University of Illinois at Urbana-Champaign Illinois Space Society Student Launch Preliminary Design Review November 3, 2017

Transcription

1 University of Illinois at Urbana-Champaign Illinois Space Society Student Launch Preliminary Design Review November 3, 2017 Illinois Space Society 104 S. Wright Street Room 18C Urbana, Illinois 61801

2 Table of Contents 1 PROJECT SUMMARY Team Summary Launch Vehicle Summary Payload Summary CHANGES SINCE PROPOSAL Launch Vehicle Changes Payload Changes Project Plan Changes VEHICLE CRITERIA Launch Vehicle Overview Mission Statement Success Criteria Mass Statement System Modeling Booster Subsystem Motor Selection and Justification Motor Casing Motor Mount Assembly Motor Retention Outer Airframe Fins Launch Rail Integration Booster Subsystem Mass Statement Avionics Subsystem Avionics Coupler Tubing Avionics Sled Configurations Bulkhead Configuration Avionics Coupler Subsystem Mass Statement Payload Bay and Upper Airframe Subsystems Payload Sled Configuration... 25

3 3.4.2 Payload Bulkhead Configuration Nosecone Nosecone Avionics Subsystems Mass Statement Recovery Subsystem Deployment Scheme Deployment Mechanisms Avionics Hardware Avionics Electrical Setup Attachment Hardware Redundancy Mission Performance Predictions Simulation Methods Flight Profile Analysis Stability FinSim Kinetic Energy Drift Subscale Rocket Overview Mass Statement Motor Selection Outer Airframe Fins Avionics Payload Recovery Simulations SAFETY Safety Plan Overview Safety Briefings Member Requirements... 53

4 4.1.3 Equipment Training NAR Mentor Energetics Handling Motor Purchase and Storage Risk Assessment Overview Personnel Hazard Analysis Failure Modes and Effects Analysis Launch Vehicle Payload Environmental Concerns Project Risk Analysis Preliminary Checklists Final Assembly Recovery Preparation Launch Compliance NAR High Power Safety Code Federal Aviation Requirements Range Safety Officer Authority PAYLOAD CRITERIA Rover Selection Process Payload Overview Payload Success Criteria Payload Design Communications Solar Cell Deployment Launch Vehicle Integration Orientation Mechanism Maneuverability Prototyping and Testing Testing Deliverables

5 5.8 Payload Mass Budget PROJECT PLAN Competition Requirement Verification Plan Launch Vehicle Payload General Project Team Requirement Verification Plan Launch Vehicle Payload General Project Educational Outreach Update Illinois Space Day Upcoming Events Budget Funding Plan Project Timeline Appendix A: Acronyms Appendix B: ISS Tech Team Safety Policy Appendix C: Education Feedback Form Appendix D: ISD Brochure Appendix E: NAR High Power Rocket Safety Code Appendix F: Federal Aviation Regulations 14 CFR, Subchapter f, Part 101, Subpart c Amateur Rockets Appendix G: Minimum Distance Table

6 List of Figures Figure 1: Flight Profile... 5 Figure 2: Fully Assembled Vehicle Figure 3: Dimensioned Drawing of Launch Vehicle Figure 4: Rear View of the Booster, Fins, and Motor Retainer Figure 5: AeroTech L1300R-P Thrust Curve Figure 6: Dimensioned Drawing of Motor Casing Figure 7: CAD model of motor mount assembly with motor retainer Figure 8: CAD model of booster with rail buttons shown Figure 9: CAD Model of Nosecone Avionics System Figure 10: Coupler Avionics System Figure 11: Avionics Sled Figure 12: CAD model of upper airframe Figure 13: Upper Rocket Section Breakdown Figure 14: Rover Orientation Mechanism Structure Figure 15: Rover Locking Mechanism Figure 16: CAD model of nose cone Figure 17: Avionics Coupler Figure 18: Upper Airframe and Nosecone Figure 19: Example flight path generated using AltOS Figure 20: AltOS s menu Figure 21: Example ground track Figure 22: PerfectFlite s DataCap software Figure 23: Electrical Schematic for Coupler Avionics Figure 24: Electrical Schematic for Nosecone Avionics Figure 25: Vehicle modeled in OpenRocket Figure 26: GUI for Custom MATLAB Simulator Figure 27: Altitude of custom simulation compared to OpenRocket Figure 28: Vertical velocity of custom simulation compared to OpenRocket Figure 29: Flight path of vehicle Figure 30: CG and CP calculated by OpenRocket Figure 31: FinSim GUI with displayed results Figure 32: H97J-10 Thrust Curve Figure 33: Subscale Fins Figure 34: OpenRocket Subscale Design Figure 35: Subscale Rocket Flight Profile Figure 36: Laser Printer Training Figure 37: Rover Circuit Schematic Figure 38: Single Segment of Rover Body Figure 39: Rover Wheel... 90

7 Figure 40: Rover Assembly with Solar Panels, Arduino, Gyroscope, and Motors Figure 41: Arduino Sender Module Figure 42: Arduino Receiver Module Figure 43: Program Procedure Figure 44: Solar Panel Schematic Figure 45: Aluminum Bulkhead with Threaded Holes Figure 46: Loop on Rover Body Figure 47: Rover Locking Mechanism with Hook Activated Figure 48: Front Locking Hook Figure 49: Back Locking Hook Figure 50: Side View of Rover Locking Mechanism with Hook Activated Figure 51: Rover Locking Mechanism with Hook Deactivated Figure 52: Front View of Rover Locking Mechanism with Hook Deactivated Figure 53: Side View of Rover Locking Mechanism with Hook Deactivated Figure 54: Lazy Susan Rotation Mechanism Figure 55: Lazy Susan Schematic Figure 56: Platform with Lazy Susan Mechanism Figure 57: Illinois Space Day logo Figure 58: Liquid Nitrogen Demonstration Figure 59: Alka-Seltzer Rockets Exhibit Figure 60: EOH Demonstrations (from top left down), Hybrid Rocket Demo, Technical Projects Exhibit, and Liquid Nitrogen Demo Figure 61: Boy Scout Merit Badge Clinic

8 Table of Tables Table 1: Blue Tube from Apogee Rockets... 2 Table 2: Centering Rings from Apogee Rockets... 3 Table 3: Bulkheads from Apogee Rockets... 4 Table 4: Vehicle and Recovery Competition Requirements... 6 Table 5: Vehicle and Recovery Team-Derived Requirements Table 6: Mass Statement Table 7: L1300R-P Physical Characteristics Table 8: L1300R-P Performance Characteristics Table 9: Booster Subsystem Mass Statement Table 10: Avionics Coupler Subsystem Mass System Table 11: Nosecone Mass Statement Table 12: Comparisons between custom simulation and OpenRocket Table 13: Initially Chosen Parachute Models Table 14: Mass under Each Parachute by Section Table 15: Calculated Terminal Velocities of Each Vehicle Section for Chosen Parachutes Table 16: Kinetic Energy of Each Vehicle Section at Impact for Chosen Parachutes Table 17: Drift Calculations for Each Section of the Launch Vehicle Table 18: Rocket Mass Statement Table 19: Summary of Physical Characteristics Table 20: Summary of Performance Characteristics Table 21: Risk Assessment Codes (RACs) Table 22: Level of Risk and Member Requirements Table 23 : Severity Definitions Table 24 : Probability Definitions Table 25: Personal Hazard Analysis Table 26: Referenced Material Safety Data Sheets (MSDS) Table 27: Structure and Recovery Risk Analysis Table 28: Payload Risk Analysis Table 29: Environmental Hazards and Solutions Table 30: Project Risk Analysis Table 31: NAR Safety Code and Mitigation Table 32: Rover Mechanism Trade Study Table 33: Payload Requirements Table 34: Rover Success Criteria Table 35: Payload Component Test Matrix Table 36: Payload Mass Budget Table 37: Competition Safety Requirements Table 38: General Competition Requirements Table 39: General Project Team-Derived Requirements

9 Table 40: Project Expenses Table 41: Projected Funding Estimate Table 42: Project Milestones and Expected Completion Dates Table 43: Minimum Distance Table

10 1 PROJECT SUMMARY 1.1 Team Summary Team Name: Illinois Space Society Student Launch Team Team Website: Mailing Address: 307 Talbot Laboratory 104 S. Wright St Urbana, Illinois Team Leader: Andrew Koehler Phone: (217) Safety Officer: Courtney Leverenz NAR Mentor: Mark Joseph, NAR Section 527, Level 2 Certification Phone: (217) Launch Vehicle Summary The launch vehicle will be 10 feet tall and 6 inches in diameter. It consists of four distinct sections: a booster tube, coupler, upper airframe, and nosecone. The total mass of the rocket is 43.5 lb. The Aerotech L1300R-P motor was selected to carry the launch vehicle to an apogee of 5,280 feet above ground level. Two seconds after apogee, an 18-inch drogue parachute is deployed. The launch vehicle falls under drogue parachute until an altitude of 1000 feet, where the nosecone separates from the rocket and falls under its own 36-inch parachute. At an altitude of 800 feet, the 96-inch main parachute is deployed, carrying the launch vehicle safely to the ground. More details about the launch vehicle are summarized in the preliminary design review flysheet that is included at the end of this document. 1.3 Payload Summary The team selected the deployable rover as the payload for this year s competition. The rover shall drive out of the top of the upper airframe after the launch vehicle has landed. It shall then drive at least five feet from the body tube and then deploy a set of foldable solar cell panels. 1

11 2 CHANGES SINCE PROPOSAL 2.1 Launch Vehicle Changes Materials are extremely important to all aspects of vehicle design and structural integrity throughout the launch and recovery process. During the material selection process, many different aspects were considered including durability, cost, ease to work with, and available sizes. This resulted in the consideration of the following materials: Blue Tube, fiberglass, carbon fiber, and aircraft plywood. The body tube material determines many other aspects of the rocket including the nosecone, centering rings, fins, and more. The choice to use Blue Tube was based on the cost, weight, familiarity, and durability of the material. In particular, Blue Tube was chosen for the body tube of the vehicle because of its low weight and cheap cost. A lighter mass provides more possibilities for payload design and allows for more control of launch apogee by adding ballasts if weight or stability is in question. The cheaper cost also frees up the budget for other subsystem developments. Finally, historically Blue Tube has been used for several previous team designs. Factoring in the team s experience working with this material, the build process should be significantly smoother than working with carbon fiber or fiberglass. The choice to use Blue Tube directly affected the materials used for the centering rings, coupler, and bulkheads. Purchasing six-inch Blue Tube, sold by Apogee Rockets and manufactured by Always Ready Rocketry, resulted in a restriction of material choice for the previously mentioned parts given that the inner and outer diameters of the body tube are both pre-manufactured dimensions. Thus, all remaining components must conform to the inner diameter of inches (see Table 1 below) in order to fit properly within the chosen body tube. In the same fashion, the motor mount tube s fixed outer diameter of inches also restricted the material choice for the centering rings. Table 1: Blue Tube from Apogee Rockets Inner Diameter (in) Outer Diameter (in) Body Tube Motor Mount Tube In the original proposal, the team proposed pre-manufactured centering rings, couplers, and bulkheads for construction of the vehicle. However, upon investigation, the minimal variety of component sizes from manufacturers became a limiting factor. 2

12 Table 2 below highlights the options available for use, all sold by Apogee Rockets and manufactured by ProLine Composites. Table 2: Centering Rings from Apogee Rockets G10 Fiberglass CR 54MM G10 Fiberglass CR 75MM G10 Fiberglass CR 98MM CR 75MM to 6.0 CR 75MM to 6.0 CR 98MM to 6 CR 98MM to 6 Material Inner Diameter (in) Outer Diameter (in) Weight (oz) Thickness (in) Cost (USD) Fiberglass Fiberglass Fiberglass Plywood Plywood Plywood Plywood As seen above, the team was limited to three fiberglass choices and four plywood choices for centering rings. This limitation existed because the outer diameter of the centering rings needed to either exactly match the existing inner diameter of the body tube, or at a minimum be slightly larger to allow for sanding to a proper fit. From there the choices were narrowed further based on the inner diameter of the centering ring, which needed to fit around the outer diameter of the motor mount tube at inches. This narrowed the choices to three total options, with only one of them being fiberglass, though the closest centering ring options still had inner diameters that were larger than the outer diameter of the motor mount. This means that the team would need to find a way to expand the motor mount tube to fit the pre-manufactured centering rings. The lack of available options and the issues that arise with pre-manufactured pieces became too much for the team to justify purchasing the centering rings online. Instead, the centering rings will be cut from purchased plywood using a laser cutter and will be customized to fit the body tube and the motor mount tube exactly, thus saving both time, money, and energy. The decisions made regarding the centering ring were also applied to the bulkheads. As seen in 3

