

space available on the rover.

The servo will turn a 16-tooth gear that will mesh with two racks stacked opposing on the gear so when the servo

turns the gear, the two racks will be moved in opposite directions. The racks are 1/8"wide, 1/8" tall, and 3.09"

long. These racks will be attached to the solar panel carriers and move the carriers are moved by the gear and

servo. Once the carriers have been fully deployed, they will bind with the rover base and be locked in place to


prevent further movement. Once fully deployed, the rover will have a total surface area of 6.838 square inches of

solar panel area exposed to the sun.

5.2.3.3 Materials Selection – Solar Panel

The solar panels that the team will be using are IXYS SLMD12H10L Panels. The team will be utilizing 6 of these

panels with the dimensions of 1.378" x 1.654" x 0.079". They will output 223mW at 6.3V with a total surface area

of 6.838 square inches.

Orientation Independency

An orientation-independent rover design was ultimately selected for the critical design review. The rover is

designed such that all operations it performs can be performed regardless of orientation, including as follows:

deployment, solar panel deployment, and driving. The wheels of the rover extend out past the body of the rocket

on both sides, allowing the wheels to have clearance and traction on either side of the rover. The rover is attached

in the payload bay in a way that allows it to have traction against the rack and pinion regardless of orientation.

5.2.4.1 Design Rationale

The team decided upon this overall design of the rover as it was found that this design maximized the ability to

utilize space efficiently while also being able to accomplish the necessary tasks to a sufficient degree. As the team

went through the process of what methods and materials to use for the rover, many possible conditions that would

pose problems were taken into consideration. After identifying those issues, solutions that would best eliminate

those concerns were found.

As the team was deciding on what deployment method to go with for the solar panels, ground clearance issues

along with orientation issues were taken into consideration. Since it is not certain how the vehicle will land and

what the orientation of the rover would be, the system needed to solve those concerns. The sliding solar panel

design does exactly that. With having the panels sliding out on either side of the rover, this resolves the issue of

knowing whether there would be enough ground clearance. There will be solar panels on both sides of the solar

panel trays, allowing the team to know that, no matter the orientation of the rover, there will be solar panels facing

towards the sky.

The team had also addressed concerns when deciding the design of the wheels of the rover. The team needed to

know that the wheels would have sufficient traction on the terrain of the launch field as well as have sufficient

traction within the payload bay. The gear wheel design not only will provide both of those, but will also provide

the team extra space within the bay to have more area for the rover body and also utilize only one type of system

for driving and deployment. While considering the possible issue of orientation when the vehicle lands, the team

will also be adding 3D printed parts, called wheel balls. Adding the wheel balls to the wheels of the rover will

ensure that even if the rover exits the vehicle on its side, it will not be able to balance on the large flat surfaces of

the wheel gears, and instead will be forced to tip to either side allowing the rover to drive away after settling on

the ground.


For these reasons, the team decided upon these designs. The designs that the team has chosen will ensure to best

avoid any and all foreseeable concerns. These designs best alleviate concerns during the deployment of the rover

along with the deployment of the solar panels, and the ability to drive sufficiently on the terrain of the launch

field.

5.3 Rover Design – Electrical Systems

Payload Electronics

The rover will consist of four main components. These include: a GPS module, an Inertial Measurement Unit

(IMU), a CO2 activation circuit, and a radio transceiver. Once the signal from the ground station is sent, the rover

will begin the deployment processes. To facilitate the operation of the deployment system, a coupling system has

been devised that allows free motion of the rover while retaining the ability to form strong electrical contacts

between the rover’s electronics and the e-match circuitry on the rocket.

5.3.1.1 Electronics Integration

The electronics of the payload will have multiple effects on different sections of both the rover and vehicle to

allow for mission success. The first effect will take place when the rocket has landed, and the deployment signal

has been sent from the ground station. This will cause a CO2 ejection charge to fire, removing the nose of the

payload bay. Then, when this is completed, the rover will engage a set of four servo motors to move the rover out

of the payload bay. Finally, when the rover has travelled the required distance, it will activate another servo motor

to deploy the solar panels.

In order to measure the distance the rover travels, the rover will collect and store Inertial Measurement Unit

(IMU) data during the mission. This will be stored in an SD card located within the rover. For redundancy, and in

the event the rover is unable to be recovered, the rover will also transmit this data to the ground station.

The five servo motors that the electronics will be running will be controlled by Pulse Width Modulation (PWM).

The ATMega32U2 that is running these motors have five lines for this, that the servo motors will be connected to.

5.3.1.2 Software Used to Program Controller

The software used to program the microcontrollers is Atmel's DFU bootloader. These tools require a C or C++

compiled binary which then can be sent to the DFU programmer to flash the program onto microcontrollers.

These tools give the team easy access to flash and verify that the program is properly installed onto the controller.

Both the bootloader and programmer are open source and well documented making it simple to write functional

code for Atmel products. The team is familiar with Atmel microcontrollers because of past experience working

with them, so the team decided to integrate Atmel microcontrollers into the final designs and using the above-

mentioned toolchains to compile the program and flash it to the microcontroller.


5.3.1.3 Rover Board Schematic

Figure 40: Main Board Schematic


Figure 41: Rover Circuit Board – Front View

Figure 42: Rover Circuit Board – Back View

Figure 43: Ground Station Circuit Board – Front and Back


Figure 44: Ground Station Schematic


Ground Control Operations

Ground control operations will be carried out via an RF transceiver connected to a laptop over USB. Custom

Python-based software records data and displays data coming from the rocket and rover in real time. Flight data is

recorded locally (on board the rover) as well as remotely (at the command station). In the event that either radio

communication to the rover is lost or recovery of the on-board SD card is not possible, data will not be lost. Upon

a successful landing, once the accelerometer data reads constant and the all clear has been given, the rover will be

deployed from the same program. See block diagram, Figure 45, below:

Figure 45: Command Station Logic Block Diagram


5.3.2.1 Communication with Rover

A Yagi-Uda antenna is used to communicate with the rover from the command station. Simulations show the

current design featuring a forward gain of 9.24 dB, standing wave ratio of 1.1, and an impedance of 47.8 ohms

which will be matched with the command station circuitry through a pi-match circuit. Two directing elements are

used to increase gain in the direction of interest since the rover is the only device the team would want to receive

information from. To further increase the forward gain, three reflecting elements are used to reduce rear facing

sensitivity. Figure 46 below show the radiation pattern with (left) and without (right) a simulated ground which

further increases the gain as the radio waves are reflected up and away. The Smith chart is also shown in Figure

47

Figure 46: Antenna Simulation 1 Meter above Ground and in Free Space


Figure 47: Smith Chart for Yagi-Uda Antenna

The boom of the antenna will be made from aluminum tubing ½" in diameter with a wall thickness of 1/16". The

reflecting and directing elements will also be made from aluminum rod ¼" in diameter. Mounting the elements to

the boom while remaining electrically separated will be accomplished through 3D printed clamps which will also

allow the antenna geometry to be modified as there will be some inconsistencies between simulations and actual

use conditions. See antenna drawing in Figure 48.


