Flight Readiness Review

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1 Flight Readiness Review University of Illinois at Urbana-Champaign NASA Student Launch Illinois Space Society 1

2 Overview Illinois Space Society 2

3 Launch Vehicle Summary Javier Brown Illinois Space Society 3

4 Flight Profile Illinois Space Society 4

5 Current Launch Vehicle Design Nose cone 1) Ejection charge at apogee 3) Nose cone separation and parachute deployment at 1000 feet Upper body tube Coupler 2) Drogue deployment at apogee Booster tube Illinois Space Society 5

6 Vehicle - Major Dimensions Total Length: 130 Total Mass: 43.5 lb. Nosecone: 30 Upper Airframe: 48 Payload Bay: 14 Avionics Coupler: 16 Booster Frame: 48 Outer Diameter: 6 Root Chord (Fins): 12 Illinois Space Society 6

7 Vehicle - Mass Statement Mass of rocket increased due to heavier nosecone and ballast Heaver nosecone required ~1 lb of ballast in top centering ring for stability Mass Breakdown Subsystem Mass (lbm) Structures Recovery 8.32 Motor 9.32 Rover 2.02 Platform 3.42 Total 40.7 Illinois Space Society 7

8 liftoff: 2.48 calibers Current CP location: Static CG location: Vehicle - Stability Ballast utilized just above top most centering ring to guarantee and ideally stabilized vehicle. Illinois Space Society 8

9 Vehicle - Propulsion Motor: L1420R-P Diameter: 2.95 (75 mm) Max thrust: 374 lbf Total impulse: 1038 lbf s Burn time: 3.18 s T/W ratio: 8.49 Off-rail speed: 61.4 ft/s 3 8 Aircraft grade plywood centering rings RMS 75/5120 Casing Illinois Space Society 9

10 U-Bolt connections for strength 1/4-20 T-nuts/Bolts for permanent attachments Two rotary switches Parachutes Main: Iris Ultra 96 Drogue: Fruity Chutes Elliptical 18 1/2 Tubular Kevlar shock cord Redundant altimeters 1 TeleMetrum altimeter for altitude and location tracking 1 StratoLogger altimeter for altitude tracking Airframe - Recovery Illinois Space Society 10

11 U-Bolt connections for strength Two rotary switches Parachute Nosecone: SkyAngle 40 1/2 Tubular Kevlar shock cord Redundant altimeters 1 Telemetrum altimeter for altitude and location tracking 1 StratoLogger altimeter for altitude tracking Nosecone - Recovery Illinois Space Society 11

12 Ejection Charges Number of shear pins based on section weights, accelerations, and shear pin maximum forces Black powder charges calculated with pressures and forces applied to the bulkhead Joint Joint and Shear Pin Properties Max Accelerati on Mass Above Joint [lbm] Max Shear Force [lbf] # of Shear Pins Required g g g Joint # of Shear Pins Amount of Black Powder Needed Diameter [in] Length [in] Illinois Space Society 12 Area [in^2] Force [lbf] Pressure [psi] Grams of FFFFG Black Powder

13 Full vehicle verification plan found in FRR Vehicle Verification Plan Major verification tasks Verified aerodynamics and construction procedure with subscale creation and flight Increased simulation accuracy Small-scale and large-scale testing of components Verified vehicle design and manufacturing during fullscale test flight Illinois Space Society 13

14 Predictions determined using OpenRocket. Terminal Velocities Nosecone ft/s Upper Airframe and Booster Frame 1 st separation: Drogue 103/85 ft/s Main ft/s Kinetic Energy Kinetic Energies Booster Frame ft lbf Avionics Coupler ft lbf Upper Airframe w/ Payload ft lbf Nosecone ft lbf All kinetic energies are within specified threshold of 75 ft lbf Illinois Space Society 14

15 Drift Predictions Predictions determined using OpenRocket. All predictions are well within the stipulated threshold of 2640 ft. Section Drift in 0 mph winds (ft) Drift in 5 mph winds (ft) Drift in 10 mph winds (ft) Drift in 15 mph winds (ft) Drift in 20 mph winds (ft) Booster and Upper Airframe Nosecone Illinois Space Society 15

16 Computational Fluid Dynamics CFD performed to verify integrity of pressure readings for nosecone altimeters Full 3D simulation done with ANSYS Results show that pressure at nosecone shoulder is very close to pressure along body Illinois Space Society 16

17 Launched on February 17 th, 2018 in Princeton, IL Launch, ascent, and descent was successful Ineffective deployment of nosecone parachute Damage to nosecone shoulder and threaded rod Altimeters successfully reported data Full Scale Test Flight Illinois Space Society 17

18 Figure of StratoLogger vs OpenRocket Nosecone and coupler avionics data match well Further proof of integrity of nosecone pressure reading Actual flight data over-performed compared to OpenRocket predictions Motor overperformance Overestimated mass Illinois Space Society 18

19 Full Scale Test Flight Ground Track TeleMetrum GPS location superposed onto Google Earth ground image Drift distance of 2137 ft., which is below competition requirement of 2500 ft. Illinois Space Society 19