13 Table 3 below, neither of the available bulkheads from Apogee Rockets online were properly fitting in diameter, resulting in the choice to use custom-cut plywood for these components as well. Table 3: Bulkheads from Apogee Rockets Fiberglass Bulkhead Disks Coupler Bulkhead Disk 6.0 Material Inner Diameter (in) Outer Diameter (in) Weight (oz) Thickness (in) Cost (USD) Fiberglass N/A Plywood N/A As was originally decided, the nosecone will be a pre-bought fiberglass ogive nosecone from Apogee Rockets. All other components will now be made of aircraft plywood, owing to its ease to work with, ability to customize, and cost. 2.2 Payload Changes The payload for ISS Student Launch has seen some major modifications since the proposal was submitted. The rover body was changed to allow enough room for all the electronics needed. Specifically, the rover was lengthened and received various holes to allow the gyro to sit in and for wires to reach from the Arduino to the motor. The locking mechanism of the rover also has been changed. Rather than have the whole back of the rover locked into the rocket, two loops have been added to the bottom of the end pieces of the rover and are locked in with hooks that come out of the platform. The team determined this would be better because this made the rover s mass more evenly distributed and decreases the chances of tipping over when traversing the furrows in the field. Instead of one gyroscope and Arduino for the whole system, there will now be one on the rover and one on the platform. 2.3 Project Plan Changes There were no changes made to the project plan since the Proposal. A detailed project plan is covered in Section 6. 4

14 3 VEHICLE CRITERIA 3.1 Launch Vehicle Overview The designed launch vehicle is uniquely tailored to the mission's rover payload. Several design modifications were completed since the proposal phase, and additional changes are forecast to ensure launch readiness and mission success. In a sense, this vehicle will mimic real-world launch vehicles, with the nosecone being utilized as part of the payload deployment process. This strategy added complications to the design, requiring innovative methods of recovering optimal stability. Figure 1 below shows a visual representation of the flight profile, with a written description provided below: At apogee, the vehicle will separate into two sections, booster and nosecone/upper airframe, joined by an 18-ft shock cord. A drogue parachute will deploy approximately 2 seconds after apogee, ensuring controlled descent. At approximately 1000 feet, the nosecone will be ejected from the upper airframe with the simultaneous deployment of a nosecone parachute to achieve a controlled descent. This is the commencement of the payload rollout process. The tethered upper airframe and booster sections will continue to fall under drogue until approximately 800 feet. At this point, another separation event will occur, with the simultaneous deployment of the main parachute to ensure a smooth landing for the tethered lower sections and internal payload. Upon touchdown of the tethered section, the autonomous payload will activate and begin performing its designed task. Figure 1: Flight Profile 5

15 3.1.1 Mission Statement The Illinois Space Society (ISS) designs, safely launches, and recovers reusable high-powered rockets capable of carrying out a variety of missions including transport of scientific payloads. We maintain strict regulations and practices in accordance with NASA and ISS internal stipulations. These practices enable the team to apply our acquired knowledge to the design criteria necessary for successful participation and performance in the Student Launch competition. Our success fosters growth and team chemistry, and we ensure mentorship for new members so they can continue the success of the team in its future endeavors. We translate this experience to not only benefit ourselves but to our community through various outreach projects we sponsor year-round, building enthusiasm in young audiences and ensuring interest in the aerospace field for years to come Success Criteria Table 4 below outlines the NASA-specified competition requirements that the ISS Student Launch Team has used as the standard for proper vehicle performance. Table 4: Vehicle and Recovery Competition Requirements Requirement Requirement Source Verification Method The payload shall be delivered to an altitude of 5280 feet AGL. A commercially available altimeter shall record the official altitude. All recovery electronics shall be powered by commercially available batteries. The launch vehicle shall be recoverable and reusable. Vehicle Requirements 1.1 Vehicle Requirements 1.2 Vehicle Requirements 1.3 Vehicle Requirements 1.4 Analysis Rocket design and motor selection has been made to achieve an apogee around a mile. Demonstration StratoLogger will report the official altitude. Inspection Recovery system design requires commercially available batteries. Demonstration Recovery system has been designed to safely land the rocket. Section Addressed The launch vehicle shall have a maximum of 4 independent sections. Vehicle Requirements 1.5 Inspection Rocket design has two independent sections. 3.1 The launch vehicle shall be limited to a single stage. Vehicle Requirements 1.6 Inspection Rocket design has only a single stage

16 The launch vehicle shall be prepared for flight at launch site within 4 hours. The launch vehicle shall be capable of remaining ready to launch on the pad for 1 hour. The launch vehicle shall be capable of being launched by a standard 12V DC firing system. The vehicle shall require no external circuitry to launch. The motor shall be commercially available. Pressure vessels on the vehicle shall adhere to certain criteria. Motor shall not have a total impulse greater than 5120 N-s. The vehicle shall have a minimum stability margin of 2.0 at rail exit. Vehicle Requirements 1.7 Vehicle Requirements 1.8 Vehicle Requirements 1.9 Vehicle Requirements 1.10 Vehicle Requirements 1.11 Vehicle Requirements 1.12 Vehicle Requirements 1.13 Vehicle Requirements 1.14 The vehicle shall exit the Vehicle Requirements rail at a minimum velocity 1.15 of 52 ft/s. All teams shall successfully launch and recover a subscale model of their rocket prior to CDR. All teams shall successfully launch and recover their full-scale rocket prior to FRR. Vehicle Requirements 1.16 Vehicle Requirements 1.17 Test At the test launch, the team will ensure that the launch vehicle can be prepared for flight in less than four hours. Demonstration If the launch is delayed, all systems (including batteries) can remain ready for at least 1 hour. Demonstration A standard 12V DC firing system will be used at the test launch. Inspection No parts of the rocket require any external circuitry for launch. Inspection The chosen motor is manufactured by AeroTech and will be purchased from a commercial retailer. Inspection There are no pressure vessels within the vehicle. Inspection The purchased motor has an impulse of 4560 N-s. Analysis OpenRocket shows a predicted stability margin of Analysis OpenRocket shows a predicted rail exit velocity of 68.5 ft/s. Demonstration The subscale rocket will be designed, built, and flown before CDR. Demonstration The full-scale rocket will be built and flown prior to FRR

17 Any structural protuberances on the rocket shall be located aft of the burnout center of gravity. Vehicle Requirements 1.18 Inspection Rocket design has no structural protuberances above the burnout center of gravity The vehicle shall not utilize forward canards. Vehicle Requirements Inspection Rocket design has no forward canards The vehicle shall not utilize forward firing motors. Vehicle Requirements Inspection Rocket design has no forward firing motors The motor shall not expel titanium sponges. Vehicle Requirements Inspection Motor does not expel titanium sponges The vehicle shall not utilize hybrid motors. Vehicle Requirements Inspection The motor uses solid fuel only The vehicle shall not utilize a cluster of motors. Vehicle Requirements Inspection The vehicle uses a single motor. 3.2 The vehicle shall not utilize friction fitting for motors. Vehicle Requirements Inspection Friction fitting will not be used for motors The vehicle shall not exceed Mach 1 at any point during flight. Vehicle Requirements Analysis Simulation shows that maximum velocity is under Mach Vehicle ballast shall not exceed 10% of total weight. Vehicle Requirements Analysis Any ballast used will be less than 10% of total weight Drogue event shall occur at apogee. Each team must perform ground ejection charge testing for all parachutes used in the system. Max kinetic energy of any independent section at landing shall not exceed 75ft-lbf. Recovery System Requirements 2.1 Recovery System Requirements 2.2 Recovery System Requirements 2.3 Demonstration Recovery system has drogue opening at separation event at apogee. Test The ejection charges will be tested on the ground before the flight of the rocket. Analysis Calculations show that each independent section has less than the maximum allowed kinetic energy

18 The recovery system shall Recovery System be electrically independent Requirements 2.4 of any payload circuits. Inspection Recovery system is designed not to involve payload circuits Recovery system shall contain redundant altimeters. Recovery System Requirements 2.5 Inspection Recovery system has redundant altimeters to ensure deployment Parachute deployment shall not use motor ejection. Recovery System Requirements 2.6 Test Parachute deployment will occur due to black powder charges Each altimeter shall be armed by a dedicated switch on exterior of rocket airframe. Recovery System Requirements 2.7 Inspection Switch band will have a switch dedicated to each altimeter Each altimeter shall have a Recovery System dedicated power supply. Requirements 2.8 Each arming switch shall be capable of being locked Recovery System in the ON position for Requirements 2.9 launch. Removable shear pins shall be used for main and Recovery System drogue parachute Requirements 2.10 compartments. Launch vehicle shall be trackable during and after flight. Recovery system shall not suffer from any interference from other components in vehicle. Recovery System Requirements 2.11 Recovery System Requirements 2.12 Inspection There will be one power supply per altimeter. Demonstration The arming switch will be locked in the ON position for the test flight. Inspection Shear pins for the main and drogue parachute compartments will be removable. Demonstration The rocket will be tracked using the TeleMetrum. Demonstration Rocket design ensures that recovery system is kept safe from any interference from other components Table 5 below presents an additional set of vehicle requirements, established by the team to supplement the aforementioned competition requirements. This list of team-derived requirements is expected to grow further as the design approaches the Critical Design Review. 9

19 Table 5: Vehicle and Recovery Team-Derived Requirements Requirement Team should promote sustainable involvement in the project by reusing as many RSO-owned parts as possible. Verification Method Analysis Try to optimize design around expensive owned parts such as parachutes and motor casings. Couplers should have items placed in a Demonstration Altimeters and Raspberry way to minimize clutter from Pi Zeros are placed in a way to minimize unnecessarily long wires. distance to rotary switches and batteries. Subscale vehicle will be designed in a way that allows the team to approximate a Cd for the full-scale vehicle. Drift should be minimized to allow the payload to process images on the way down as well as to time spent on recovery efforts. Rocket should look aesthetically pleasing to better the team s presence at community and member recruitment events Mass Statement Analysis Subscale will have the same outer airframe material and paint as the fullscale vehicle. Analysis Combination of Jolly Logic Chute Releases allows the team to minimize drift without failing the competition kinetic energy requirement. Inspection Team will collaborate on a paint design for the rocket and implement it for the full-scale vehicle. Section Addressed Table 6 below presents the estimated mass breakdown of the total system. In order to present the data more clearly, the mass statement has been broken down by subsystems. A complete mass total, including all of these subsystems, is presented at the bottom of the table. Unknown masses, such as the completed payload system or epoxy totals, contain appropriate builtin margins in anticipation of future mass growth. The team has accurately estimated the mass of its system for the last few years of the competition, and this previous experience gives the team great confidence in the following mass report. Should any systems change by the next design review, this statement will be revised and motor selection and structural design will be fine-tuned to optimize performance. N/A 10

20 Table 6: Mass Statement Item Total Mass [lb] Purpose Structures: Booster Tube 2.62 Houses motor and fins Trapezoidal Fins (3) 1.51 Fins Motor Mount Tube 3.44 Tube for motor Centering Rings (3) 0.12 Centering motor inside booster tube Epoxy and Resin 1.50 Structural joints Motor Retainer 0.50 Motor retainer Avionics Switch Band 0.34 Switch Band for Avionics Bay Avionics Coupler 1.85 Avionics Coupler Tubing 6 Coupler Bulkhead (2) 0.15 Bulkhead for Coupler Tubing Upper Nosecone Bulkhead 0.11 Bulkhead for Upper Nosecone Lower Nosecone Bulkhead 0.15 Bulkhead for Lower Nosecone Rover Bulkhead 0.16 Bulkhead for Rover Payload Nuts, Bolts, Washers, and Screws 0.10 Connections 1515 Rail Button (2) 0.05 Connection to Launch Rail Upper Airframe 2.52 Houses Payload Parachute Fiberglass Nosecone 1.78 Nosecone Margin 0.20 Future Growth Structures Total Mass: 17.1 Recovery Equipment: StratoLogger CF (1) 0.03 Altimeter TeleMetrum 2.0 (1) 0.03 Altimeter/Tracker 9V Battery (1) 0.10 Battery for StratoLogger 9V Battery Clip (1) 0.02 Attach 9V Batteries to Sleds TeleMetrum Li-Po Battery (1) 0.03 Battery for TeleMetrum Main Parachute 1.22 Main Parachute 20ft Main Shock Cord 0.57 Tubular nylon Drogue Parachute 0.15 Drogue Parachute 20ft Drogue Shock Cord 0.6 Elastic Cord Nosecone Parachute 0.10 Nosecone Parachute 5ft Nosecone Shock Cod 0.16 Kevlar Quick Links (3) 0.75 Attachment Hardware Nylon Shear Pins 0.01 Shear Pins ¼ Threaded Rods (2) 0.07 Mounts for Sleds 1/8 Plywood Sheet 0.10 Sleds for Mounting Equipment Terminal Blocks (4) 0.05 Connect Altimeters to Black Powder Charges Rotary Switches (2) 0.05 For Activating Altimeters on the Pad Margin 0.25 Further Growth 11