Figure 48: Yagi-Uda Antenna Drawing

Messages from the rover to the command station will be structured as so:

ID, temperature, latitude, longitude, speed, time stamp, x-axis accel, y-axis accel, z-axis accel, checksum.

The first segment is to confirm that the messages being received are from the correct rover assuming others will

also be transmitting at 433 MHz. The next seven segments represent temperature, GPS, and accelerometer data.

The final segment is a basic checksum for detecting transmission errors. Before the message is sent, all values

included in the message are added together to create this final value. The command station then adds the received

values to make sure that the message was received correctly. If not, then the offending data point is flagged as

faulty for later review.

5.3.2.2 Remote Deployment

To trigger the ejection of the rover from the rocket, a 433MHz RF transceiver will be used. The chip that will be

integrated into the rover will be the ON Semiconductor AX5043. The AX5043 is a General ISM band RF

transceiver with selectable RF frequency. The team chose 433 MHz as the frequency to use because it is a low

frequency that will yield further range compared to a higher frequency carrier wave at the same power output

while also allowing the team to use small readily available antennas that are already matched to 50 ohms further

simplifying the system.

The CO2 ejection mechanism requires an e-match to trigger the ejection. To ignite the e-match an N-channel

MOSFET will complete the circuit connecting the E-Match directly to the 7.4V 2S Lithium Polymer battery on


the rover. Since the e-match and CO2 canister will be fixed to the rocket body, a coupling system must be utilized

so that the rover can separate completely from the rocket body while retaining a mechanism to activate the

canister. To this end, the team intends to incorporate spring-loaded pogo pins mounted to the main electronics

board. These pins will contact another PCB containing large contact pads for each pogo pin that will connect to

the CO2 deployment system through screw terminals. Two pads will be used to trigger the e-match and two will

be used to ensure continuity has been achieved before triggering. This system requires no mechanical coupling,

only the ability to drive the rover into the contacts which is facilitated by the rack-pinion system. A rotary switch

like those used in the recovery subsystem will be wired in series with the e-match to prevent accidental separation

of the rocket body before the rocket is loaded on the launch pad.

These systems are not active till the radio signal is received and verified which will then cause the rover to do two

more additional checks. The GPS module will be processed to see if the rocket body is in motion. Once the GPS

shows no movement, the rover will begin its second movement check. The IMU (Inertial measurement unit) is

then checked for orientation and any roll in three axes. Once the rover has passed all checks there will be a

continuity test on the connection CO2 ejection charges. The idea behind this check is to make sure the charges

never go off unless the rover is ready and the key switch is active.

5.3.2.3 Distance Reporting

The distance from the vehicle will be measured by GPS and IMU acceleration data. Data from the GPS will be in

the format of position and time. This data is received by the MCUs UART and is parsed out to leave it with only

latitude and longitude. From there, the coordinates are in DD MM SS form and are converted to Radians. After

that, the Haversine formula is applied to calculate the path the rover took along the surface of the Earth. Distances

will be reported to the ground station using the protocol described in section 5.3.2.1 above.

After taking in the GPS data, the rover will be pulling IMU data. The data returned from the IMU is the

acceleration at a given time. This data can be used to calculate a velocity with each pull and compare the time

between reads. During this time, the data is being run through an evaluation function which will compare the IMU

and the time of when it was taken to get an estimate of the current speed. This value will be compared with the

GPS speed and will help obtain an overall more accurate speed thus improving our distance reporting function.

Remote Frequency Compliance

According to the AX5043 datasheet, the transceiver IC has a maximum power output of 16 dBm at 433 MHz..

Below is the conversion from dBm to mW.

𝑚𝑊 = 1 𝑚𝑊𝑥10𝑑𝐵𝑚

10

𝑚𝑊 = 1 𝑚𝑊𝑥1016 𝑑𝐵𝑚

10

𝑚𝑊 = 39.81𝑚𝑊

The radio max output power will be 40 mW at max transmission, which is under the threshold set by the NASA

Student Launch of 250 mW. The output power of the radio is roughly at 16% of the stated limit.


6 Project Plan

6.1 Comprehensive Testing Procedure

The comprehensive testing procedure described below is designed to verify that many of the components used in

the rocket will be able to withstand the expected forces that can occur at the worst-case scenarios and to verify

that the rocket will perform at the desired level in a reliable fashion.

Rover Deployment & Execution Testing

Testing Objective:

In order to ensure that the rover is able to deploy in a multitude of conditions, the rover will be ground tested in

various terrains and circumstances. The primary condition that the team is interested in investigating is in an open

farm field. In order to test the rover self-deployment, the team will build the payload bay and take it out to an

open field. The team will then set the rover, nosecone, and payload ejection bay up in a way that the vehicle

would possibly land and run the simulation to make sure that the rover is able to deploy and exit the payload bay

without any malfunctions. For the team to test the remote deployment, the team would set the ground station

controls up within an expected range that the rover might have landed in. This range will be based on the drift

distances that were calculated in Section 3.4.6. The remote communication with the rover will be tested at each of

the drift distances to ensure the signal is received and processed by the rover. The team will also be looking for

the rover’s return signal indicating that a specific procedure has already occurred.

Passing Criteria:

In Table 32, the criteria for passing the test is given.

