NASA s Student Launch Initiative :
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1 NASA s Student Launch Initiative : Critical Design Review Payload: Fragile Material Protection 1
2 Agenda 1. Design Overview 2. Payload 3. Recovery I. Sub-Scale Predictions II. Sub-Scale Test III. Full Scale Predictions I. Requirement Compliance II. Schedule 6. III. Budget 2
3 Overview 3
4 Final Launch Vehicle and Payload Dimensions 4
5 Key Design Features Carbon Fiber Airframe Fragile Materials Handling Middle-Out Dual Deployment L850W 5
6 Weight Breakdown Launch Weight 34.6 Recovery % Aerodynami cs % Electronic Payload % Burnout Weight 30.1 Propulsion % Main Payload % Misc % 6
7 Final Motor Choice & Retention System Manufacturer Make Total Impulse Type Max Thrust Weight (Empty) AeroTech L850W 3695Ns Reloadable 1185 N 3.54 lbs Using the AeroPack 75mm P Retention System 7
8 Main Payload 8
9 Decision Matrix Payload Option Cost Force Reduction Acceleration Reduction Parallel Spring System Single Mounted Cylinder with Support Material Series and Parallel Spring System Δ X O O X X Δ O O 9
10 Conceptual Design Concentric cylinder design Series and Parallel spring design Wire rope isolators for 360 vibration coverage Easily removable Variable fill design 10
11 Mathematical Design Payload M 3 x 3 k 2 c 1 Housing M 2 x 2 k 1 c 2 Rocket M 1 x 1 F 11
12 ሶ ሶ ሶ Design Overview Payload Recovery k 1 x 2 k 1 x 2 c 1 x 1 ሶ c 1 x 2 k 2 x 2 w 3 c 2 x 2 M 1 M 3 ΣF y = 0 = M 1 xሷ 1 = F + k 1 x 2 x 1 F k 1 x 2 w 2 + c 1 ( xሶ 2 ሶ c 1 x 2 x 1 ൯ k 2 x 3 c 2 xሶ 3 ΣF y = 0 = M 3 xሷ 3 = w 3 + k 2 x 2 x 3 + c 2 ( xሶ 2 ሶ x 3 ൯ M 2 k 1 x 1 ΣF y = 0 = M 2 xሷ 2 = w 2 + k x 2 x 1 c 1 xሶ 2 xሶ 1 + k 2 x 3 x 2 + c 2 ( xሶ 3 ሶ c 1 xሶ 1 x 2 ൯ 12
13 Mathematical Model Inputs Thrust curve Impact force Parachute deployment force Spring constant (k) values Damping coefficient (c) values Outputs Relative position graph Relative velocity graph Relative acceleration graph Relative force calculation 13
14 Shifting Mass Situation Center of Mass of Payload (From Recovery Plate) Stability of Rocket Springs Compressed Springs at Free Length Springs Extended
15 Final System Values of Inner Cylinder/Fragile Material Constants Value (N/m) Spring Constant for vibration (k v ) Output (worst case, initial thrust from engine curve) Value % Reduction from Original Damping Coefficient for vibration (c v ) 7.6 Maximum Inner Cylinder Displacement.59 in N/A Spring Constant for Shock (k s ) Maximum Inner Cylinder Acceleration 82 ft s % Damping Coefficient for Shock (c s ) Maximum Inner Cylinder Force Worst 8.37 ft lb 99.37% 15
16 Recovery Dual-deployment Coupling tube houses recovery electronics Drogue above, main below 16
17 Recovery Drogue Parachute Model Fruity Chutes CFC-24 Shape Elliptical Diameter 24 in Deployment Altitude Apogee Deployment Velocity 0 ft/s Descent Velocity 72.4 ft/s _systems/classic_elliptical_chutes.htm 17
18 Recovery Main Parachute Model Fruity Chutes IFC-96 Shape Iris Diameter 96 in Deployment Altitude 750 ft Deployment Velocity 72.4 ft/s Descent Velocity 15.3 ft/s _systems/iris_ultra_parachutes.htm 18
19 Recovery Recovery Harness Manufacturer OneBadHawk Material Tubular Nylon Size 1 in Length 35 ft Minimum Breaking Force 4000 lb 19
20 Recovery Mounting Hardware 5/16 steel U-bolt center-to-center 5.5 -diameter aluminum bulkhead 0.25 thickness Steel hex nuts and lock washers Epoxied to body tube/coupling tube G5000 RocketPoxy 20