21 Recovery Equipment Total Mass: 4.59 Motor Equipment: L1300R-P Reload Kit 10.8 Motor fuel grain Motor Casing 2.30 Motor casing Forward Closure 1.08 Closure for motor casing Aft Closure 0.37 Close for motor casing Motor Equipment Total Mass: Total Mass of System: System Modeling The design of the launch vehicle was modeled using Siemens NX 10, a reliable software suite that the team has past experience with for design representation. Figure 2 below displays the fully assembled rocket and its setup on launch day. Color-coded areas signify different sections of the rocket as follows: Green Booster Section Red Coupler Switch-band (Full coupler partially concealed) Pink Upper Airframe Blue Nosecone 12

22 Figure 2: Fully Assembled Vehicle 13

23 A fully dimensioned version of the model is also included in Figure 3. Figure 3: Dimensioned Drawing of Launch Vehicle 3.2 Booster Subsystem The booster subsystem is the lowermost section of the vehicle and is primarily responsible for providing thrust for the rocket. It also produces stability for the rocket and enables it to fly as straight as possible. This subsystem also contains many structural components that are necessary for safety and aerodynamics. The main components of the booster subsystem are the motor, motor casing, motor mount, motor retention subsystem, outer airframe, and fins. The motor produces thrust, while the casing, mount, and retention subsystems make sure that the motor stays correctly oriented and attached to the airframe. The fins are attached with a through-the-wall technique to the outer airframe and are the 14

24 main component responsible for stability and control. These components ensure that the rocket exits the launch rail with the desired velocity and stability and is able to reach the intended final altitude. A CAD model of the booster section is shown in Figure 4. Figure 4: Rear View of the Booster, Fins, and Motor Retainer Motor Selection and Justification For the Student Launch competition, the team has chosen to use an AeroTech L1300R- P motor. As per competition requirements, this motor does not expel titanium sponges, is not a hybrid motor, is not clustered, and will not propel the launch vehicle above Mach 1 based on simulations. The motor is also able to be ignited using a 12-volt firing system and does not utilize any forward firing motors. According to updated OpenRocket simulations and the characteristics of the team s chosen motor, the vehicle s thrust-to-weight ratio is eight with the L1300R-P. Thrustto-weight ratios greater than 5 are typically considered safe for high-powered rockets. Performance specifications for the L1300R-P motor were found at thrustcurve.org. The thrust curve for this specific motor can be found in Figure 5 below. As shown in the figure, the motor reaches a maximum thrust of lbf in about 1.25 seconds. The motor provides an average thrust of lbf with a total burn time of 3.4 seconds. Specific physical characteristics of the motor can be found in Table 7, and performance characteristics are summarized in Table 8 below. 15

25 Figure 5: AeroTech L1300R-P Thrust Curve Table 7: L1300R-P Physical Characteristics Characteristic Motor Diameter Motor Length Propellant Weight 3.86 in 17.4 in oz Value Table 8: L1300R-P Performance Characteristics Characteristic Max Thrust Average Thrust Burn Time Total Impulse lbf lbf 3.5 seconds lbf*s Value In summary, the AeroTech L1300R-P motor was chosen because it had all the necessary requirements for impulse, thrust, and dimensions that enabled a seamless fit into the launch vehicle s design Motor Casing The AeroTech RMS 98/5120 motor casing will be used to house the L1300R-P motor. This motor casing is made of aluminum, allowing it to withstand the high temperatures and forces created by the motor during launch. In addition, the top of the casing will serve as the lower attachment point for the drogue parachute. The casing is inches long with an outer diameter of inches. 16

26 Figure 6 below shows a detailed dimensioned drawing of the motor casing, acquired from the manufacturer s website. Figure 6: Dimensioned Drawing of Motor Casing Motor Mount Assembly The motor mount assembly will consist of the motor mount tube, centering rings, and fins. The purpose of the motor mount is to keep the motor and motor casing in a stable position during flight. The motor mount tube will be constructed from a 22-inch length of Blue Tube with an outer diameter of 4.2 inches. This tube, held in place by three plywood centering rings, will house the motor and motor casing. This is a change from the previous design, which involved using fiberglass centering rings. These centering rings will have a thickness of inches, and each will be epoxied onto the outside of the motor mount tube. The first centering ring will be placed flush with the bottom end of the rocket, the second will be placed inches away from the bottom of the rocket, and the third will be placed 19 inches from the bottom of the rocket. The motor mount assembly also provides a rigid mount point for the fins. The three fiberglass fins will have fin tabs with a height of inches and a length of 10 inches. This will allow them to be epoxied between the two lower centering rings, prior to the entire assembly being inserted into the lower airframe. 17

27 3.2.4 Motor Retention The final component of the motor system will be an Aero Pack motor retainer. This is an aluminum part designed to keep the motor safely inside the rocket during flight, as well as allow for quick loading and unloading of the entire motor assembly. This motor container consists of a threaded mount, set on the outside of the lowest centering ring using screws, and a screw-on cap. The cap then screws on to the outside of the threaded mount, allowing for safe retention of the motor and easy access. A CAD model of the motor mount assembly with the motor retainer attached is shown below in Figure 7. Figure 7: CAD model of motor mount assembly with motor retainer Outer Airframe In selecting a material for the outer airframe, the team considered three options: Blue Tube, fiberglass, and carbon fiber. Unanimously, the team voted on Blue Tube because of its low cost and its lower density, providing less weight compared to fiberglass or carbon fiber. The team has also had great success using Blue Tube for past projects. The outer airframe will be comprised of two 48-inch lengths of Blue Tube, one each for the booster and upper airframe sections. Each piece will have an outer diameter of inches and an inner diameter of inches. The main reason that fiberglass was not chosen was due to weight and density concerns. At last year's Student Launch competition, the team learned that the density value for fiberglass in 18

28 OpenRocket was different from the actual density of fiberglass obtained from the manufacturer, which led to a slightly heavier rocket than expected. This extra mass prevented the rocket from obtaining the desired apogee, a critical mission objective. For carbon fiber, even though the quality of the material outweighs both Blue Tube and fiberglass, high cost was a major factor in the decision not to use it Fins To ensure that the rocket is stable and maintains its intended flight path, three fins will be attached to the body tube with a symmetrical lateral separation of 120º. Following a simulation using FinSim software, the decision was made to change the thickness of the fiberglass used for fins from 1/8 to 3/16 to mitigate the risk of aerodynamic flutter in flight. The latter dimension provides a higher tensile strength, allowing the fins to withstand any possible aero-elastic forces Launch Rail Integration The purpose of integrating rail buttons is to ensure that the rocket is guided during launch until a sufficient velocity is reached for the fins to stabilize the rocket. The rail buttons also help keep the rocket steady in case of windy conditions prior to launch. Using the motor that the team has decided upon, the L1300R-P, the rocket will reach an off-the-rail velocity of 68.5 ft/s per OpenRocket. Each rail button will be attached to a mounting point secured to one of the vehicle s centering rings, as seen in Figure 8. This mounting point will consist of a plywood block with a T-nut. This allows the rail buttons to easily screw in and out in case one needs to be replaced, but it also provides for a secure mounting configuration. Additionally, this method mitigates any damage to the structural integrity of the relatively thin centering rings. Figure 8: CAD model of booster with rail buttons shown. 19

29 3.2.8 Booster Subsystem Mass Statement A mass statement for the booster subsystem has been documented in Table 9. Values for the mass of various components were found using documentation from manufacturers or taken from the team s historical data. Some component masses are estimates that cannot be accurately predicted, such as the total epoxy and resin mass, but these values are overestimated to leave room for future growth. For further robustness, a small margin is added to the total mass to generate a safety factor for uncertain values. In general, the team avoids large blanket mass margins due to their relative inaccuracy, causing problems in previous years with underweight rockets overshooting the desired altitudes. Table 9: Booster Subsystem Mass Statement Item Total Mass [lb] Use Structure Booster Tube 2.62 Houses motor and fins Trapezoidal Fins (3) 1.51 Fins Motor Mount Tube 3.44 Tube for motor Centering Rings (3) 0.12 Centering motor inside booster tube Epoxy and Resin 1.50 Structural joints Motor Retainer 0.50 Motor retainer Nuts, Bolts, Washers, and Screws 0.10 Connections 1515 Rail Buttons (2) 0.05 Attachment to launch rail Margin 0.20 Future Growth Structures Total Mass Motor Equipment L1300R-P Reload Kit 10.8 Motor fuel grain Motor Casing 2.30 Motor casing Forward Closure 1.08 Closure for motor casing Aft Closure 0.37 Close for motor casing Motor Equipment Total Mass Total Mass of System: Avionics Subsystem The avionics subsystem contains the hardware required to track and safely recover the vehicle. This subsystem is broken up into two pieces, the nosecone avionics and the vehicle avionics. The nosecone avionics contain the recovery hardware to separate the nosecone, while the vehicle avionics will track and provide the recovery events for the rest of the vehicle. The vehicle avionics will be located in the coupler tubing, while the nosecone avionics will be housed within the 20

30 nosecone. The avionics for the nosecone and vehicle can be seen below in Figure 9 and Figure 10, respectively. Figure 9: CAD Model of Nosecone Avionics System Figure 10: Coupler Avionics System Avionics Coupler Tubing The coupler shoulder and switch band will be made from Blue Tube, the same material as the outer airframe. Blue Tube keeps the outer diameter of the vehicle constant throughout the entire body. The coupler tube will be 16 inches long with a 4-inch switch band around the middle, leaving 6 inches on each side of the coupler for the shoulder. This length is one caliber or 6 inches, considered long enough for a stable connection based on high-powered rocketry standards. The switch band length was chosen to ensure that there is enough room for the rotary switches, which will be used to turn on the altimeters from the outside of the vehicle. 21

31 3.3.2 Avionics Sled Configurations The avionics in both the coupler and the nosecone will be mounted to 1/8 inch plywood. These sleds are then mounted to threaded aluminum rods using 3D printed brackets. The brackets will be made into an L shape and epoxied onto the plywood. The brackets will hold the fragile electronics in place to ensure the recovery events happen and the vehicle can be recovered safely. Plastic was chosen over metal to save on weight. 3D printing the brackets will also allow the team to custom make them and to do so with minimal cost. Members of the team have used 3D printed brackets effectively in previously flown rockets. This allows the team to move confidently forward with this decision. The aluminum rods will run the length of the coupler and nosecone. In the coupler, the aluminum rods will hold the two bulkheads to the end of the coupler. In the nosecone, the top bulkhead will be epoxied to the nosecone while the aluminum rods will hold the bottom bulkhead into place. The coupler avionics configuration can be seen below in Figure 11. The two altimeters and their batteries are attached to the avionics sled. The two brown boxes are the 9-volt batteries. The batteries will be mounted so the terminals are aligned vertically. This will ensure that the batteries do not lose connection during the rapid acceleration of takeoff. Each altimeter will have their own independent power supply to make this system completely redundant. The red altimeter shown in six is the StratoLogger while the green one is the TeleMetrum. The TeleMetrum will be mounted so the antenna is vertical. In order for the TeleMetrum to function properly, this must be done. Figure 11: Avionics Sled Bulkhead Configuration The bulkhead must be able to withstand high pressures caused by wind and black powder charges. It is also essential that the bulkhead is amenable to screws, U-bolts, and other pieces of hardware. Plywood was selected as a material that could fit the role needed for the bulkhead because of its strength, lightweight, and durability. Black powder charges and E-matches are attached to the bulkheads with putty due to its strength and stability when compared to other materials such as tape, black tack, or blue tack. There is no significant advantage between U-bolts and Eyebolts. While U-bolts have a greater distribution of force, decreasing the chance of a single point failure, U-bolts take up more space 22

32 than Eye bolts. Eyebolts are better for small spaces because of their size, however they do need to be welded closed which creates greater chances for single point failures. With this knowledge, U- bolts are a better fit Avionics Coupler Subsystem Mass Statement Table 10: Avionics Coupler Subsystem Mass System below is the mass statement of the avionics subsystem. Mass data has been taken from manufacturer documentation or from measurements previously taken by the team. Small mass margins have been added in order to combat past years where larger mass margins have caused underweight rockets to have higher altitudes than expected. Table 10: Avionics Coupler Subsystem Mass System Item Total Mass [lb] Use Structure: Avionics Switch Band 0.34 Switch Band for Avionics Bay Avionics Coupler 1.85 Avionics Coupler Tubing 6 Coupler Bulkhead (2) 0.15 Bulkhead for Coupler Tubing Upper Nosecone Bulkhead 0.11 Bulkhead for Upper Nosecone Lower Nosecone Bulkhead 0.15 Bulkhead for Lower Nosecone Rover Bulkhead 0.16 Bulkhead for Rover Payload Nuts, Bolts, Washers, and 0.10 Connections Screws 1515 Rail Button (2) 0.05 Connection to Launch Rail Margin 0.20 Future Growth Structures Total Mass: 3.11 Recovery Equipment: StratoLogger CF (1) 0.03 Altimeter TeleMetrum 2.0 (1) 0.03 Altimeter/Tracker 9V Battery (1) 0.10 Battery for StratoLogger 9V Battery Clip (1) 0.02 Attach 9V Batteries to Sleds TeleMetrum Li-Po Battery (1) 0.03 Battery for TeleMetrum Main Parachute 1.22 Main Parachute 20ft Main Shock Cord 0.57 Tubular nylon Drogue Parachute 0.15 Drogue Parachute 20ft Drogue Shock Cord 0.6 Elastic Cord Quick Links (3) 0.75 Attachment Hardware Nylon Shear Pins 0.01 Shear Pins ¼ Threaded Rods (2) 0.07 Mounts for Sleds 23