Table 32: Rover Deployment & Execution Testing Passing Criteria

Item # Test Requirement Passing Criteria

1 The rover is able to receive communication from the ground

station at the following intervals:

1) 0 ft

2) 583 ft

3) 1165 ft

4) 1747 ft

5) 2329ft

The rover receives communication

from the ground station and

performs the task communicated

from the ground station

2 The rover is able to communicate back to the ground station at

the intervals described in Item # 1.

Ground station receives the

appropriate communication from

the rover at the given intervals.

3 The rover is able to successfully leave the airframe. Rover has fully disengaged the

rack gear and is outside of the

airframe.

4 The rover is able to travel outside of the rocket a minimum

distance of 5 ft.

Ground station receives

communication from the rover that

the distance traveled is greater than

5 ft.


5 Solar panels successfully deploy from the rover. Solar panels are physically

deployed and are beginning to

charge the on-board battery.

Ground station must receive

communication that charging is

happening

6 The rover is successfully able to rotate onto the wheels when

deployed from the side.

The rover manages to correct the

orientation without human

intervention.

Test Results:

Test Not Completed; The test has yet to be completed. Testing is scheduled to occur once the rover has been built

and has been sufficiently prepared for ground testing. Results will be communicated in the FRR.

CO2 Ejection Testing

Testing Objective:

The team needs to test the CO2 Ejection system to make sure that there will be no issues in ejecting the nose cone

from the vehicle so that the rover can properly deploy and move the distance required. To test this, the team will

set up the three components of the vehicle and simulate the deployment of the rover and ejection of the nose cone.

Passing Criteria:


Table 33: CO2 Ejection Testing Passing Criteria


1 E-match ignition E-match puncture the CO2 bottle

seal and releases the gas.

2 Nose cone separation.

Nose cone moves a sufficient

distance to allow rover

deployment. Nose cone is intact

and no cracks were formed.

3 Payload Ejection Bay Remains in Place The Payload Ejection Bay is not

ejected by the force of the CO2

canister ejecting the Nosecone

4 Payload Canister successfully is punctured The payload canister is

successfully punctured and releases

the CO2 to eject the nosecone.

Test Results:

Test Not Completed; The test has yet to be completed. Testing is scheduled to occur once the Payload Ejection

System has been built and has been sufficiently prepared for ground testing. Results will be communicated in the

FRR.


Remote Operations Testing

Testing Objective:

The team will use the main application developed to interface with the rover and test its components. The

interface will show the data received from GPS and IMU modules. This will allow an operator to visually check

that the data is correct and being sent over the rover's radio transceiver. Test commands will be sent via the main

application and will have the rover perform various test actions to see all five servos operate. Once the rover has

passed this test normal operations may begin. If the rover fails any parts of these test the operator can refer to the

preflight electronics checklist to make sure all steps are done correctly.

Passing Criteria:


Table 34: Remote Operations Testing Passing Criteria


1 Radio connection can be made with the rover. Main application detects the rover

and is able to send and receive

data.

2 Commands can be understood by the rover. Rover turns on the corresponding

test wheel based on the command

sent by the main application.

Test Results:

Test Not Completed; The test has yet to be completed. Testing is scheduled to occur once the rover has been built

and has been sufficiently prepared for ground testing. Results will be communicated in the FRR.

Parachute Inflation Testing

Testing Objective:

This is to test the folding methods the team is using to ensure proper parachute deployment. Improper folding

methods can lead to parachute entanglement and mission failure.

Passing Criteria:


Table 35: Parachute Inflation Testing Passing Criteria


1 Parachute opens. Parachute opens fully with a test

weight while being dropped from a

high point.


Test Results:

Test Not Completed; The test has yet to be completed. Testing is scheduled to occur once the parachutes have

been received and the final method for folding the parachutes has been determined. Results will be communicated

in the FRR.

Static Ground Testing

Testing Objective:

Testing the amount of black powder in the E-match for the CO2 ejection system needed to open the seal.

Passing Criteria:


Table 36: Static Ground Testing Passing Criteria


1 Set off an E-match to test the amount of black powder needed to

open the CO2 canister.

CO2 canister opens and release

gasses in a controlled manner. No

server damages we caused by the

black powder.

Test Results:

Test Not Completed; The test has yet to be completed. Testing is scheduled to occur once the Electronics Bay and

the connecting parachute has been built and has been sufficiently prepared for ground testing. Results will be

communicated in the FRR.

Sub-Scale Vehicle Design Launch

Testing Objective:

The team will design and launch a sub-scale version of the proposed rocket design to ensure stability and design

feasibility. This rocket will contain a smaller motor, and GPS tracking in order to determine any variation with

projections, and allow for a model with which to judge the behavior of the full-scale vehicle.

Passing Criteria:

The passing criteria is described in Section 3.2.

Test Results:

Testing Complete; the testing has been completed. Reference Section 3.2 for the overview of the test results.

Parachute Shock Force

The parachute shock force will tell how much force is loaded on the parachute during its initial loading and during

the steady state descent. This will be calculated using a paper published by the Naval Ordinance Laboratory with


originator report number NOLTR 72-146. In the paper, the max shock force and steady state force is shown. For

the purposes of lower level high powered rocketry, it can be assumed that the maximum shock force will be no

higher than 1.5 times the steady state force therefore, only the steady state force will be calculated.

The equation to determine the steady state force is given as:

𝐹𝑠 =1

2𝜌𝑣2𝐶𝐷𝐴𝑆

Where:

𝐹𝑆 = Steady State Force of Parachute Tension [N]

𝜌 = Density of Air [kg/m3]

𝑣2 = Descent Velocity at Time of Parachute Opening [m/s]

𝐶𝐷 = Parachute Coefficient of Drag

𝐴𝑆 = Surface area of Parachute [m2]

All calculations are performed in metric units and the final value is converted into imperial units.

In order to perform this calculation, the density of air was assumed to be 1.225 kg/m3. This is the standard

approximation for atmospheric air at 15C. It is also assumed that the coefficient of drag for the drogue parachute

is 1.14 and main parachute it is 1.26 the surface area is of the drogue parachute is 1.059m2 and main parachute is

5.295m2 where both values come from the manufacturer's product description. The descent velocity of the rocket

is pulled from the OpenRocket Simulation. In order to cover a large variety of scenarios, the best and worst-case

scenario will be looked at. Below is a sample calculation for the best-case scenario drogue chute ejection. The

best-case scenario is the lowest ejection speed. For drogue, this is near zero and for main, this is the expected

velocity with the drogue. The worst-case scenario looks at the highest speed each parachute may experience. In

this case, this is the terminal velocity of the rocket. The terminal velocity is calculated to be 130ft/sec or

39.624m/s.