21 Recovery - Electronics Altimeter PerfectFlite Stratologger CF Battery 9-Volt Lithium Ion Switch Connectors Ejection Charge Igniter Rotary Locking 4-Pin Molex Terminal Blocks QuickBurst QBECS 21
22 PRIMARY CIRCUIT Primary Battery On/Off Switch Primary Altimeter Primary Main Igniter Primary Drogue Igniter Primary Main Charge Primary Drogue Charge BACKUP CIRCUIT Backup Battery On/Off Switch Backup Altimeter Backup Drogue Igniter Backup Main Igniter Backup Drogue Charge Backup Main Charge Drogue Parachute Main Parachute 22
23 Recovery Drift Distance Wind Speed (mph) Lateral Distance (ft)
24 Recovery Kinetic Energy (ft-lbf) Bow Body Tube Coupling Tube Aft Body Tube Descent Under Drogue Descent Under Main
25 Sub Scale Predictions Scaling Method Prediction Reyold s Number Length Scale: 5.5 / 3 Equal Thrust Scale Apogee of prediction determined by thrust scale (2500 ft.) OpenRocket: 2492 ft. Rocksim: 2527 ft. 25
26 Sub Scale Test Launch Day Conditions Actual Flight Data 30 Calm wind conditions (0-2 mph) 1 atm Sunny Flight 1: 2592 ft. Flight 2: 2498 ft. 26
27 Sub Scale Test Ejection Tests Multiple successful ejection tests for each body tube Black powder mass calculated with NASSA tool First Flight Main Parachute Deployment Failure Insufficient Ejection Charge Second Flight - Success Flown without competition altimeter 27
28 Altitude (ft) Design Overview Payload Recovery Sub Scale Test 3000 Predicted versus Actual Time (sec) OpenRocket Flight 1 Flight 2 28
29 Altitude (ft) Design Overview Payload Recovery Sub Scale Test Best Fit Curve Time (sec) Best Fit Altitude (ft) Simulation Altitude (ft) 29
30 Altitude (ft) Percent Error Design Overview Payload Recovery Sub Scale Test % % 4% % % 2% % % 1% % Time (sec) Simulation Altitude (ft) Percent Error 30
31 Altitude (ft) Percent Error Design Overview Payload Recovery Sub Scale Test Initial Launch Low Level Recovery Initial 3 seconds Up to 35% error Final 10 seconds % 35% 30% 25% 20% Up to 24% error % 10% Remaining Flight Below 5% error % 0% Time (sec) Flight 2 Actual Altitude (ft) Percent Error 31
32 Sub Scale Test Error Sources Systematic Random Best Fit Curve Modeling Software Impact On Full Scale Validated mission performance predictions Increased ejection charge mass Gained efficiency in build phase 32
33 Fin Change Model Predicted Altitude (ft) Program Goal Trials Program Altitude (ft) Stability Trial 1 Difference from Original (ft) OpenRocket Rocksim Full-scale 5174 OpenRocket Rocksim 5200 Trial 2 OpenRocket Rocksim Trial 3 OpenRocket Rocksim
34 Ballast Plan to add ballast No Ballast 1 lbs 2 lbs 3.2 lbs OpenRocket 5648 ft 5464 ft 5283 ft 5069 ft Rocksim 5385 ft 5235 ft 5091 ft 4594 ft 34
35 Altitude (ft) Altitude (ft) Design Overview Payload Recovery Predicted Altitude Time (s) Time (s) OpenRocket 5648 ft Percent Difference 4.7% Rocksim 5385 ft 35
36 Rocket Information Thrust to Weight Ratio 5.59 :1 Rail Exit Velocity 67 ft/s 36
37 Stability (cal) Design Overview Payload Recovery Stability Parachute deployment Stability (No ballast) Off Rail: 2.11 Static: 2.71 Stability (2 lbs) Off Rail: 2.67 Static: Time (sec) 37
38 Testing Plan Parachute Ejection Testing Parachute Testing Payload Wind Tunnel Sub-Scale Test Bulkhead Altimeter Full Scale Test 38
39 Testing Parachutes Ejection Test Ensures working electronics and enough force to shear the shear pins Horizontally mount the rocket body Padding to catch the end being tested 5 successful tests in a row needed to be acceptable Testing showed 0.35 grams were needed for the aft body tube 39