33 1/8 Plywood Sheet 0.10 Sleds for Mounting Equipment Terminal Blocks (4) 0.05 Connect Altimeters to Black Powder Charges Rotary Switches (2) 0.05 For Activating Altimeters on the Pad Margin 0.25 Further Growth Recovery Equipment Total Mass: 3.79 Total Mass of System: Payload Bay and Upper Airframe Subsystems The rover will be housed in the payload bay located between the nosecone and the main parachute in the upper section of the rocket. To keep the upper section attached to the parachute, a Kevlar shock cord will be tied to a U-bolt on the nosecone. A CAD model of the upper airframe is shown in Figure 12 and a labelled diagram of the upper rocket section is shown in Figure 13. Figure 12: CAD model of upper airframe 24

34 Figure 13: Upper Rocket Section Breakdown The payload bay will store both the rover and the parachute for the nosecone. It serves the dual purpose of protecting the rover from black powder charge as well as limiting movement of the rover during flight. The parachute will be stored on the other side of the bulkhead that attaches to the rover orientation mechanism and the payload section will connect to the nosecone, which includes its own avionics bay. The nosecone bay includes two altimeters, 9V batteries, and black powder ejection canisters on the bulkhead to facilitate the deployment of the parachute. The altimeter switch for the nosecone parachute will be located between the nosecone and the upper airframe. It will be situated so that it only cuts a semicircle into the airframe and will leave with the nosecone once the parachute is deployed. To ensure that the nosecone and upper airframe will be pointing down during flight when the drogue is deployed, the nosecone will be deployed between drogue ejection and main parachute deployment. For the purposes of safety of persons and property, the nosecone will be deployed before the main parachute so that its deployment is not close to ground level Payload Sled Configuration Added onto the structure is a platform that will hold the rover and allow for easy exit once activated. As illustrated in Figure 14, this sled includes a pin that attaches to the bevel gear. This allows the entire rover and sled to rotate around the fixed bevel gear. The two rectangular holes on the sled secure the rover during flight and landing. Once the latches are removed, the rover will be activated and able to exit the vehicle. An illustration of the latches is included in Figure

35 Figure 14: Rover Orientation Mechanism Structure Figure 15: Rover Locking Mechanism The rover locks to the bay through a process shown in Figure 15. The two servos under the rover rotate a linkage and latch onto small rings in the rover body. The two linkages face opposite directions so the rover has even less of a chance to slip out. 26

36 3.4.2 Payload Bulkhead Configuration To create a tighter seal inside the rocket, two bulkheads will be utilized. By gluing together two bulkheads that fit into the main airframe and the coupler individually, the cap will prevent the wind from disrupting all instruments inside the payload. The material of the bulkhead will be aircraft plywood. The team arrived at this decision based on cost and it being highly workable. A more detailed explanation of this material choice can be seen in the sub-section Payload Changes. The placement of items on the bulkhead will be as follows: The upper and lower bulkheads will be in and 30.5 in from the top of the nosecone, respectively. The rover will be in from the top of the upper airframe. The coupler bulkhead will be 16 in from the bottom of the airframe and 6'' from the top of the booster frame. The upper, mid, and lower centering rings will be in, 30 in, and 48 in from the top of the booster respectively. For the recovery system, the team compared U-bolts and eyebolts. While both would provide sufficient strength, the team opted to use U-bolts. The eyebolt has a higher chance for single point failure as opposed to the U-bolt because the U-bolt offers a greater distribution of force. Despite the fact that the U-bolt takes up more space than the eyebolt, size and space is not an issue on bulkheads of this size Nosecone The nosecone is a pivotal component to any rocket, needed to reduce drag as well as house the data instruments. The team has currently chosen to use a 6-inch fiberglass ogive nosecone. As opposed to various other nosecones, the fiberglass ogive meets the team s needs the best. With regard to material, fiberglass offers the ideal compromise of being light, strong, and easy to work with. With respect to the shape of the nosecone, the ogive provides ample room for the avionics bay and allows for the high speeds of the rocket to be achieved. As with all aspects of the rocket, assessing the trade-offs and needs of the mission determine the choice for parts. A CAD model of the nosecone is shown below in Figure

37 Figure 16: CAD model of nose cone Nosecone Avionics Subsystems Mass Statement Table 11 below is the mass statement for the nosecone avionics subsystem. Mass data has been taken from manufacturer documentation or form measurements previously taken by the team. Small margins have been have been added to allow for uncertain measurements such as the amount of epoxy and to allow for future growth. Small mass margins have been added in order to combat past years where larger mass margins have caused underweight rockets to have higher altitudes than expected. Table 11: Nosecone Mass Statement Item Total Mass [lb] Use Structure: Upper Airframe 2.52 Houses Payload Parachute 6 Coupler Bulkhead (2) 0.15 Bulkhead for Coupler Tubing Upper Nosecone Bulkhead 0.11 Bulkhead for Upper Nosecone Lower Nosecone Bulkhead 0.15 Bulkhead for Lower Nosecone Fiberglass Nosecone 1.78 Nosecone Nuts, Bolts, Washers, and Screws 0.10 Connections Margin 0.20 Future Growth Structures Total Mass:

38 Item Total Mass [lb] Use Recovery Equipment StratoLogger CF (1) 0.03 Altimeter TeleMetrum 2.0 (1) 0.03 Altimeter/Tracker 9V Battery (1) 0.10 Battery for StratoLogger 9V Battery Clip (1) 0.02 Attach 9V Batteries to Sleds TeleMetrum Li-Po Battery (1) 0.03 Battery for TeleMetrum Nosecone Parachute 0.10 Nosecone Parachute 5ft Nosecone Shock Cord 0.16 Kevlar Quick Links (3) 0.75 Attachment Hardware Nylon Shear Pins 0.01 Shear Pins ¼ Threaded Rods (2) 0.07 Mounts for Sleds 1/8 Plywood Sheet 0.10 Sleds for Mounting Equipment Terminal Blocks (4) 0.05 Connect Altimeters to Black Powder Charges Rotary Switches (2) 0.05 For Activating Altimeters on the Pad Margin 0.25 Further Growth Recovery Equipment Total 3.75 Mass: Total Mass of System: Recovery Subsystem The recovery subsystem is a vital part of the rocket. This subsystem allows the three components of the rocket to land at velocities that are both safe for bystanders and for the rocket itself. Recovery subsystem also considers the drift distance of the rocket's components to ensure the most efficient and safe procedures are followed. Parachutes were selected with these important factors in mind. This rocket will use three parachutes: a main parachute, a drogue parachute, and a nosecone parachute. The main parachute will be a Fruity Chutes Iris Ultra with a diameter of 96 in. The drogue parachute will also be from the company Fruity Chutes but with a diameter of 24 in. The nosecone parachute will be purchased from SkyAngle and have a diameter of 36 in Deployment Scheme The deployment of the parachutes is marked by three separation events. The first of these occurs at apogee, which separates the booster section from the avionics coupler, which releases the drogue parachute. After release, the two sections remain connected to each other by the shock cord. This event happens at a high altitude in order to ensure that the rocket slows down enough to be able to safely release the main parachute. Next, at an altitude of 1000 ft., the nosecone separates from the upper airframe and the nosecone parachute is released. The nosecone fully disconnects from the rest of the rocket in order to open the top of the upper airframe to let the payload eventually exit 29

39 the rocket. Finally, at an altitude of 800 ft., the upper airframe will separate from the avionics coupler and the main parachute will be released. This altitude is sufficiently high enough to slow the rocket to safe landing speeds, but also low enough that drift would not exceed the competition maximum of 2500 ft. Figure 17: Avionics Coupler Figure 18: Upper Airframe and Nosecone 30

40 3.5.2 Deployment Mechanisms The motor does not come with an ejection charge, and more than one separation event is needed, so black powder ejection charges will be used instead. This allows the separations to be timed so that they can happen at various altitudes. The charges themselves are stored in small canisters that are ignited by e-matches that light when the proper electrical signal from the altimeters is received. Once ignited, the pressure from the black powder explosion forces the shear pins connecting the two sections out, leaving the two sections free to open apart. A notable advantage of using the black powder charges is that we can calibrate the amount of black powder used in each separation event to make sure that each charge is capable of safely separating the section. We first make a preliminary estimate of the amount of black powder needed based on calculations, and then further refine this number via ejection charge testing of every separation event in the planned flight configuration. Calculations for black powder are based on the ideal gas law; relevant equations are provided below. PV = nrt Force = Presure Area Avionics Hardware A total of four altimeters will be used for triggering separation events to deploy parachutes, along with acquiring data about the altitude of the rocket throughout the flight. Two altimeters will be placed in the avionics coupler and will be responsible for the separation events that release the main and drogue parachutes. Another two altimeters will be in the nosecone for triggering the nosecone s separation and parachute deployment. The two altimeters used in each section will be the PerfectFlite StratoLoggerCF and the Altus Metrum TeleMetrum 2.0. These altimeters are commercially available and operate by using a barometer for measuring altitude. The primary altimeter in each section will be the StratoLogger, with the TeleMetrum being the secondary. One of these altimeters would be able to handle triggering two separation events on its own, but two are used in each section in order to ensure redundancy. Making sure the separation events have adequate redundancy to ensure that parachutes deploy is important for both the safety of the rocket and of bystanders on the ground. These altimeters will operate by detecting certain activation parameters such as reaching the apogee point or reaching a preset altitude. When the activation requirements are met, the altimeters send current to e-matches that are mounted with the black powder charges, which will trigger the separation event TeleMetrum The secondary altimeter that will be used in the avionics system is Altus Metrum s TeleMetrum. This altimeter is powered by a 4V lithium ion battery that can be obtained commercially. The TeleMetrum is similar to the StratoLogger in that it can be connected to a switch, emits beeps for different flight parameters, and is capable of dual deployment events. The switch will allow the TeleMetrum to be turned on at the launch pad and off before the competition altimeters altitude is reported to the NASA official. Each altimeter will have its own rotary switch so they can be turned on and off independently. Unlike the StratoLogger, the TeleMetrum has GPS capabilities. The 31

41 TeleMetrum has an on-board integrated GPS receiver that will allow it to transmit its coordinates to the ground station s dongle in real time. Members of the team have experience using the TeleMetrum, giving the team confidence for its use in this competition. Two TeleMetrums will be used to track the coupler section and the nose cone as well as providing redundancy to the deployment of the parachutes. Altus Metrum offers a software called AltOS. This software allows the team to both get a live feed of the rocket s GPS coordinates and export flight profile data for later analysis. Figure 19 shows a graph generated by AltOS and from data collected using a TeleMetrum. Figure 19: Example flight path generated using AltOS For the TeleMetrum to acquire a GPS lock, the antenna must be oriented upright inside the vehicle. The payload sled was designed so the antenna is oriented upright. AltOS allows the TeleMetrum to communicate to a ground station via a dongle and antenna setup. The dongle interfaces with a computer via USB port. Before launches, a laptop will be connected to the dongle and ground station antenna. The ground station will then acquire a connection to the altimeter. The ground station will also ensure that the TeleMetrum has GPS lock before the vehicle is launched. Figure 21 shows an example of a vehicles ground track recorded using a TeleMetrum. This was updated in real time during the flight of the vehicle and allowed the team to track the vehicle s drift. 32

42 Figure 20: AltOS s menu. Figure 21: Example ground track. Since the vehicle separates into two sections, the vehicle will use two TeleMetrums for tracking. Research was conducted to see if two TeleMetrums would interfere with each other. Through the research and the experience of using two TeleMetrums in one rocket, it was determined that despite their close proximity, the altimeters signals would not interfere with each other provided that they are operating on different frequencies. This finding was based on the altimeters usage of radio waves. Radio waves, in actuality do interfere but this interference is negligible as seen with the transmission of radio waves throughout the country. The ability of receivers to tune to a specific frequency allows for the reduction of any significant interference being transmitted during the process. This means the altimeters will not interfere with each other but they do require the use two different antennas to be able to receive the telemetry at each distinct frequency. Two laptops will be used on the ground station. One dedicated to each one of the TeleMetrums StratoLogger The StratoLogger altimeter is powered by a commercial 9 Volt battery. The altimeter is capable of being connected to a switch, allowing it to be turned on from the outside of the vehicle before 33

