Illinois Space Society Flight Readiness Review. University of Illinois Urbana-Champaign NASA Student Launch March 30, 2016

Transcription

1 Illinois Space Society Flight Readiness Review University of Illinois Urbana-Champaign NASA Student Launch March 30, 2016

2 Team Managers Project Manager: Ian Charter Structures and Recovery Manager: Stephen Vrkljan AGSE Manger: Benjamin Collins Safety Officer: Andrew Koehler

3 System Overview

4 Vehicle Criteria

5 Vehicle Dimensions Overall vehicle length: 90.5 Nose cone length: Shoulder: 3.25 Length of parachute compartments: -Drogue: 13 -Main: 16 Booster system length: Booster body tube length: 40.25

6 Vehicle Dimensions Upper airframe body length: 26.1 Airframe tubing OD: Coupler: Coupler tube: 15" -Switch band: 7.1 -Shoulder: 3.9 Exterior Payload Hole: 6 L X 2 W Interior Payload Hole: 6 L X 1.5 W

7 Booster Subsystem Includes: -Motor, fin, and rail button subsystems -Blue Tube construction length, outer diameter Functionality: -Ascent stage of flight -Houses motor assembly -Mounting point for rail buttons -Fins constructed of fiberglass create stability

8 Motor Selection and Justification Motor: Aerotech K1000T-P Highly reputable Team experience Quickly reaches maximum thrust Rail exit velocity of 74.5 ft/s Meets target altitude Thrust to weight: 10.69

9 Motor Subsystem cont. Centering Rings - Ensures motor mount tube and casing are centered - Three rings composed of plywood Motor Retainer - High strength aluminum - Prevents motor from moving forward or aft during flight - Employs a body and screw cap design - Permanently affixed to lower centering ring

10 Fins: Fin Subsystem - Provides aerodynamic restoring force - 3 trapezoidal fins spaced 120 degrees apart - Fiberglass construction - Root chord: Tip chord: Height: Sweep Length: Thickness: Attached between centering rings -Fin tab height of 0.457

11 Rail Button Subsystem Rail Buttons: - Holds vehicle to rail during first stage of flight standard rail buttons - Designed for a 1.5 slotted rail - Secured to vehicle s centering rings - Mounted via a plywood block with T-nut for removability

12 Includes: Recovery Subsystem -Parachutes (main and drogue) -Parachute ejection charges -Attachment hardware -Avionics bay with altimeters -1 Telemetrum & 1 Stratologger Functionality: -Most important for safety of flight -Must properly deploy both parachutes -Armed through switches on exterior of rocket -Isolated environment for recovery electronics

13 Recovery Subsystem Drogue Parachute - Fruity Chutes 15 elliptical parachute - Deployed at apogee -Backup 2 seconds after - Stowed in booster tube Main Parachute - Iris Ultra 60 Parachute - Deployed at 550 AGL -Backup at 450 AGL -Stowed in upper airframe

14 Robustness of Recovery Subsystem Includes: - Zinc Plated U-bolt attachments - Steel quick links - 0.5, tubular, Kevlar shock cords (520,000 psi) - Ripstop nylon parachutes Functionality: - U-bolt to withstand loadings - Quick links sealed with threaded cap for robust sealing - Safely return all components with less than 75 ft-lbf of KE upon impact

15 Payload Containment Payload will be attached to hatch door and placed on rocket Hatch will be guided and held via 4 side magnets Mortice latches will lock hatch into place Thin tab and holes will be added to allow for removal Payload section isolated from rest of coupler - No damage in unlikely event gripper loses payload

16 Upper Airframe Subsystem Contains main parachute and main parachute shock cord during flight Polypropylene plastic nosecone -Lightweight -Aerodynamic ogive shape -Team experience with material

17 Test Plans and Procedures Dimensions and weights verified on arrival of components Components and hardware inspected for quality and manually load tested Electronics and connections tested and inspected Parachute pull test Hatch door lock mechanisms will be tested for durability and functionality Integration with AGSE system - Loading vehicle on rail, inserting hatch, erecting launch pad, and inserting igniter Full scale test flight

18 Staged Recovery System Testing Plan Ejection charges and parachutes loaded in the same manner as on launch day Ballast mass used to replace fragile components Setup to allow remote deploy: wire E-match remote firing system Shear pins determined by actual weight and predicted accelerations Electronic testing: power lifetime, functionality, and interference

19 Ejection Charge and Shear Pin Testing 1. Number of shear pins chosen based on expected forces 2. Safety margin of ~1.5 applied 3. Then determined black powder sizes to break shear pins Joint Grams of Black Powder (Main) Drogue Main 2 3 Number of Shear Pins

20 Launch Vehicle Verification and Overview Verification implemented through: - Simulations - Full Scale Test Flight - Inspection - Rigorous ground testing of hatch door, recovery equipment, AGSE integration Overview: Combination of simulations and Hand Calculations to solve for the following -Velocity predictions -Altitude verifications -Kinetic energy predictions -Drift -Descent rates -Launch rail exit velocity