20 Hard impact to shoulder and bulkhead of nosecone Fiberglass shoulder severely cracked Protruding end of threaded rod bent Bulkhead alignment to nosecone compromised Damages to Nosecone Illinois Space Society 20

21 Minor delamination on surface of blue tube Caused by snow packed into section from parachute dragging section on ground Most fraying near rotary switch cutout Slight swelling and warping near tips Makes fit with nosecone slightly difficult Damages to Body Tube Illinois Space Society 21

22 Deployable Rover Payload Ryan Noe and Destiny Fawley Illinois Space Society 22

23 NASA Student Launch Requirements: Payload Requirements 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 5ft. (in any direction) from the launch vehicle. The rover will deploy a set of solar panels once it has traveled the 5ft. Required by the competition. Internal Team Requirements: Upon landing, the orientation mechanism must be able to rotate the rover to a position in which it can properly deploy. After the rover has deployed the solar panels, the Arduino will receive readings from the solar panels. 5 lb. limit 5.95 diameter x 14.5 length Illinois Space Society 23

24 Payload Overview Rover Orientation Mechanism Illinois Space Society 24

25 Rover Design Iterations Version 1 (Proposal) Version 2 (PDR) Final Design Version 3 (CDR) Illinois Space Society 25

26 Wheel Design Iteration Windmill wheels Five point wheels Less jarring Optimized grip Improved servo mount Illinois Space Society 26

27 Rover Overview Miniaturized Off-Road Remote Terrain Explorer (MORRTE) Consists of 3 segments attached with steel axles All 3D-printed components Each segment is specific to certain electronics Front Segment Middle Segment Back Segment Illinois Space Society 27

28 2 solar cells Two, five point wheels Two servo motors Servo-driven hinge Orientation system latching loop Electronics: SD Card Reader Power Boost 3.7V Li-ion Battery Front Segment of the Rover Illinois Space Society 28

29 Camera and camera cover mounted on bridge 2 servo motors 2, 5 point wheels Electronics: Arduino Micro MPU 6050 HC-12 Middle Segment of the Rover Illinois Space Society 29

30 6V NiCd battery Servo connection panel Safety bridge 2 servo motors 2, 5 point wheels Orientation system latching loop Back Segment of the Rover Illinois Space Society 30

31 Rover Prototyping First Round of Prototyping Final Round of Prototyping Prototyping Changes Rover segment modifications Wheel modifications Bridge designs Solar cells hinge/bridge assembly Camera mount Illinois Space Society 31

32 Orientation System Overview System to ensure rover leaves airframe upright Bulkhead screwed to Upper Airframe Platform rotated by servo motor Controlled by Arduino Micro system Illinois Space Society 32

33 Orientation System Design Iterations Version 1 (Proposal) Version 2 (PDR) Final Design Version 3 (CDR) Illinois Space Society 33

34 AL6061 Bulkhead AL6061 Platform 3D-printed electronics Cover Aluminum Axle & Gear Electronics Arduino Micro Continuous Rotation Servo 2x Servo MPU6050 9DOF Accelerometer/Gyroscope HC-12 Transceiver Module PowerBoost 500C 6V Ni-Ca Battery Pack 3.7V Li-ion Battery Orientation System Hardware Illinois Space Society 34

35 Orientation System Prototyping Early prototype: change motor speed using orientation Successfully used MPU6050 accelerometer data for orientation Early prototyping changed motor speed based on breadboard orientation critical to the orientation system Illinois Space Society 35

36 Electrical Schematics Orientation System Schematic Rover Schematic Illinois Space Society 36

37 Payload System Software Two systems activated shortly before rocket assembly Rover and Orientation System act semi-independently Illinois Space Society 37

38 Rover Testing Successfully tested Ambulated from body tube Maneuvered multiple terrains Over a hill On grass and dirt Regular, tile floor Illinois Space Society 38

39 Orientation System Testing Successfully tested Orientation scheme is successful Latches lock and unlock at the same time Illinois Space Society 39

40 Full Scale Test Flight Payload system flown on full scale test flight Rover attached to orientation system bulkhead with Kevlar cord Orientation system loaded with functional code, no rover code Results: Rover survived intact Solar panels lost upon main chute ejection Front servo horn pulled from threads, back servo PLA arm sheared Rover successfully kept from falling with Kevlar cord Power issue prevented orientation system from properly functioning Orientation system components intact, functional Illinois Space Society 40

41 Payload Future Work Resolve orientation system power issue to ensure battery-only functionality Communications code and capabilities testing Construct, program, and test ground station button Integrate on-off switch on rover and orientation system Demonstrate full payload functionality on second full-scale launch Illinois Space Society 41

42 Safety Courtney Leverenz Illinois Space Society 42

43 Operations Procedure Completed Operations Procedure Illinois Space Society 43

44 Operations Procedure Explanation Verification (SO/A Team Lead) Verification of Critical Operation (SO/A Team Lead) Caution of Hazard Procedure for Correct Operation Illinois Space Society 44

45 Updates Environmental Concerns Spilt and updated Affects to/from project Verification References Cross-sectioned Illinois Space Society 45

46 Questions? Illinois Space Society 46

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