43 launch. The StratoLogger has a small speaker that communicates different parameters about the flight via a series of beeps before launch. These beeps will tell the team when the parachutes will be deployed and that there is continuity to the e-matches. Continuity is important to check since it will ensure the e-matches are lit and therefore allow the vehicle to be recovered safely. After the vehicle has landed, the altimeter will emit a new series of beeps that reports the altitude of the last flight. This will allow the altitude to be recorded by the NASA official on launch day. The StratoLogger is also resistant to loss of power. The altimeter will stay on for a full two seconds without connection to the battery. This resistance adds security to the altimeter s data collection without any additional complexity. The StratoLogger was also chosen because members of the student launch team have used StratoLoggers successfully on other high power rockets. The PerfectFlite allows the team to pull flight profile, altitude, and velocity from the altimeter following launch. PerfectFlite offers a software called DataCap to export the flight data off the StratoLogger. DataCap can be used to graph the data too. An example a flight profile can be seen graphed in DataCap below in Figure 22. The altitude is graphed in blue and the velocity is graphed in red. DataCap can also be used to perform some statistics on the data. The data can be passed through filters to make it appear smoother. The max altitude and velocity can also be displayed easily using DataCap. 34

44 Figure 22: PerfectFlite s DataCap software Avionics Electrical Setup The electrical schematics for both the nose cone avionics and the coupler avionics can be seen below in Figure 23 and Figure 24 below. The schematics show how the batteries are wired to the charges that will be used for the recovery events. In the coupler section of the vehicle, the primary altimeter is a StratoLoggerCF. This altimeter will be powered with a 9V battery. This altimeter will be connected to via a rotary switch. This rotary switch will allow the avionics to be turned on from the outside of the vehicle. The rotary switch can be locked into the on position. This will ensure that the avionics will remain on while the vehicle is on the launch pad and through the entire flight. This will allow the safe recovery of the vehicle. At apogee the altimeter will pass current from the battery to the E-match for the drogue parachute. Similarly, at the designated altitude, the altimeter will pass current to the main parachutes E-match. The secondary system in the coupler will consist of a 4V LiPo battery, a TeleMetrum, and two separate charges. This makes 35

45 the avionics completely redundant. The electrical wiring in the nose cone is similar to that in the coupler. The only difference is there is only one charge per altimeter. The charge will be activated at the specified altitude to separate the nose cone from the vehicle. Figure 23: Electrical Schematic for Coupler Avionics Attachment Hardware Figure 24: Electrical Schematic for Nosecone Avionics. The shock cord for the rocket will be ½ inch-width tubular Kevlar, noted for its superior strength, heat resistance, and durability. Tubular Kevlar of ½ inch-widths safely support forces in excess of 7,200 lbf. Accordingly, the Kevlar should reliably withstand the large tensile stresses experienced during parachute deployments. The shock cord attaches the fiberglass nosecone and upper airframe to the main parachute. Furthermore, the shock cord connects the coupler and booster sections to both the main and drogue parachutes. For a secure fit, the shroud lines of the 36

46 parachute are looped through the shock cord, and the parachute is passed through the looped shroud lines. As is common practice, a steel quick link and steel eyebolt will be used to attach the shock cord to the motor mount. The eyebolt fits securely into a slot on top of the motor mount. The quick link is a preferable design from both a convenience and safety standpoint. It is convenient for assembling and disassembling the rocket as well as providing a secure connection. The main Iris Ultra parachute will be attached to the avionics bay. A U-bolt, fastened with nuts and washers on each side, screws into the plywood bulkhead attached to the avionics bay. The nuts and washers will be epoxied for additional support. The drogue parachute attaches to the avionics bay in a similar fashion, on the side opposite as the main parachute. The payload parachute will be attached to a bulkhead in the upper airframe using a steel quick link and U-bolt akin to the other parachutes. Epoxy will hold the upper airframe bulkhead into place. Machine screws will connect the fiberglass nosecone to the upper airframe. Nylon shear pins will be installed to connect the upper airframe to the payload coupler, and coupler to the booster section. The shear pins prevent premature separation of the nosecone during flight. Once the ejection charges ignite, the shear pins will break apart, permitting the nosecone to separate. The main parachute will be housed between the coupler and upper airframe. The drogue parachute will sit in the booster tube beneath coupler. Three shear pins will be inserted in the coupler. The payload parachute is housed in the upper airframe under the nosecone. Four shear pins will attach the nosecone to the upper airframe Redundancy The redundancy of altitude measurements and ejection systems are critical to both mission success and safety. Consistent altitude measurements and ejection procedures ensure mission success and, most importantly, safety. All parachutes are equipped with a fully capable backup system. Each ejection is triggered by independent primary and secondary charges. Separate altimeters control their respective ejection charges. For optimal safety, each altimeter receives power from its own independent power supply. The secondary charge is larger than the initial charge, ensuring that separation will be achieved. This redundancy is necessary for the protection of all observers. High power rockets can achieve lethal speeds if parachutes do not deploy, and the rocket will most likely be destroyed as well. The Jolly Logic Chute Releases tethered to the main parachute are also wholly redundant. The two devices are joined in series. If one fails to release, the other should independently perform the duties required for a successful parachute deployment. This redundancy assures minimum drift distance while satisfying the competition kinetic energy restriction. 3.6 Mission Performance Predictions Reputable software, such as MATLAB and OpenRocket, in conjunction with hand calculations allowed the team to reliably previse the performance of the current launch vehicle design. Moreover, these tests ensure that all safety and performance requirements are assuredly met. 37

47 3.6.1 Simulation Methods Multiple simulation methods were used to ensure the stability and performance requirements of the rocket. The main simulator used is the OpenRocket software, due to the team s historical success in data acquired from this source along with OpenRocket s high regard within the highpower rocketry community. Additional simulation methods will be attempted, including attempts at using RockSim and custom-written MATLAB code created by the team in order to help validate data acquired from OpenRocket OpenRocket OpenRocket is a free, open-source program that will be used to simulate the flight of the vehicle. OpenRocket allows users to design a high-power rocket and simulate its flight performance in a variety of conditions. The user may select materials, densities, and dimensions for all components of the rocket, which allows for a virtually unlimited range of possible designs. For example, the length, height, diameter, wall thickness, and material of the body tube may be adjusted. Mass components may be added to simulate the mass of payload and avionics. The size, shape, and thickness of fins may also be adjusted, as well as parachute diameter, material, and position. There is also a wide range of engine selections available, which is helpful for determining the suitable engine to achieve the competition goal altitude of 5,280 ft. Once all components of the vehicle are adjusted, OpenRocket can then calculate the stability of the rocket and simulate its flight, and finally export performance characteristics including acceleration, velocity, altitude, and drift distance to a spreadsheet. The team s experience from previous years shows that OpenRocket s apogee prediction is quite close to actual results, though errors in estimating mass for epoxy and small parts could result in OpenRocket giving a more optimistic apogee value than actual flight. Still, the flexibility and accuracy of the program allows for rapid design cycles that improve the vehicle s performance, and any minor overestimation will be countered by comparison with the additional simulation methods detailed below. This flexibility, combined with the team s familiarity with the program, has led the team to choose OpenRocket as the primary simulation software for the competition. Figure 25 shows the current vehicle configuration in OpenRocket. 38

48 Figure 25: Vehicle modeled in OpenRocket RockSim The team decided to select the Deployable Rover (Option 2) as the team s payload/experimental requirement. As such, this required the design of an uncommon launch vehicle that involved avionics and payload recovery systems to be located in the nose cone and shoulder sections. However, the capabilities of RockSim does not allow for the accurate simulation of avionics and recovery systems in such a position. It was concluded that, due to these limitations, a simulated rocket design from RockSim would be an inaccurate estimation of the performance of the launch vehicle. As such, the team decided to refrain from utilizing RockSim for an alternative simulation method. OpenRocket is still exceedingly accurate in its simulation procedures and has proven to be a reliable simulation technique over past projects. Other methods of simulation, outlined below, will be utilized to validate data generated by OpenRrocket Custom MATLAB Program In order to help validate and verify the predictions made by the commercial software that was talked about above, the team decided to create its own custom simulation. The simulator was written in MATLAB. It uses a custom user interface to take in different parameters of the vehicle (i.e. mass, body tube diameter, cd of body, and fin dimensions), motor thrust curve, parachute sizes, and event heights. It also allows the user to vary the launch angle and wind speed to help better match the conditions that the launch vehicle will be flying under. An image of the user interface is located below in Figure

49 Figure 26: GUI for Custom MATLAB Simulator. The simulation runs by numerically integrating the equations of motion. The integration is done using MATLAB s ode45 function. It uses a Runge-Kutta (4,5) scheme with a varying time step for more efficient computing. It is accurate to the 5 th order with accumulated error to the 4 th order. It is a single step solver. This means to find y(tn), the function only needs y(tn-1) where y is the system s state and tn is the time at step n. Because it is a single step solver, it requires the initial conditions of the vehicle to be given. However, since the vehicle is at rest at the beginning of the launch, these are already known. The results from the custom simulations have been compared to the OpenRocket results in Figure 27, Figure 28, and Table 12. The altitude predicted by the MATLAB simulation predicted the altitude to be about 460 ft. less than that of OpenRocket. The custom simulation has under predicted the apogee of rockets flow previously by members of the team. Since the custom MATLAB simulation has not varied much since the previous years, the lower predicted apogee does not raise any concerns at this time. The off the rail speeds predicted by these two simulators are similar. This allow the team to be more confident that the vehicle will achieve a safe exit rail velocity during the actual launches. The decent speeds of both simulators are also similar. The drogue speed that the MATLAB simulation predicted is generally considered too fast for a safe recovery. The team will look more closely at the custom simulation to see if this will in fact be a problem for the recovery of the vehicle. 40

50 Figure 27: Altitude of custom simulation compared to OpenRocket. Figure 28: Vertical velocity of custom simulation compared to OpenRocket. 41

51 Table 12: Comparisons between custom simulation and OpenRocket. Parameter OpenRocket Value Custom Simulation Value Max Altitude 5295 ft 4805 ft. Velocity of the Rail 68.5 ft/s 66.1 ft/s Average Drogue Descent speed 93 ft/s 111 ft/s Average Main Descent speed 15.5 ft/s 25.9 ft/s Flight Profile Analysis The rocket will launch 0.04 seconds after the ignition of its motors, which will continue to burn for seconds before the motors burn out. Following motor burnout, the rocket will reach apogee at an altitude of feet within 14.99s. At this point, an ejection charge will deploy the drogue parachute. The booster and nosecone will be tethered together and will descend at a rate of 115 ft/s. Once the rocket reaches an altitude of 1000 ft, 58 seconds into flight, the nosecone and booster will separate via an ejection charge seconds later the nosecone will use another ejection charge to release a parachute and descend separately from the rocket at a terminal velocity of about 25 ft/s and hit the ground seconds after motor ignition. Meanwhile the booster will deploy the main parachute with the third ejection charge at an altitude of 800 ft. The booster s descent rate will fall to about 14 ft/s and will hit the ground seconds after ignition of the motor. Following the landing of the booster, the rover deployment will begin. A diagram of the flight profile can be seen in Figure 29 below. This current flight profile is very similar to the flight profile detailed in the Proposal documentation with the exception of the material of the bulkheads and centering rings. Previously, the team s bulkheads and centering rings were planned to be made of fiberglass, but they have been changed to plywood to save weight. This has allowed the rocket to reach a higher apogee by achieving greater acceleration. 42

52 3.6.3 Stability Figure 29: Flight path of vehicle. Sustaining stability is critical to keeping the rocket from tipping over during flight. This can be achieved by ensuring that the vehicle s center of gravity (Cg) is higher up on the rocket than its center of pressure (Cp). This causes airflow to induce a restoring force that naturally corrects the rocket s orientation. If there is not enough distance between Cg and Cp, there will not be sufficient restoring force to correct orientation. Meanwhile, too great a distance between Cg and Cp will cause the rocket to oscillate past its equilibrium position due to disturbing forces. The suitable separation between Cg and Cp is measured by the stability margin. The equation for calculating this value is: Stability Margin = C g C p D D is the diameter of the rocket and Cg along with Cp are positions measured from the top of the nose cone. Stability margin is measured in units of Calibers. Ideally, a rocket should have a stability margin of about 2 calibers. Anything significantly under 2 calibers is consider unstable, while anything significantly over is considered over-stable. The software, OpenRocket, was used to calculate the stability margin of the rocket while on the launch rail. As seen below in Figure 30, the stability is 2.33 Calibers, Cg is 83.8 inches, and Cp is inches. A stability margin of greater than 2 calibers at launch is in line with competition requirements. 43