Table 37: Expected Best and Worst Case Scenario Data

Parachute Scenario Descent Velocity [m/s] CD AS [m2]

Drogue Best 0.604 1.14 1.059

Drogue Worst 39.624 1.14 1.059

Main Best 17.051 1.26 5.295

Main Worst 39.624 1.26 5.295

𝐹𝑆 =1

2(1.225)(0.604)2(1.14)(1.059) = 0.270 𝑁

Below is a table that shows all of the expected forces for the best and worst-case scenarios.

Table 38: Expected Steady State Parachute Force

Parachute Scenario Expected Steady State

Force [N]

Expected Steady State

Force [Lbf]

Drogue Best 0.270 0.061

Drogue Worst 1160.977 260.998


Main Best 1188.071 267.088

Main Worst 6415.924 1442.357

Below is a table that shows all of the expected max forces for the best and worst-case scenarios. The max force is

1.5 times the steady state force.

Table 39: Expected Max Parachute Force

Parachute Scenario Expected Max Force [N] Expected Max Force [Lbf]

Drogue Best 0.405 0.091

Drogue Worst 1741.466 391.497

Main Best 1782.107 400.633

Main Worst 9623.886 2163.536

The results of the calculations show that, regardless of the expected velocity in both the best and worst-case

scenario, both the drogue parachute, which is rated at 950lbf, and the main parachute, which is rated at 2,250lbf,

will be able to survive the shock force and will not tear or disconnect from the rocket.

Full-Scale Vehicle Design Launch

Testing Overview:

Once all of the required components for each sub system have been received and the materials for the vehicle

body have been received, the team will develop and test a full-scale model of the rocket. This model will follow

all of the requirements set forth by NASA and will adhere to the design that has been laid forth in the CDR and

PDR. This will be the first Full-Scale test of the rocket as a whole. This test must be reported on in the FRR in

order to be eligible to attend the NASA SL Competition in Huntsville, AL.

Passing Criteria:

The passing criteria for a successful launch can be found in the Mission Success Criteria that has been laid out in

Section 3.1.1.

Test Results:

Test Not Completed; The test has yet to be completed. Testing is scheduled to occur once all components for each

sub system and the components for the vehicle have been received and assembled. Results will be communicated

in the FRR.

6.2 NASA SL Requirement Compliance Matrix

Table 40: NASA SL Requirement Compliance Matrix

Requirement Requirement Description Verification Method

1.1 Students on the team will do 100% of the project, including design, construction, written reports, presentations, and flight preparation with the exception of assembling the motors and handling black powder or any variant of ejection charges,

The University of Toledo Rocketry club is comprised only of active students at the University of Toledo. The team has members with experience with high powered rocketry, along with L1 and L2 certifications. The team will be


or preparing and installing electric matches (to be done by the team’s mentor).

instructed on how to assemble and prepare the rocket.

1.2 The team will provide and maintain a project plan to include, but not limited to the following items: project milestones, budget and community support, checklists, personnel assigned, educational engagement events, and risks and mitigations.

The project plan for Project Kronos is detailed in section 6.

1.3 Foreign National (FN) team members must be identified by the Preliminary Design Review (PDR) and may or may not have access to certain activities during launch week due to security restrictions. In addition, FN’s may be separated from their team during these activities.

There are no Foreign Nationals to report to NASA.

1.4.1-1.4.3 The team must identify all team members attending launch week activities by the Critical Design Review (CDR). Team members will include:

1.4.1. Students actively engaged in the project throughout the entire year. One mentor (see requirement 1.14). No more than two adult educators.

The team will report members attending launch week by CDR. The team has one mentor and one educator from the University of Toledo.

1.5 The team will engage a minimum of 200 participants in educational, hands-on science, technology, engineering, and mathematics (STEM) activities, as defined in the Educational Engagement Activity Report, by FRR. An educational engagement activity report will be completed and submitted within two weeks after completion of an event. A sample of the educational engagement activity report can be found on page 31 of the handbook. To satisfy this requirement, all events must occur between project acceptance and the FRR due date.

The education team has already educated 352 youths with hands on projects. These are detailed in section 6.2.

1.6 The team will develop and host a website for project documentation.

The website is active at http://utrocketry.com and has been updated regularly over the past two years.

1.7

Teams will post, and make available for download, the required deliverables to the team Web site by the due dates specified in the project timeline.

Documents are hosted on utrocketry.com and will be emailed as pdf attachments to the leadership of USLI.

http://utrocketry.com/


1.8 All deliverables must be in PDF format. All deliverables will be PDF format and available on the team website and emailed to NASA.

1.9 In every report, teams will provide a table of contents including major sections and their respective sub-sections.

The table of contents is located at the beginning of every report, along with a table of tables and list of figures.

1.10 In every report, the team will include the page number at the bottom of the page.

Page numbers are located in the footer of every page of the report.

1.11 The team will provide any computer equipment necessary to perform a video teleconference with the review panel. This includes, but is not limited to, a computer system, video camera, speaker telephone, and a broadband Internet connection. Cellular phones can be used for speakerphone capability only as a last resort.

The university of Toledo has numerous conferences rooms with conference phone systems that are available for the rocketry team's use.

1.12 All teams will be required to use the launch pads provided by Student Launch’s launch service provider. No custom pads will be permitted on the launch field. Launch services will have 8 ft. 1010 rails, and 8 and 12 ft. 1515 rails available for use.

Kronos is designed to use rail buttons for either 1010 or 1515 rails, dependent on speed off rail calculations.

1.13 Teams must implement the Architectural and Transportation Barriers Compliance Board Electronic and Information Technology (EIT) Accessibility Standards (36 CFR Part 1194)

The rocketry club will follow the standards of EIT.