40 Testing Half-Scale Model Ensures all components work as a system, not just individually Two flights were done to test the model Main parachute did not deploy on Flight 1 More black powder for Flight 2, and a successful landing 40
41 Testing - Parachutes Determine force upon main parachute deployment Create apparatus for simulated deployment conditions Mount parachute to electronic force meter Pack parachute into tube segment Mount apparatus to vehicle, accelerate to 50 mph Deploy parachute and analyze force data 41
42 Testing - Bulkheads Determine maximum force allowed by mounting hardware Create apparatus for simulated deployment conditions Assemble bulkhead with U-bolts and nuts Epoxy bulkhead to spare body tube segment Use tensile testing machine to stress the hardware until failure Analyze force response to determine acceptable stress 42
43 Testing - Payload Determine filler material for the inner cylinder Payload will be subjected to drop tests and charpy impact tests Force gauges and accelerometers attach to the payload and the container The payload along with the filler material will be varied Using the results with the decision matrix will help us select a final filler material 43
44 Testing - Payload Testing Materials Weight # To be Tested Egg 1.75 oz 2 Glass Stir Rod 0.2 oz 1 Glass Sheet N/A N/ A Light Bulb 1.1 oz 3 Small Ceramic/Porcelain China N/A N/A Contact Support Materials (within Cylinder 1) Weight per cubic ft. Density Aerogel N/A N/A Packing Peanuts 0.2 lb N/A Styrofoam Pellets 0.2 lb N/A Non-Newtonian Fluid N/A N/A High Density Foam (Cubes/sheets) Varies 0.93 g/cm^3 Spray in High Density Foam (Injection system) Varies 3 lb/ft^3 44
45 Testing - Altimeter Ensure the GPS works on the main scoring altimeter The altimeter will be attached to a drone and flown around Allows us to check the GPS location, and the live feed Recovery altimeters were also tested to check deployment altitude 45
46 Testing Wind Tunnel 3D printed model will be tested Held in place by a cantilever beam with an attached strain gauge Coefficients of drag found from the force exerted on the model The Wind Tunnel validates CFD and Open Rocket 46
47 Safety Hazard Analysis and Risk Assessment Hazard Identification Effect Consideration Impact and Likelihood Evaluation Risk Control and Mitigation Review of Hazard 47
48 Personnel Hazard Analysis Black Powder Fire Rocket Propellant Major Severity Low Likelihood Electrical Shock Improper Work Attire *Full Analysis can be seen in CDR Report* Debris Fly Into Team Members Eyes Craft/Exacto Knives Heavy Machinery Misusage Minor Severity Fractured Particles During Testing Tripping Hazards Handheld Tool Misusage Epoxy Fumes Dust Particles High Likelihood 48
49 Failure Modes and Effects Analysis Motor Mishandling/ Accidental Ignition Launch Failure Main Parachute Deployment Failure Major Severity Excessively Tight Coupler Low Likelihood Drogue Parachute Deployment Failure Instability During Flight Inability to Secure Payload High Likelihood Testing Apparatus Over Usage Payload not Secured Properly Altimeter/Electronics Malfunction Improper Storage of Materials/Equipment Minor Severity *Full Analysis can be seen in CDR Report* 49
50 Environmental Consideration Analysis Rocket Motor Ignition Major Severity Water Low Likelihood Debris from Rocket Strong Winds High Likelihood Low Visibility Humidity Minor Severity Improper Disposal of Epoxy Epoxy Fumes Dust Particles *Full Analysis can be seen in CDR Report* 50