53 3.6.4 FinSim Figure 30: CG and CP calculated by OpenRocket A fin simulation software was used to ensure that any encountered aero-elastic effects during flight would not be able to tear the fins off the rocket. This simulation took values such as fin thickness and material, and calculated a divergence speed. This divergence speed is the speed at which the air flowing past the fin would add energy to the fin oscillation, and subsequently go past the tensile strength of the material. Figure XX shows the GUI of the FinSim software. It displays the divergence speed as being ft/s, below the maximum velocity obtained by the rocket in any of the simulations run by Figure 31: FinSim GUI with displayed results the team. This gives confidence to the idea that the rocket will not experience a catastrophic failure and can be recovered in a flyable condition. 44

54 3.6.5 Kinetic Energy When designing the launch vehicle, it is important to consider the kinetic energy each portion of the vehicle will have during descent in order to properly size parachutes. If a portion of the rocket falls too quickly, it can have a hard impact with the ground that could potentially cause damage to the vehicle components. Since the vehicle is designed to be reusable, parachutes must be adequately sized to limit the kinetic energy and prevent damage. The competition also sets forth a maximum kinetic energy upon impact of 75 ft*lbf per individual section of the rocket. In order to determine the kinetic energy of each section of the rocket, the terminal velocities of each section under its respective parachute must be considered. With knowledge of the weight under the parachute, the drag coefficient of the chute, and the area of the chute, the terminal velocity of each section can be determined by the following relation: v t = 2mg ρac d The density of air can be approximated as a constant value of lbm/ft 3, and g is a constant equivalent to ft/s 2. With terminal velocities known, the kinetic energy of each section can be calculated via the following equation: KE = 1 2 mv t 2 where m is the mass of the vehicle section, and vt is the terminal velocity in ft/s. With these equations, the recovery team worked to properly size parachutes that would satisfy the competition s kinetic energy requirement, while also maintain a sufficiently slow descent speed. The goal was for sections under drogue to descend between 80 and 100 ft/s, and sections under main to descend between 10 and 20 ft/s. These values are consistent with what the higher-powered rocketry community generally views as safe descent speeds. Drift calculations were also taken into account, but full analysis on drift is included in a separate section. Table 13 below shows the following parachutes were chosen to be used on the vehicle: Table 13: Initially Chosen Parachute Models Recovery Device Model Cd Diameter (in) Main Parachute Fruity Chutes Iris Ultra Drogue Parachute Fruity Chutes IFC Nosecone Parachute SkyAngle

55 Concerning the recovery of the nosecone section, deviations from the standard dual deployment system had to be made in order to be able to successfully complete the designated payload tasks. As such, the launch vehicle actually as three distinct parachute, with the last being used specifically for the recovery of the nosecone, which will detach in order for the payload to complete its task. Due to only one compartment being available for a nosecone parachute, the recovery team decided that single parachute should be used. Deploying two parachutes from one compartment would introduce the risk of parachutes tangling. This was a scenario the team wanted to avoid at all costs. Below is a mass breakdown for each of the separate sections that will be landing, and how much mass is under each parachute: Table 14: Mass under Each Parachute by Section Drogue/Main Parachute Mass (lb) Section 1: Booster (dry) Section 2: Avionics Coupler 4.94 Section 3: Upper Airframe 9.8 Total Mass Under Drogue/Main Chute Nosecone Parachute Section 4: Nosecone 6.38 Total Mass Under Nosecone Chute 6.38 From the masses described in Table 14, the terminal velocity of each section can be found: Table 15: Calculated Terminal Velocities of Each Vehicle Section for Chosen Parachutes Vehicle Section Terminal Velocity ft/s Nosecone Upper Airframe/Coupler/Booster Tube The values in Table 15 fall quite well into the margin of safe descent speeds listed above. The nosecone s descent is not explicitly under 20 ft/s. However, due to the team s decision to utilize only one parachute for the nosecone, and a necessity to balance safe descent speed while also minimizing drift distance, this speed was deemed acceptable. Not only is the speed very close to the desired change, but it also results in a nice balance between safe descent speed and minimal drift of the nosecone. With all the information needed to calculate kinetic energies of separate rocket sections known, the following values were calculated: 46

56 Table 16: Kinetic Energy of Each Vehicle Section at Impact for Chosen Parachutes Vehicle Section Terminal Kinetic Energy (ft*lbf) Booster Tube Avionics Coupler Upper Airframe Nosecone All of the calculated values in Table 16 fall within the competition limit of 75 ft*lbf. As such, it was concluded that the chosen parachutes are, in fact, the proper size to be able to both meet competition requirements, and the team s own desire to ensure a safe descent speed of each vehicle component Drift Drift distance is a determining factor in the selection of the parachutes and deployment scheme. Once these simulations are complete, the team can be confident that the components of the vehicle will land within the allowed recovery area of the competition, which is a 2,500 ft radius from the launch pad. As specified in the Student Launch handbook, the distances shown in Table 17 were calculated using crosswind speeds from 0-20 mph with 5 mph increments. Analysis was done assuming a launch angle of zero degrees as stated in the handbook. Table 17: Drift Calculations for Each Section of the Launch Vehicle Section Booster and Upper Airframe 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) Nosecone Using the idealized zero-degree launch angle, no drift distances exceeded the 2,500 ft drift requirement. These results further justify the teams parachute selections. 47

57 3.7 Subscale Rocket Overview A subscale rocket will be constructed to acquire data for analysis. The team decided to construct a half scale rocket, which will be inches in length and 3.1 inches in diameter. The subscale rocket will weigh oz. on the launch pad and reach an apogee of over 850 ft. before descending under a single parachute Mass Statement Component Table 18: Rocket Mass Statement Mass Nose Cone + Upper Airframe Nose Cone Upper Airframe Payload Switch Band Coupler Bulkhead (Upper) Bulkhead (Lower) Avionics Subtotal Booster Booster Tube Parachute Shock Chord Motor Mount Tube Motor (H97J-10) Centering Ring (Upper) Centering Ring (Lower) Epoxy Trapezoidal Fins (3) Subtotal Total 4.83 oz 9.98 oz oz 0.72 oz 7.30 oz oz oz 4.00 oz oz 9.98 oz 5.00 oz oz 3.86 oz 9.93 oz oz oz 3.00 oz 6.33 oz oz oz Motor Selection The subscale rocket will use a H97J-10 motor to achieve a predicted apogee of 870 ft. The thrust curve of the motor was obtained from thrustcurve.org and shown below. 48

58 The motor burns for 1.59 seconds, producing an average thrust of 26 lbf and a max thrust of lbf 0.5 seconds after ignition. Figure 32: H97J-10 Thrust Curve Motor Dimensions The H97J-10 motor is 1.14 inches in diameter and 9.41 inches in length. It has a wet mass of 9.93 oz. and a dry mass of 4.96 oz. Table 19: Summary of Physical Characteristics Feature Diameter Length Dry Mass Wet Mass Value 1.14 in in oz oz. Table 20: Summary of Performance Characteristics Feature Max Thrust Average Thrust Burn Time Total Impulse Value lbf lbf 1.59 s lbf*s 49

59 Motor Mount Assembly The motor mount assembly will consist of two centering rings and a motor mount tube. The motor will be secured in place by the motor mount tube, which is in turn constrained by the two centering rings. The centering rings will be made of ¼ in. plywood, with an outer diameter of in. and an inner diameter of 1.41 in. One centering ring will be located at the aft end of the rocket, and the other will be 5 inches above. The motor mount tube will be 9.5 inches in length, with an outer diameter of 1.41 in. and inner diameter of 1.14 in. Epoxy will be applied to secure the motor mount assembly, and to secure the entire assembly to the booster segment of the rocket Outer Airframe The outer airframe of the subscale rocket will be made of BlueTube with a 3.1 in. outer diameter and 3.0 in. inner diameter. The booster segment will be 24 inches long, providing ample space to store the parachute, shock chord, and motor. The booster airframe will weigh 9.98 oz., while the overall booster section will weigh oz. The upper airframe will be 24 inches long, with a 10 oz. payload stored to simulate the rover. The upper airframe will also weigh 9.98 oz Fins The subscale rocket will utilize three trapezoidal fins arranged in 120 offsets at the aft end of the rocket. The fins will be made from 1/8 in. plywood. A diagram of the fins is given below in Figure 33. Figure 33: Subscale Fins 50

60 The fins will experience greater aerodynamic pressure if the rocket deviates from prograde, which will cause the rocket to naturally point back towards prograde. The specific shape and size of the fins were chosen to match the full-scale rocket, which retaining a stability margin of over 2. Due to stability concerns, the fins were not scaled to ½ of full-scale size like the rest of the subscale rocket, but instead to 55% of full-scale size. The team believes this is a reasonable difference due to the stability benefits gained Avionics The subscale rocket will have an avionics bay located in the coupler segment of the rocket. On board the avionics bay will be an altimeter to document flight events and apogee of the subscale rocket. The model of altimeter will be a StratoLogger CF. The team will not be using the StratoLogger to set ejection charges. Instead, the subscale rocket will utilize the motor ejection charge on the motor for separation and parachute deployment. This approach greatly reduces complexity of the avionics bay and avoids wiring, which results in greater reliability. The motor ejection charge of the H97J-10 motor is fired shortly after apogee, which conveniently allows for the implementation of this method Payload A dummy payload will be used to simulate the rover that will be used for the full-scale rocket. Since the subscale rocket is half-scale, the dummy payload will be 1/8 of the mass of the full-scale rocket. The team estimated the dummy payload to weigh 10 oz. This allows for a very similar mass distribution for the subscale rocket as compared to the full-scale rocket, which in turn provides a more accurate subscale test flight. The team will not be launching a subscale rover paired with the subscale rocket, since it would be difficult to scale down the rover. Instead, an independent test will be conducted on the full-scale rover with a 6-inch Blue Tube segment Recovery The subscale rocket will descend under a 36-inch FruityChute parachute deployed at motor ejection, approximately 3.6 seconds after apogee. The rocket will separate into two components at the coupler via the motor ejection charge, but will stay connected via a shock cord. The parachute will deploy, bringing the descent velocity down to 20 ft/s at landing. The team also simulated drift via OpenRocket to ensure the rocket will not drift too far for tracking and recovery. According to simulations in OpenRocket, the rocket will drift under 1,150 ft. in 20 mph winds, and under 220 ft. in 5 mph winds, which is well within acceptable limits. The kinetic energy of the subscale rocket at landing is ft-lbf Simulations The subscale rocket was simulated in OpenRocket. The graphs below show the current design and flight profile of the subscale rocket. 51

61 Figure 34: OpenRocket Subscale Design Figure 35: Subscale Rocket Flight Profile 52

62 4 SAFETY 4.1 Safety Plan Overview Safety is always the main concern for the ISS Student Launch Team, so if a situation should occur, safety would always come before the success of the project. This year s safety officer is Courtney Leverenz, who oversee a few team members that will perform a complete analysis of risks the Student Launch team may face in when building or testing. Courtney and her team will create procedures and guides to minimize these risks. Using safety trainings, building briefings, and documentation requirements, the team will be engaged in compliance for safety protocols. These components for safety will be required by all team members desiring to participate in construction or attend launch. By having the safety officer and a team of trained in safety, the Student Launch team can warrant that all members working in the labs understand conventions Safety Briefings To guarantee safe practices all team members will be required to attend in person meetings with the Safety Officer. These meetings will cover basic safety and rules. These safety briefings also cover tool use, material safety, proper personal protective equipment (PPE), and other smart lab practices. Anything that may be possibly harmful to the team or the project will be covered in extensive detail and given and proper action plan for worst-case scenario situations. Some required PPE include long hair being tied back, safety glasses at all times, and a minimum of two people in the lab at any time. All rules regarding to the labs specifically accessed for this project will be followed when in use. These includes undergraduate student labs 18A, 18B, and 18C in Talbot Laboratory that fall under the department of Aerospace Engineering at the University of Illinois at Urbana-Champaign. These safety briefings are only one of many member requirements that are put in place by the team s Safety Officer Member Requirements All members of the Illinois Space Society Student Launch team are required to comply, complete, and follow a set of rules regarding lab use, building procedures and general safety. Each of these is implemented and enforced by Courtney. Before any lab work or builds begin, each team member is required to complete an online training module regarding general lab safety, provided by The University of Illinois. This is basic lab safety concepts and practices, finalized with a quiz that proves one has successfully completed training and properly understands the material. All certifications are then uploaded for the Safety Officer to check and prove that each member has their requirements completed. One of the rules that all members have to follow is the act of never working alone in a lab setting. For safety purposes, members are never allowed to work solo, but rather must always work in a minimum group of two people. This ensures that one can check the other, prevent and minimize any possible dangers that may arise throughout build processes. Working in groups of two is not only taught in the online training module, but also required at all times by the Safety Officer. 53