1.14 Each team must identify a “mentor.” A mentor is defined as an adult who is included as a team member, who will be supporting the team (or multiple teams) throughout the project year, and may or may not be affiliated with the school, institution, or organization. The mentor must maintain a current certification, and be in good standing, through the National Association of Rocketry (NAR) or Tripoli Rocketry Association (TRA) for the motor impulse of the launch vehicle and must have flown and successfully recovered (using electronic, staged recovery) a minimum of 2 flights in this or a higher impulse class, prior to PDR. The mentor is designated as the individual owner of the rocket for liability purposes and must travel with the team to launch week.

The team's mentor is Art Upton, who is L3 certified with NAR and has more than 2 high powered flights in his history. The rocket is his for liability purposes.


2.1 The vehicle will deliver the payload to an apogee altitude of 5,280 feet above ground level (AGL).

The predicted altitude is detailed in section 3.3.

2.2 The vehicle will carry one commercially available, barometric altimeter for recording the official altitude used in determining the altitude award winner. Teams will receive the maximum number of altitude points (5,280) if the official scoring altimeter reads a value of exactly 5280 feet AGL. The team will lose one point for every foot above or below the required altitude.

The rocket will fly with two StrattologgerCF Altimeters, one will be marked for judging after the flight.

2.3 Each altimeter will 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.

Each altimeter will be activated with a turn switch that will only be activated when the rocket is prepared on the pad.

2.4 Each altimeter will have a dedicated power supply.

Each altimeter will be powered by their own, securely fastened, 9 volt battery.

2.5 Each arming switch will be capable of being locked in the ON position for launch (i.e. cannot be disarmed due to flight forces).

The altimeters' arming switches are turn switches that cannot be rotated by forces during flight.

2.6 The launch vehicle will be designed to be recoverable and reusable. Reusable is defined as being able to launch again on the same day without repairs or modifications.

The rocket is built with a fiberglass body, and all parts of the rocket are fully reusable.

2.7 The launch vehicle will have a maximum of four (4) independent sections. An independent section is defined as a section that is either tethered to the main vehicle or is recovered separately from the main vehicle using its own parachute.

The rocket has only two independent body parts that will descend under parachute tethered with tubular nylon shock cord.

2.8 The launch vehicle will be limited to a single stage.

The rocket is propelled by a single stage using a commercially available solid fuel motor.

2.9 The launch vehicle will be capable of being prepared for flight at the launch site within 3 hours of the time the Federal Aviation Administration flight waiver opens.

The rocket is designed such that it can be prepared within three hours. Additionally, the team will be trained and practice set up of the vehicle, so that assembly and preparation of the rocket during launch day can be completed in a timely manner.

2.10 The launch vehicle will 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 components.

All electronics systems on the rocket have adequate battery life to have a pad stay time of at least 1 hour.


2.11 The launch vehicle will 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.

The rocket utilizes a commercially available solid fuel motor that is designed to operate on typical 12 volt ignition systems.

2.12 The launch vehicle will require no external circuitry or special ground support equipment to initiate launch (other than what is provided by Range Services).

The rocket requires only the motor igniter to launch the vehicle.

2.13 The launch vehicle will 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).

The vehicle is utilizing an Aerotech motor, which is approved and certified by NAR, TRA and CAR.

2.14 Pressure vessels on the vehicle will be approved by the RSO and will meet the following criteria:

The minimum factor of safety (Burst or Ultimate pressure versus Max Expected Operating Pressure) will be 4:1 with supporting design documentation included in all milestone reviews. Each pressure vessel will include a pressure relief valve that sees the full pressure of the valve that is capable of withstanding the maximum pressure and flow rate of the tank. Full pedigree of the tank will 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.

The details of the pressure vessel are listed in section 3.5.2.2. The pressure vessel is a commercially available CO2 canister designed for recovery ejection systems for high powered rockets, and is suitable for the payload ejection purpose.

2.15 The total impulse provided by a College and/or University launch vehicle will not exceed 5,120 Newton-seconds (L-class).

The preliminary motor chosen for the vehicle is a K-class motor, which is below an L-class motor.

2.16 The launch vehicle will have a minimum static stability margin of 2.0 at the point of rail exit. Rail exit is defined at the point

The static stability margin is detailed in section 3.3.2 and is above 2.0 calibers.


where the forward rail button loses contact with the rail.

2.17 The launch vehicle will accelerate to a minimum velocity of 52 fps at rail exit.

The velocity of the rocket is detailed in section 3.3 The team has a motor selection form that ensures the rocket will have a rail exit velocity of 52 ft/s.

2.18 All teams will successfully launch and recover a subscale model of their rocket prior to CDR. Subscales are not required to be high power rockets.

A subscale model of the vehicle is currently being designed and a launch window identified that is before CDR is due.

2.19 All teams will 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 to be flown on launch day.

After CDR approval of the design, the full-scale rocket will be constructed and flown. Launch windows have been identified before FRR is due.

2.20 Any structural protuberance on the rocket will be located aft of the burnout center of gravity.

There are no structural protuberances on the rocket, with the exception of the fins which are located aft of the burnout center of gravity.

2.21.1-2.21.8 Vehicle Prohibitions:

The launch vehicle will not utilize forward canards. The launch vehicle will not utilize forward firing motors. The launch vehicle will not utilize motors that expel titanium sponges (Sparky, Skidmark, MetalStorm, etc.) The launch vehicle will not utilize hybrid motors. The launch vehicle will not utilize a cluster of motors. The launch vehicle will not utilize friction fitting for motors. The launch vehicle will not exceed Mach 1 at any point during flight. Vehicle ballast will not exceed 10% of the total weight of the rocket.

As detailed in section 3 and the following subsections, the vehicle design does not utilizes any of the prohibitions in requirement 2.21.

3.1 The launch vehicle will stage the deployment of its recovery devices, where a drogue parachute is deployed at apogee and a main parachute is deployed at a lower altitude. Tumble or streamer recovery from apogee to main parachute deployment is also permissible, provided that kinetic

As detailed in section 3.2, a drogue will be deployed at apogee, followed by a main parachute at 700 feet. The kinetic energy under both main and drogue are detailed in the same section and in the Milestone Review Flysheet


energy during drogue-stage descent is reasonable, as deemed by the RSO.

3.2 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.