51 General Risk Assessment Major Severity Limited Resources Tight/Minimal Budget Low Likelihood Mismanagement of Time Increase in Safety Regulations Underestimation of Scope of Work High Likelihood Minor Severity *Full Analysis can be seen in CDR Report* 51
52 Education Engagement Outreach Activities Students Reached Age Groups Reached % 31% 51% 50 NTI STEMFest UExplores Engineering Remaining Engineering Rocks Private Event Elementary (K-5) Middle School (6-8) High School (9-12) 52
53 Requirement Compliance Requirement Verification Method Description of Verification Method Status Electronics must operate in cold temperatures Demonstration Testing Temperature sensitive components will be identified then tested in a 0-10 F environment Batteries were found to be sensitive to temperature; batteries replaced with Lithium version. Tested OK. Mach number must remain less than 0.6 Simulation Testing OpenRocket and Rocksim will be used for simulation, full scale test will confirm. Both OpenRocket & Rocksim show Mach numbers of less than 0.6. Will be confirmed February 12 th. Reach an altitude between 5,200 and 5,400 feet Simulation Testing OpenRocket and Rocksim will show an apogee as desired, will be confirmed with Full- Scale Testing OpenRocket & Rocksim Simulations show feasibility. Test February 12 th. 53
54 Requirement Compliance Requirement Verification Method Description of Verification Method Status Payload must reduce force felt by object(s) by 50 % Demonstration Testing MATLAB model will show theoretical results, payload testing to prove MATLAB model shows a 99.3% reduction. Testing in progress. Altimeter must transmit location to ground station Testing Sub-Scale & Full-Scale test will confirm that location transmits from location. Successful Sub-Scale Test. Determined altimeter must be vertical. Full-Scale confirmation February 12 th. Have a Factor of Safety above 2 for the Combustion Analysis and Shear Stress Analysis Demonstration Analytically determine the F.O.S. Both were found to be >15 54
55 Design Design Overview Payload Recovery Schedule Design Phase Period Highlight: 20 Plan Duration Actual Start % Complete Actual (beyond plan) % Complete (beyond plan) Motor Type Selection Motor Mount Design Rocksim Model Body Component Selection 3D Rocket Model CFD Model Payload A Design Payload B Design Data Acquisition Design Data Transmission Design Design of Recovery System Design Tracking System Design Education Activity 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 55
56 Construction Design Overview Payload Recovery Schedule Construction Phase Period Highlight: 20 Plan Duration Actual Start % Complete Actual (beyond plan) % Complete (beyond plan) Propulsion Construction Body Construction Payload A Construction Payload B Construction Recovery System Construction Data Systems Construction Scale Model Construction 100% 90% 90% 90% 90% 90% 100% 56
57 Budget Item Forecasted Amount Amount Spent Amount Remaining Operating $ $ $10.00 Travel / Lodging $2, Launch Pad $ $ $22.41 Aerodynamics (Body) $1, $ $ Propulsion $2, $1, $ Main Payload $ $ $64.34 Electronic Payload $ $ $15.14 Recovery $1, $ $ Scale Model $1, $ $6.95 Educational Engagement $ $0 $ Total ($) $10, $6,247.00* $1,553.00* Total (%) 100% 80.1%* 19.9%* 57 * Indicates a figure where Travel/Lodging was neglected
58 Thank you for your time! Questions? 58
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