63 As mentioned in the section above, members will also have to sit through safety briefings with the Safety Officer. These times allow for reinforcement of safe practices and education on any new safety regulations or situations that arise. Members are also allowed to ask questions in person and get direct feedback on concerns. This is an extremely practical way to approach safety. Another safety precaution taken is the act of sharing contact info with all members. Every person on the ISS Student Launch team has the contact information, including s and cell phones numbers, for each sub-team lead. This includes the ISS Technical Director, ISS Student Launch Tech Lead, Structures Sub-team Lead, Payload Sub-team Lead, and the Safety Officer. By having ready access to contact information if at any moment the team members encounter a problem or questionable situation, it is possible to attain instantaneous feedback on how to proceed or not proceed. Finally, all ISS Student Launch team members will also follow any laws required by the federal government, state government, and country/regional governments. Team members will also act under all university requirements and act within the code required to use the facilities of The University of Illinois at Urbana-Champaign. All bi-codes implemented by the Student Launch Competition will be followed too. Finally, any and all public lab use rules will be followed in accordance to The University of Illinois Aerospace Engineering Department Equipment Training Team members will have knowledge on the operations of the equipment and tools that are available for usage in the labs. The safety team will arrange tutorial sessions for all members about the equipment and will have procedures readily available. During the month of October, to prepare for Sub-Scale launch, the ISS Student Launch team hosted the first training session. Dr. Woodard, who is in charge of the labs, trained members on how to properly use the Laser Printer. Team members learned correct set up, materials allowed for use, and clean up. In Figure 36, you can see team members learning about the user interface of the printer. 54

64 Figure 36: Laser Printer Training In addition to this session, Courtney and her safety team will host additional sessions that will include: 3D printer Disk sander Diamond Saw Down draft Table Table Saw Dremel tool In order to operate the equipment and participate in the manufacturing process of student launch, team members will have to attend these safety tutorial sessions or contact the Safety Officer. By hosting training sessions, the ISS Student Launch team is decreasing the chance of error due to misuse of equipment. 4.2 NAR Mentor This year s NAR team mentor for the ISS Student Launch team is Mark Joseph. Mark has mentored the ISS team for the past five years and is familiar with the competition structure. His primary role outside of general design guidance will be to handle and train students on the handling of energetics and the explosive motor fuel grains the team will utilize Energetics Handling In addition to providing NAR Standards design input and accompanying the team to Huntsville, the NAR team mentor will be tasked with handling and training students in the handling of all energetics. This includes both the subscale and full-scale vehicle, as well as the e-match ejection charges used for stage separations and parachute deployments. Any student handling energetics 55

65 will be closely supervised by the NAR mentor in a one-on-one environment to ensure all care and protections are taken for the safety of the team Motor Purchase and Storage Motor storage, transport, and preparation will be in accordance with the National Fire Protection Agency, specifically NFPA code The motor shall be stored in a Type 3 or Type 4 indoor magazine as the selected motor is under 50 lbs. Transportation of the motor will comply with 49 CRF Subchapter C Hazardous Materials Regulation, which covers packaging, handling, and transportation of high-power rocket motors. The operations motor will be posted on the team website upon arrival. Mark will purchase and store motors until needed. Once the Student Launch team requires the motor, the team lead and safety officer will work with the NAR Mentor in procedures and final checks. However before motor is needed, all team members will be required to review and sign a team safety agreement. This agreement discusses and requires signers to abide by the terms including all pertinent laws and regulations. Environmental regulations will be referenced during the course of this project to ensure compliance. The safety officer is accountable for finding relevant regulations for the handling and proper disposal of hazardous or environmentally harmful materials. 4.3 Risk Assessment Overview To better prepare for issues that inevitably arise during any project of large scale and to prioritize the team s time, the safety team conducted a thorough risk analysis based on the severity of these issues. The safety team analyzed risks to the project, the environment, and above all, the health of team members during the construction process. The team used Risk Assessment Codes (RACs) to evaluate the various hazards to both personnel and the project. Table 21 introduces the risk matrix and the risk assessment codes that will be used to classify risks throughout the rest of the safety section. Risks are color-coded based on the severity and Table 22 discusses the team s response to these various levels. Table 23 defines the levels of severity as it relates to personnel, project, and environmental health. Finally, Table 24 defines individual instance probability and probability of occurrence of these risks throughout the entire project timeline. Table 21: Risk Assessment Codes (RACs) Severity Probability 1 Catastrophic 2 Critical 3 Marginal 4 Negligible A - Frequent 1A 2A 3A 4A B - Probable 1B 2B 3B 4B C - Occasional 1C 2C 3C 4C D - Remote 1D 2D 3D 4D E - Improbable 1E 2E 3E 4E 56

66 Table 22: Level of Risk and Member Requirements Level of Risk High Risk Moderate Risk Low Risk Minimal Risk Level of Training and Supervision Required Highly undesirable. The risk factor will be compared with the importance to the success of the project. Procedure or equipment operation must be done by the Safety Officer or Project Manager, or under their direct supervision. Undesirable. Procedure or equipment operation requires documented approval from Safety Officer and Project Manager in the form of training and proof of online safety training completion. Procedure or equipment operation requires supervision. Acceptable. Procedure or equipment operation requires training, but no direct oversight is necessary. Acceptable. Procedure or equipment operation require almost no training and no direct oversight. Instruction is highly recommended for new members. Table 23 : Severity Definitions Description Personnel Safety Project Success Environmental 1 Catastrophic Loss of life or permanent injury. 2 Critical Severe injury or illness requiring hospitalization. 3 Marginal Minor injury or operation-related illness. No hospitalization required. 4 Negligible Very minor injury or operation-related illness. Loss of or irreparable damage to launch vehicle. Failure to meet critical mission goals. Severe but reparable damage to launch vehicle. Failure to meet critical mission goals. Reparable damage to launch vehicle. Failure to meet non-critical mission goals. Minor or cosmetic damage to launch vehicle. All mission goals successfully met. Irreversible and severe damage that violates law or regulation. Loss of project. Reversible damage to environment that violates law or regulation. Significant damage to project. Reversible damage to environment that does not violate law or regulation. Minor damage done to project. Minimal effect on environment or project. 57

67 Description A Frequent B Probable C Occasional D Remote Table 24 : Probability Definitions Definition Highly likely to occur in any individual session and likely to be experienced continuously throughout the course of the project. Likely to occur in any individual session and expected to occur regularly throughout the course of the project. Expected to occur a few times throughout the course of the project. Unlikely to occur in any individual session but expected to occur once throughout the course of the project. E Improbable Highly unlikely to occur in any individual session and not expected to occur throughout the course of the project. 4.4 Personnel Hazard Analysis The safety of all team members is priority to the ISS Student Launch team. Any potential for human injury, however minor, must be considered. To fully identify and understand all involved hazards, the safety officer has developed mitigation strategies to prevent harm to participants. A comprehensive personnel hazard analysis has been completed to identify all known personnel risk factors and how best to address any safety concerns. The results of this analysis are presented in Table 25. For each identified risk, the team has considered four factors: its likely cause, its impact on personnel, its pre and post Risk Assessment Code, and an optimal mitigation strategy. This hazard analysis will help the team anticipate risks for human injury well in advance, with the Risk Assessment Codes allowing the safety officer to pay particular attention to regulating higher-risk activities. The ultimate goal is to preemptively implement mitigation strategies before, not after, incidents occur. To provide a thorough personnel hazard analysis, the safety team referenced a variation of Material Safety Data Sheets (MSDS). These sheets allowed the team to better understand the risks of working with various materials, as well as the standard safety protocols associated with each. The safety team will become familiar with all of the materials that will be used during the construction process and will create summarized hazards and harm mitigation techniques for each of them. The safety officer will also instruct members working with hazardous materials on the dangers of a given material, how to safely work with it, and what to do if something go wrong. A list of all 58

68 referenced MSDS is presented in Table 26: Referenced Material Safety Data Sheets (MSDS), following the personnel hazard analysis. Table 25: Personal Hazard Analysis Electric Shock Risk Cause Impact Mitigation Verification Hearing Damage Injury from Diamond Saw Contact with exposed electrical equipment and outlets Improper use or lack of hearing protection 1) Hand slipping or incorrect placement 2) Kickback due to improper blade height or inadequate maintenance 3) Flying debris due to cutting action 1) Fire hazard 2) Electric shock resulting in burns, muscle pains, or death Permanent hearing damage or hearing loss 1) Minor irritation up to severe injury to eyes due to flying debris 2) Laceratio n to hands 1) Team members must know proper grounding procedures. 2) Ensure equipment and workspace safety prior to handling electrical equipment. Ensure all team members using or in vicinity of power tools wear hearing protection gear. 1) Always use guards, and use a push stick for small parts. 2) Check and adjust blade height, stand to side to avoid flying debris. 3) Always equip eye protection. 4) Perform routine maintenance and remove broken blades. 5) Allow only trained members Team members completing General Lab Safety Certificate Team members completing General Lab Safety Certificate Tool Safety Briefings will instruct team members on correct usage. RAC w/mitigation 1E 1E 2D 59

69 Injury from Falling Objects Ignition or Dispersion of Black Powder Early ignition of Rocket Motor Retrieving items stored on shelves Improper storage or handling of black powder Mishandling and/or faulty installation of the rocket motor Head trauma, minor cuts, and possible concussion 1) Possible bodily injuries such as skin burns 2) Respirator y track damage if inhaled Second to third-degree skin burns to access the table saw. 1) Ensure steady footing while retrieving shelved items. 2) Encourage team members to ask others for help if needed. 1) Black powder will be stored only in approved containers. 2) Only the minimal amount of black powder should be exposed at any time. The main container should be separated from the main workspace. 3) Open flames and heat sources are strictly prohibited in vicinity of black powder. 1) The team mentor will be working with all motor-related components as per regulations. 2) Consult minimum distance table before each launch or firing test. Black powder will only be handled by the team mentor, team lead, and safety officer. 2E 2E 2E Chemical Burns from Ignition of Mishandling and/or faulty installation of Second to third-degree skin burns 1) Consult the minimum distance table The team mentor will be working 2E 60

70 Rocket Motor Sunburn Various Accidents Slippage of Power Drill the rocket motor, premature ignition of the motor s fuel grains Intense UV rays Cluttered lab space and distractions in the workspace Dull drill bits are hard to handle and prone to slippage. Severe sunburn, sun poisoning, and or skin cancer in the future. Ranges from minor cuts and scrapes to severe injuries including concussions and broken bones Mild lacerations or puncture wounds to hands and other extremities before all launches and motor tests. Sunscreen will be available to all personnel, as the danger that the sun can cause will be stressed to all. 1) Keep work area clean, well lit, and organized. 2) Place clearly visible signs where tripping or slipping hazards exist. Spills should be mopped up immediately. 3) Do not operate any power tools in volatile environments. 4) Do not operate machinery that poses any threat of danger in the presence of distractions. 1) Always keep drill bits sharp. 2) Drill small pilot holes before drilling large holes. 3) Make sure the chuck is securely with all components related to the motor Weather monitored beforehand. Team will have sunscreen on hand. Team members completing General Lab Safety Certificate and other team members present making planned decisions. Tool Safety Briefings will instruct team members on correct usage. 3C 3D 3D 61

71 Slippage of Reciprocati ng Saw Skin Injury and Respiratory Issues, Blue Tube Skin Injury and Respiratory Issues, Fiberglass 1) Cutting material using only tip of cutting blade 2) Forcing blade through improper material 3) Failing to keep personnel clear of the area beneath the saw 1) Blue Tube can have sharp edges when cut 2) Dust generated during cutting can be an eye irritant. 1) Splinters from freshly cut fiberglass can puncture skin. 2) Fiberglass dust is very hazardous and hard to avoid when cutting or sanding. Moderate to severe skin lacerations Mild eye irritation or skin damage 1) Irritation of the eyes and skin. 2) Inhalation of dust when cutting or sanding can cause respiratory issues. tightened before use. 1) Cut with the entire blade to reduce the risk of the blade tip breaking off 2) Only use cutting blade with approved materials. Never force the blade. 3) Keep arms and legs clear of the area directly beneath the saw. 1) Use gloves when handling Blue Tube that has been cut but not sanded. 2) Wear surgeon s mask when sanding Blue Tube. 1) Gloves, goggles, and a respirator must be worn at all times when cutting or sanding fiberglass. 2) Fiberglass will only be cut and sanded in properly ventilated areas that are approved by the safety officer. Tool Safety Briefings will instruct team members on correct usage. Safety briefings informing team members of dangers and providing required protective equipment. Safety briefings by safety officer informing team members of dangers and providing required protective equipment. 3D 3E 3D 62