A ground test will be performed before every flight to ensure proper performance of the recovery system. Flights will be grounded unless a successful ground test is performed.

3.3 At landing, each independent sections of the launch vehicle will have a maximum kinetic energy of 75 ft-lbf.

The kinetic energy of each segment is detailed in section 3.2 as well as the milestone review flysheet and will be checked before each flight against the simulation to ensure they are below the 75 ft-lbf requirement.

3.4 The recovery system electrical circuits will be completely independent of any payload electrical circuits.

The recovery electronics are located in a separate compartment from the payload, separated by the main parachute compartment. The electronics systems are entirely separate.

3.5 All recovery electronics will be powered by commercially available batteries.

The team utilizes Duracell 9 bolt batteries for powering the recovery system, new batteries are used for each flight.

3.6 The recovery system will contain redundant, commercially available altimeters. The term “altimeters” includes both simple altimeters and more sophisticated flight computers.

The vehicle utilizes two StrattologgerCF altimeters that work as a redundant system. One altimeter will be set to activate shortly after the primary altimeter, as detailed in section 3.2.

3.7 Motor ejection is not a permissible form of primary or secondary deployment.

The motor used will be plugged or have the ejection charge dumped, the recovery system utilizes drogue and main charges activated by the altimeters.

3.8 Removable shear pins will be used for both the main parachute compartment and the drogue parachute compartment.

Nylon shear pins have been selected as shear pins and will be used to secure any sections that are designed to separate during flight.

3.9 Recovery area will be limited to a 2500 ft. radius from the launch pads.

Drift distances have been calculated and will be updated as the design progresses, and are detailed in section 3.3.4, the maximum drift distance in 20 mph winds is less than 2500 ft.

3.10 An electronic tracking device will be installed in the launch vehicle and will transmit the position of the tethered vehicle or any independent section to a ground receiver.

The vehicle utilizes as TeleGPS system which will be located in the nose of the rocket. This will transmit the location of the rocket over HAM band radio to the team's ground station.


3.11 The recovery system electronics will not be adversely affected by any other on-board electronic devices during flight (from launch until landing).

The recovery system altimeters are located in an independent segment of the rocket and will not be adversely affected by the other electronics located in the payload bay and nose.

4.3 If the team chooses to fly additional experiments, they will provide the appropriate documentation in all design reports, so experiments may be reviewed for flight safety.

The vehicle will only operate the rover experiment.

4.5.1 Teams will design a custom rover that will deploy from the internal structure of the launch vehicle. At landing, the team will remotely activate a trigger to deploy the rover from the rocket. After deployment, the rover will autonomously move at least 5 ft. (in any direction) from the launch vehicle. Once the rover has reached its final destination, it will deploy a set of foldable solar cell panels.

As detailed in section 5, the rover will meet these requirements. The verifications for these requirements and additional team-derived requirements are explained in section 5.1.2.

5.1 Each team will use a launch and safety checklist. The final checklists will be included in the FRR report and used during the Launch Readiness Review (LRR) and any launch day operations.

Launch and safety checklists will be developed that are representative of the Project Kronos vehicle and will be a part of FRR and utilized during full-scale test flight following CDR.

5.2 Each team must identify a student safety officer who will be responsible for all items in section 5.3.

The safety officer for UT Rocketry is Victoria Raber.

5.3 The role and responsibilities of each safety officer will include, but not limited to: Monitor team activities with an emphasis on Safety during: Design of vehicle and payload Construction of vehicle and payload Assembly of vehicle and payload Ground testing of vehicle and payload Sub-scale launch test(s) Full-scale launch test(s)

The Safety Officer for the team has been briefed on her duties, and is a nursing student with experience in safety. The responsibilities and expectations for the safety officer are detailed in section 4 of this report.


Launch day Recovery activities Educational Engagement Activities

5.4 During test flights, teams will abide by the rules and guidance of the local rocketry club’s RSO. The allowance of certain vehicle configurations and/or payloads at the NASA Student Launch Initiative does not give explicit or implicit authority for teams to fly those certain vehicle configurations and/or payloads at other club launches. Teams should communicate their intentions to the local club’s President or Prefect and RSO before attending any NAR or TRA launch.

Multiple members in the team are L1 and L2 certified, experienced with obeying NAR regulations. The team has developed relationships with local NAR chapters, who have worked with the team to meet team needs for launches and receive proper approval.

5.5 Teams will abide by all rules set forth by the FAA.

The team has L1 and L2 certified members who are aware of FAA regulations and will ensure the team abides by them appropriately.

6.3 Team Derived Requirements

Table 41: UT Rocketry Team Derived Requirements

Team Derived Requirement Requirement Verification

The payload will be able to detect the transmitted signal from at least 2,500 feet away.

A high sensitivity transceiver will be selected, and the transmitting antenna will be supplied sufficient power while staying with regulated power levels.

The incoming radio signals will be filtered so that the response of the deployment system will only occur for the team’s generated signal and at safe operating conditions.

A filter will be designed and constructed on the payload to process incoming signals to locate the desired signal, likely a desired pattern, before the deployment mechanism is activated. Further, data from the IMU and GPS will be analyzed to determine that the rocket has come to a stop after launching to prevent potential activations before reaching a safe deployment position.

The rover’s locking mechanism (servos, wheels, rack) will be able to hold the rover position for a rocket acceleration of up to 15g.

Servos with sufficiently high stall torques will be fixed to geared wheels and a rack that can resist the forces experienced at 15g. Careful consideration of the servos’ fastening system will be considered. The retaining rail design will be evaluated for strength within the potential operating conditions whilst retaining sufficient traction on the geared surface.

The rover’s battery life will be at least 2 hours under the average expected operating conditions.

A high capacity, low form factor battery will be selected for use on the payload. Preliminary current measurements will be made and


evaluated to determine the average expected current draw and compared to the selected battery size.

The solar panels will completely slide out from their position on the rover.

The rails the solar panel rides on will be rigidly constructed and any material residue will be removed to ensure the fit is snug during deployment. Tests will be performed with the servo to ensure proper deployment time is observed for the expected operating conditions.

The nose cone will be ejected sufficiently far from the rocket body so as not to interfere with the deploying rover.