21 Launch Vehicle Verification: Mass Statement Ballast added following construction Total mass predicted with component breakdown Using manufacturer specs. or prior measurements Mass prediction: 22.51lbs ~1lb below CDR design mass Mass Breakdown: Booster: 13.3 lbs Coupler: 4.7 lbs Upper Airframe: 3.5 lbs Total Mass: 21.5 lbs Limited future mass growth

22 Static Stability Margin cont. Stability Margin: (Cp-Cg)/D Recommended: <1, Under stable >>2, Over stable Constructed Value: 2.04 Calibers Locations: Marked on Booster Tube Cp: 71.3 from nosecone Cg: 63.1 from nosecone

23 Launch Vehicle Verification: Flight Profile Simulated at average wind speed (10 mph) Predicted Apogees: OpenRocket: 5,360 ft. Custom Sim: 5,370 ft. Wind speed negligibly affects apogee Simulations agree on a time to apogee of 17.3 s Drag parameters adjusted to increase accuracy

24 Full Scale Test Flight Completed March 18 th Flew fully loaded vehicle without operational hatch Upward stability was optimal Apogee at 5472ft Recovery Events occurred as designed Used 20 Drogue for test flight Iris Ultra took a few seconds to fully deploy Photo taken by Greg Smith, CIA

25 Full Scale Test Flight Results

26 Full Scale Test Flight Results

27 Full Scale Test Flight Results

28 Main Deployment

29 Launch Vehicle Verification: Kinetic Energy Test Flight Kinetic Energy Upon Landing: Booster 61.2 ft*lbf Coupler 29.2 ft*lbf Upper Airframe 21.6 ft*lbf No vehicle section is expected to approach 75 ft-lbf of kinetic energy Terminal Descent Rates: Drogue (safe under 100 ft/s): Simulated (15 ): 91.6 ft/s Hand Calculation (15 ): 88.3 ft/s Test Flight (20 ): 80 ft/s Main (safe between ft/s): Simulated: 18.7 ft/s Hand Calculation: 18.4 ft/s Test Flight: 20 ft/s

30 Launch Vehicle Verification: Drift Drift predictions done with a 0 degree launch angle as specified by NASA All distances are well within 2,500 ft. limit Worst case real flight scenario still results in satisfactory drift of 2,490 ft. 5 degree launch angle, along 20 mph winds Wind Speed [mph] 0 7 Open Rocket Prediction [ft] , ,600

31 AGSE

32 2 Stepper Motors 360 degree rotation 4 steel turntable Chain 1 x1 x2 aluminum 1 x1 square aluminum plate Wooden shelf below for electronics 14 reach Carbon fiber makeup Vertical and horizontal arms 1 square tubes Horizontal arm 20 length 0.25 x2 crane rods 40 length Pulley system Crane System

33 Electromagnet Hatch door Blue Tube 0.03 lbs PLA plastic clips Magnets at corners Steel strip 3 x1 x lbs Guide piece - arc of steel above Blue Tube 0.20 lb Mortice latches Hatch and Clip

34 Requires 12 V Needs to be switched on and off Run through relay Relay controlled by Arduino 2 x1 3 8 x1 Electromagnet

35 Rail System 18 Stroke 12 Volt DC Motor 0.60 Inches per Second Tip placed 20.1 along rail Base placed 4.6 in front of the hinge below base plate

36 Maximum force required lb Rest length at 28.8 Extended length of 39.1 Gives 5 off vertical Approximate runtime of 17 seconds 8 rail of 80/20 aluminum 10.8 lb Center of mass (C.O.M.) 4 Weight of rocket is lb Combined gives C.O.M. to be 41.6 from the pad end of the system Rail System Cont.

37 35 lb. Force 5 degree angle 12 Volt DC Motor 24 stroke 25 light wooden rod 0.60 inches per second 40 second runtime Guide funnel Ignition System

38 3 cell LiPo battery 2 Stepper motors Motor Controllers 2 Linear Actuators 2 LEDs 2 Limit Switches 1 Relay Pause Switch Master Kill Switch Arduino Mega Electronics

39 Electronics Cont. 12 V Battery 60 A Idle power draws 0.25 A Arduino Crane operation draws 3.75 A Arduino + electromagnet + stepper x2 Linear actuators draw 5.25 A Arduino + actuator (one at a time) Arduino shield allows 5 V Arduino to power 12 V motor

40 AGSE Structure Volume at initial position: 157 ft 3 Lowered height: in Raised height: in Max width: in Max length: in Estimated mass: lbs

41 AGSE Verification Results of Testing Securing the payload in the clip Crane can hold the hatch and payload during motion Gears, chains, and belts function properly, do not fall off Rocket can be lifted by linear actuator to correct positon Launch pad does not tip over Igniter smoothly enters motor System can be paused Reliable and repeatable Correctly functioning electronics Estimated AGSE run time: 3 minutes 2.5 minutes for crane, 17 seconds for rail system, 36 seconds for ignitor

42 Questions?