A properly sized CO2 cylinder will be utilized for the given volume of the payload bay. Shear pins will be utilized to fasten the nose cone so that the energetics can properly eject the nose cone.

Utilization of the GPS and the onboard Inertial Measurement System will be able to determine rover position to within 4 feet.

A GPS receiver will be located on the rover alongside an IMU containing gyroscopes and accelerometers. A sensing protocol (e.g. Kalman Filter) will be used to improve the positional accuracy of the sensor suite.

The Rover will be able to transmit its GPS coordinates back to receivers near the ground station during and after flight.

A high sensitivity receiver will be used at the ground station to pick up signals from the payload to account for its inherently low power design.

The gas discharge used to free the nose cone will not dislodge the rover from its position within the payload bay.

The rover will be rigidly fixed by a combination of the servos, rack-pinion system, and the ‘lower’ guide rail. The concentrated discharge will be offset from the rover’s position so that most of the discharge passes harmlessly around the rover.

The electrical coupling system from the rover to the CO2 cylinder’s e-match will successfully separate during rover deployment.

The coupling system will be rigid, so as to resist the flight conditions, but will be susceptible to the force output by the rover in the desired orientation.

All subsystems must be accurately represented in simulations.

All masses and dimensions of components will be measured once the components are obtained, then they must match the OpenRocket model.

The rocket must assemble in a way that allows all subsystems to work as planned.

After each component is installed and secured, it will be remeasured.

Minimize chances of system failure wherever possible.

Have the vehicle team leader confirm each part has been properly attached.

Maintain a straight flight path. Measure the angle between each fin and use a level to make sure the fins are straight.

Educate 750 youth during the competition The club has reached a total of 352 as of PDR. Additional events are planned for the future.


6.4 Educational Outreach

The team would like to educate 750 youth on the topics of rocketry and space exploration. Currently, the club has

educated 352 youth with hands on rocketry events. There are several events that the team will be participating in

to accomplish this goal.

The team participated in a Cub Scout recruiting day. They assisted children age 5-7 in building their model

rockets and taught kids the science behind how a rocket works. The team also had a table to display the rockets

used in the past two Student Launch competitions. The team taught the scouts how the rockets worked. When

building the model rockets the kids learned the basic parts of a rocket. In addition to that they also learned how a

rocket operates.

The team went to an event at the University of Toledo called Hallow-engineering. Kids from the Toledo area

came to learn about engineering. The team had a table for the main station. They constructed balloon rockets

with the goal of moving as many paperclips as possible up to the ceiling. Kids learned how differences in mass

can change how high and fast the balloons can rise. They also learned how the amount of air in the balloon can

help the speed and height of the launch. The kid's competed to see who could get the most paperclips. This event

made the kids excited about rockets and space.

The team will be going to Clay High School to give a presentation to upper physics classes about rocketry basics,

go a little in depth on some physics equations such as F = ma, trajectory equations, how to find center of mass of a

rocket how to apply them in situations. The team will also talk about famous rockets in history and what can be

accomplished with them, as well as what the team is currently working with the competition. The presentation

will end with the club launching a rocket for the students on an F motor.

Two events were also added from the PDR to the CDR which were the engineering design competition and a Boy

Scout banquet. The University of Toledo hosted an engineering competition for high schools in the Toledo area.

In teams of four they built stomp rockets out of paper, paper clips, mail labels, and tin foil. They then launched

the rockets off of a launcher made of PVC. They stomped on a water bottle they were given. Their score was the

product of the distance and the mass of the rocket. The team staffed the event doing jobs such as recording the

distance and weight of each rocket. The event allowed the team to educate 160 youth.

The Boy Scout banquet was the Marnoc Lodge 2017 Winter Banquet. Marnoc Lodge is the local lodge for the

Akron area section of the Order of the Arrow. The Order of the Arrow is the National Honor Society of the Boy

Scouts of America. t a team member brought last year’s competition rocket and talked about High Powered

Rocketry. The scouts got to build rockets out of paper and tape. The scouts were really impressed with the team

because in scouts the rockets they launch use A-B engines and are about one feet tall. The event allowed the team

to educate 210 youth and 20 adults.

With these events the team plans to educate roughly 750 youth about rocketry and space exploration. More

events may be attended as the year goes on, allowing greater opportunity to expand and reach out to more people

every year.


6.5 Budget

The budget is one of the key driving factors in allowing the club to continue to participate in the NASA Student

Launch Competition. Without adequate funding, the team would be unable to perform testing, construct a

subscale and full-scale rocket, and be able to travel to participate in the NASA SL Competition in Huntsville, AL.

Below, changes made to the PDR, a Detailed Budget, and the team’s Expected Funding plan is expanded upon.

Changes from PDR to CDR

There have been many changes to the budget since the PDR. The main area that had significant changes made was

the electronics section, though the team also saw changes made in the following sections as well: recovery, body

hardware, and travel. The changes made in the electronics portion of the budget were due to needing to add a lot

of material so that the team would have everything necessary to properly construct all of the electronics items,

increasing the electronics section from needing to spend $30.79 to now needing to purchase $110.51 worth of

items. The changes in recovery and body hardware are smaller though. The portion of the budget for recovery will

increase from needing to spend $397.13 to purchasing $421.55 worth of materials. The body hardware budget

increases from $613.62 to spending $629.72. Finally, the last changes made to the budget for the team is for

travel. The team was unable to acquire hotel room reservations in the hotel the team had anticipated, causing the

budget to increase from spending $1,912.08 to spending $2,358.63 on travel.

Detailed Budget

Table 42: Itemized Team Budget

2017-2018 Projected Budget

Part Quantity Unit Cost Expected Cost

Payload Electronics

CAP CER 33PF 50V 10 $0.07 $0.71

CONN USB MICRO B RECPT 3 $0.46 $1.38

CONN HEADER 12 POS 2.54 6 $0.54 $3.24

SWITCH TACTILE 0.05A 12V 3 $1.00 $3.00

IC MCU 8BIT 32KB FLASH 3 $3.07 $9.21

IC REC LINEAR 3.3V 300MA 3 $0.42 $1.26

CRYSTAL 8.0 MHZ 18PF SMT 3 $0.66 $1.98

CAP CER 1UF 10V 10 $0.04 $0.41

RES SMD 22 OHM 5% 10 $0.01 $0.11

PTC RESET FUSE 12V 4A 3 $0.81 $2.43

PTC RESET FUSE 24V 500MA 6 $0.20 $1.20

CAP CER 10UF 20 $0.15 $2.92

CRYSTAL 8.0 MHZ 18PF SMD 3 $0.63 $1.89


CRYSTAL 16.0MHZ 18PF SMD 3 $0.69 $2.07

LED YELLOW CLEAR 5 $0.49 $2.45

LED BLUE CLEAR 5 $0.58 $2.90

LED RED CLEAR 5 $0.55 $2.75

IMU ACCEL/GYRO/MAG 12C/SPI 1 $10.63 $10.63

IC MCU 8BIT 32KB FLASH 2 $3.05 $6.10

MOSFET N-CH 30V 6.2A 3 $0.45 $1.35

UUSB B REC BOTMT 3 $0.87 $2.61

CONN MICRO SD CARD 2 $4.16 $8.32

DIODE SCHOTTKY 40V 1A 10 $0.29 $2.89

CONN HEADER RT/A 100 4POS 3 $0.88 $2.64

CONN RECPT 2POS 3 $0.40 $1.20

CONN RECPT 4POS 2 $0.58 $1.16

CONN HEADER RT/A 100 4POS 2 $0.98 $1.96

CONN UMCC JACK STR 500HM 3 $0.49 $1.47

RP-SMA BULKHEAD 2 $4.40 $8.80

CONN SOCKET 22-26AWG 25 $0.12 $3.01

IC REG LINEAR POS 2 $2.24 $4.48

RES SMD 3.6K OHM 10 $0.01 $0.12

RES SMD 61.9K OHM 10 $0.01 $0.14

RES SMD 1K OHM 10 $0.01 $0.12

ANTENNA 433MHZ 2 $6.80 $13.60

$110.51

Payload Hardware

Large 36 T Nylon Gear 2.25" dia 4 $15.83 $63.32

Small 16 T Nylon Gear 1/3" dia 1 $7.51 $7.51

Continuous Rotation Micro Servo 4 $7.50 $30.00

IXYS SLMD121H10L Panel 6 $13.13 $78.78

Hitec HS-35HD Ultra Micro Servo 1 $24.95 $24.95

1/8" Rack Gear 2 $5.82 $11.64

Mounting Hardware 1 $20.00 $20.00

Wheel Ball 4 NA NA

Rover Base 1 NA NA

Panel Carrier 2 NA NA

Peregine Raptor CO2 kit 1 $179.00 $179.00

Payload Base 1 NA NA

5/16" Rack Gear 1 $8.88 $8.88

$236.20

Body Hardware

Nosecone 1 $99.00 $99.00


5" Fiberglass Tubing 6 $36.00 $216.00

75mm Fiberglass Tubing 2 $25.00 $50.00

Fiberglass Centering Ring 3 $7.00 $21.00

Bulkhead 1 $7.00 $7.00

2/56 Shear Pin 12 $2.95 $35.40

Fiberglass Fin 4 $8.05 $32.20

Screws 8 $1.00 $8.00

AeroPak Motor Retainer 1 $38.00 $38.00

AeroPoxy 1 $53.30 $53.30

JB Weld 2 $22.76 $45.52

Welded Eye Bolts 4 $2.50 $10.00

Washers 4 $1.00 $4.00

Nuts 2 $0.50 $1.00

1515 Rail Buttons 2 $4.65 $9.30

$629.72

Recovery

Recovery Bay 1 $80.00 $80.00

CERT 3 DROGUE 32" CHUTE 1 $37.50 $27.50

Braided Nylon Shock Cord 28 $1.50 $42.00

SkyAngle Cert 3 Large 1 $139.00 $139.00

Nomex Blanket 4 $8.95 $35.80

Cable Ties 1 $9.99 $9.99

Terminal Blocks 4 $3.25 $13.00

Ejection Canister 4 $3.00 $12.00

Rotary Switch 4 $9.46 $37.84

1/4 in Quick Link 4 $0.93 $3.72

9V Battery 1 $17.72 $17.72

9V Battery Connector 2 $1.49 $2.98

$421.55

Propulsion

AeroTech K1000T 2 $159.00 $318.00

CTI H100 1 $35.00 $35.00

75 mm Motor Mount Tube 1 $331.50 $331.50

Motor Retainer 1 $50.00 $50.00

$353.00

Education

F-Class Model Rocket Motors 3 $27.99 $83.97

Estes Pro Series II 3 Model Rocket 1 $44.99 $44.99

Estes A3-4T Motors 3 $10.29 $30.87

$159.83

Travel


15-Person Van 1 $494.70 $494.70

Fuel 1 $187.38 $187.38

Hotel 3 $558.85 $1,676.55

$2,358.63

Total Rocket Cost $1,910.81

Total Year Cost $4,269.44

Funding Plan

Table 43: Team Funding Plan

Funding Plan 2017-2018 Source Amount

Marathon Petroleum Inc. $2,000.00

Pilkington $500.00

UT MIME Department $1,500.00

Dassalt Systems $500.00

DTE Energy $500.00

Rotary Club $750.00

OHIO Space Grant $2,500.00

Libbey Glass $1,500.00

Solscient Energy $1,500.00

Resonance Group $1,500.00

Modern Data $500.00

Accrued Funds Total: $5,750.00

Tentative Funds Total: $13,250.00


6.6 Project Timeline

Figure 49: Project Timeline


7 Conclusion The University of Toledo Rocketry Club continues to work towards the goal of participating in the NASA Student

Launch Competition to fly in Huntsville, AL this spring. The UT Rocketry will have prepared a 7.25 ft tall rocket

capable of carrying a deployable rover and flying to a mile in the sky. The team will also continue its educational

outreach goal in efforts to spark curiosity in the youngest members of society in order to help foster the next

generation of young scientists and engineers.

8 Appendix A

8.1 Miscellaneous Drawings and Reference Material

Figure 50: Solar Panel Dimensions


Figure 51: Wheel Ball Dimensional Drawing


Figure 52: Rover Deployment Bulkhead for CO2 Canister


Figure 53: Manufacturer’s Servo Information