72 Exposure to RocketPoxy Injury from Use of 3D Printer Pricking from Needles and Syringes Smoke Inhalation Epoxy is a toxic substance and not safe to touch directly. Its fumes are harmful as well. 1) Contact with hot surfaces such as printer head block and UV lamp 2) Printing materials such as thermoplastics can be flammable Mishandling of needles and syringes when applying epoxy Personnel working on ejection charge Irritant contact dermatitis and allergic reactions if epoxy comes in contact with skin. Hands, wrists, and eyes are the most exposed areas. Minor burns to skin 1) Slight cuts or puncture wounds 2) Needle stick injuries can cause exposure to blood and other infectious materials. Prolonged irritation to 1) Gloves will be worn when working with epoxy and changed at any sign of damage. 2) Goggles will be worn when mixing epoxy to avoid splashing into the eyes. 3) Uncured epoxy is to be treated as hazardous waste and disposed of as such. 1) Keep body parts away from 3D printer when it is in use. 2) Only personnel with proper training will be permitted to operate the 3D printer. 1) Exercise proper care when dealing with needles. 2) Dispose of all needles properly in sharps containers. 1) Ensure all members are wearing personal Additional team members will be there to assist members epoxying Tool Safety Briefings will instruct team members on correct usage. Team members completing General Lab Safety Certificate Safety Officer will monitor 3D 3E 3E 3E 63

73 Inhaling of Spray Paint Propellant Contact with Operating Dremel Tool Bits Looking at Operating Laser Cutter testing could inhale smoke from the charges. Spray painting a component with no ventilation or little to no airflow 1) Sharp, fast rotating objects 2) Bits can fail and create shrapnel when cutting hard material. Lasers emit high levels of energy. respiratory system Dizziness, loss of consciousnes s, and potential brain damage 1) Cuts, scrapes, and other mild skin injuries 2) Eye injuries from flying debris Possible damage to vision, with the severity depending on duration of viewing protective equipment including masks and goggles. 2) Make sure all charge testing is done with the assistance of the team mentor. Ensure proper ventilation and airflow in painting areas. All painting should be done in an outdoor environment if possible. 1) Keep bystanders away while operating the dremel. 2) Do not operate in explosive environments, such as in the presence of flammable liquid or dust. 3) Members wear eye protection and are aware of the proper bits to use for different types of materials. 1) Team members will be instructed not to look at the laser cutting station when it is in use. progress of air quality and will adjust accordingly. Safety Officer will monitor progress of air quality around individual and will adjust accordingly. Tool Safety Briefings will instruct team members on correct usage. Tool Safety Briefings will instruct team members on correct usage. 3E 4B 4D 64

74 2) Only those with proper training permitted to operate the laser cutter. Table 26: Referenced Material Safety Data Sheets (MSDS) Material Rust- Oleum Spray Paint Blue Tube Black Powder Fiberglass Aerotech Rocket Motors MSDS Source ing/hobas-msds-sheet.pdf 65

75 4.5 Failure Modes and Effects Analysis In order to anticipate any safety or operational hazards that could arise during the launch process, both the structures and recovery and the payload sub teams conducted a comprehensive analysis to identify specific risks and their consequences. When considering the failure modes of these systems, the goal of the study was to identify all anomalies that could occur during each stage. Similar to the personnel hazard analysis, the risk analysis associates each identified risk with its cause, impact on the vehicle, Risk Assessment Code, and optimal mitigation strategy with the exception of a Pre-RAC Launch Vehicle The ISS Student Launch structures and recovery team has provided vehicle-associated hazards that are considered to directly influence the flight path or structural integrity of the rocket. The safety, structures, and recovery team wanted all risks to the team members to be accounted for. When considering the failure modes of the launch vehicle, the goal of the study was to identify all anomalies that could occur during each stage of flight, including ignition, ascent, and recovery. These identifications have been recorded and can be found in Table 27. Table 27: Structure and Recovery Risk Analysis Hazard Cause Effect Nosecone does not separate from upper airframe. Bulkhead placement in nosecone fails Altimeter failure. Motor retainer fails. 1) Ejection charge fails. 2) Material of nose cone and of upper airframe have too much friction. Inadequately secured 1 Altimeters lose power during flight. 2 Altimeters cannot receive adequate airflow. 1) Insufficiently secured Payload is trapped Nosecone does not eject Incorrect to no flight data is recorded. Unrestrained motor falls out the Pre- RAC 2A 1C 2C 1C Mitigation Providing correct force to cause separate. 1) Adjust sizing of bulkhead. 2) Epoxy thoroughly 1) Test altimeter systems beforehand. 2) Confirm sufficient battery voltage prior to launch 3) Correct number of holes and location 1) Secure motor retainer to lower centering ring with Verification The team will calculate the force needed to separate and will model with tests. Javier will ensure bulkhead unable to move. Team members with be trained in correct altimeter usage. NAR mentor and safety Post- RAC 2D 1E 2E 1E 66

76 Motor mount tube separates from outer airframe during launch. Motor ignition fails. Motor ignition is delayed or the motor chuffs before full ignition. Motor ignites prematurely motor retainer 2) Cap not properly tightened 1) Improperly installed motor mount tube 2) Lack of epoxy on centering rings 1) Defect in motor 2) Igniter not securely placed 1) Defect in motor 2) Ignitor not securely placed 1) Igniter prematurely triggered 2) Fuel grains exposed to open flames or other heat source bottom of rocket. Unrestrained motor travels through rocket body or falls out the bottom. Vehicle fails to launch. Non-optimal vehicle performance off the launch rail 1) Vehicle launches unexpectedly. 2) Some electronic components may have yet to be activated. 1B 3A 2C 2B epoxy and machine screws. 2) Ensure aft retainer cap is secure before launch. Adequately coat centering rings with epoxy when affixing motor mount inside booster tube. 1) Ensure igniter is placed as far up the motor as possible. 2) Review launch sequence beforehand. 1) Ensure adequate placement of igniter. 2) Inspect propellant grains for obvious defects before motor assembly. 3) Buy motors from trusted manufacturers. 1) Keep open flames and heat sources away from rocket at all times during setup. 2) Only arm igniter immediately before launch. officer will perform checks to ensure nonfailure. Javier will confirm with team lead correct seal. NAR mentor, team lead, and safety officer will perform checks to ensure mitigation in place. NAR mentor will examine pre-launch motor components. Safety officer and team lead will give permission for ignition. 1E 3C 2D 1E Motor backfires or experiences a severe internal Motor defect Loss of the vehicle 1A 1) Inspect propellant grains for obvious defects before motor assembly. NAR mentor will advise team in choosing motor and 1E 67

77 anomaly during flight. Main parachute ejection charges fail. 1) Continuity not achieved 2) Defect in e-match 1) Booster and payload sections do not separate. 2) Main parachute cannot deploy. 1A 2) Buy motors from trusted manufacturers. 1) Test ejection charge systems for continuity beforehand. 2) Use redundant charges and altimeters. assist in correct set up. Structures and Recovery team along with NAR mentor will run calculations for correct charge measure and perform various assessments. 1E Drogue parachute ejection charges fail. 1) Continuity not achieved 2) Defect in e-match 1) Drogue parachute cannot deploy. 2) High descent speeds will prevent deployment of main parachute. 3) Loss of booster section 1B 1) Test ejection charge systems for continuity beforehand. 2) Use redundant charges and altimeters. Structures and Recovery team along with NAR mentor will run calculations for correct charge measure and perform various assessments. 1E Main parachute tether systems fail. Re-usage of parachute Defect in parachute release Fraying of parachute and hole breaches 1) Main parachute cannot deploy. 2) Damage likely to booster section Parachute unable to 1B 2C 1) Test system beforehand. 2) Use redundant chute releases tethered together. Inspect all parachutes. Properly dispose of A group of team members will familiarize with the parachutes and receive final check with Javier. Sub team leaders will 1E 2E 68

78 Vehicle sections drift excessively far or into hazardous terrain. Rail buttons scrape excessively along launch rail. One or more vehicle components splinter upon landing. Vehicle spins excessively during launch. One or more fins separate at liftoff or in flight. from previous launches 1)Main parachute deployment at apogee 2) Payload parachute deployment at apogee 1) Improperly sized rail buttons for the given launch rail 2) Inefficient sanded rail buttons Vehicle sections impact ground at extreme speeds. Improperly aligned fins Inadequate epoxy application and/or support to motor casing. provide safe descent Vehicle components are unrecoverable or require excessive time to locate. Decreased vehicle performance off the launch rail. Timeconsuming repairs required before a second launch can take place. Possible damage to sensitive internal components. Loss of Stability. Rocket spins violent, goes off projected path. 2C 2C 2B 2A 2B parachutes with breaches. 1) Model the vehicle s flight characteristics and size parachutes appropriately to minimize drift distance. 2) Cancel launch in the event of excessive wind. 1) Ensure rail buttons are a proper fit for the launch rail selected. 2) Avoid use of excessive rail buttons. 1) Use simulations to predict and implement sufficiently low descent velocities. 2) Ensure all outer components (fins) are firmly fixed to vehicle body with epoxy. 1) Use a fin jig during construction to maintain vertical alignment of fins. 1) Apply epoxy liberally to ensure a sturdy adhesion to booster frame and to motor casing, using multiple fillets. 2) Insert fins between motor mount centering rings for added structural support. inspect parachutes. Team will perform simulations the day of launch to give most accurate conditions. Ensure correct positioning with confirmation from team members. Inspection of correct sealing by safety officer and sub-team lead. Javier and experienced Student Launch members will create precise fin jig. Inspection of correct usage of fin jig and sealing procedures by safety officer and sub-team lead. 2D 1E 2E 2E 2D 69

79 4.5.2 Payload The ISS Student Launch Payload sub team understands the complexity of the Rover payload. Destiny and her sub team have communicated with the safety team on design, testing, and performance components and have completed a risk analysis that can be viewed in Table 28. This allows both sub teams to recognize unforeseen safety hazards and reexamine currently known risks. The payload team will be implementing these mitigation strategies both now, during the prototyping phase, as well as later during final construction and operation. Table 28: Payload Risk Analysis Hazard Cause Effect Lazy Susan does not rotate properly Software components fail Rover does not become unlocked Rover becomes unlocked during flight 1) Gears not meshed 2) Gyro or Arduino fails 1) Improper coding 2) Electronics damaged during flight 1) Arduino fails 2) Transceiver fails 1) Locking hinge breaks 2) Arduino fails 1) Rover is unable to exit rocket 2) If Rover manages to exit, it will damage electronics upon exit 1) Arduino unable to command rover's actions 1) Rover never exits rocket 1) Rover is damaged severely by moving around Pre- RAC 2B 1A 1A 1A Mitigation 1) Test gears before hand 2) Test gyro and Arduino beforehand 1) Ensure coding is functional 2)Electronics are properly protects during rocket's flight 1) Ensure electronic devices are functional 1) Ensure hinge is strong enough to withstand force 2) Make sure Arduino works Verification Testing will be done by rotating the Lazy Susan inside a tube of the rockets diameter 1) Code will be run several times to ensure success. 2) Electronics will be put under stresses similar to inflight stresses, to simulate protection of the electronics. 1) Destiny will purchase components from credited source 2) Test Arduino and transceiver multiple times with far ranges 1) Testing will be done to ensure hinge is strong enough to withstand Post- RAC 2D 1E 1D 1D 70

80 Unable to communicate with rover Solar panels fail to deploy Pieces shatter or chip on rover before flight Pieces break on rover during flight 1) Transceiver failure 2) Signal blocked or out of range 1) Arduino fails 2) Improper coding Mishandling of rover 1) Black powder charge too much pressure 2) Impact of landing jolts rover and cracks or breaks it inside rocket. 1) Rover never leave rocket 1) Solar panels fail to deploy 2) No voltage created by solar cells to power LED Rover cannot function properly 1) Rover is unable to leave the upper airframe 2) Rover cannot function properly 2C 2D 1D 1C 1) Transceiver is functional and within range 1) Ensure hardware and coding is functional Have multiple pieces of each rover part in the event one breaks before launch Ensure the parts will have enough strength to withstand blasts maximum force upon it 2) Arduino code is run beforehand and finalized by Destiny. 1)Test transceiver at multiple ranges 2) Make sure parachute is not deployed too soon to drift rocket far 1) Team will run code trials. Tests should result in outcome after multiple tests. Team will travel and treat rover with care. Extra pieces of rover will be on hand in case of accident. Destiny and the payload team will perform stress tests to see which components have higher potential to splinter. 2E 2E 1E 1D 71

81 4.6 Environmental Concerns High-powered rocketry requires special precautions to prevent and minimize impacts to the surrounding environment. Primary ground testing will include rover operations and black powder charge separation ground tests to verify system functionality and will be performed outdoors. Additional tests include the subscale rocket and full scale test and competition launches. The team will obey all federal, state, and local laws including University policies regulating outdoor activities in public spaces. The safety officer will also ensure that the team follows all regulations by reviewing any pertinent legal documentation, providing the test crew with a document outlining all relevant requirements, and briefing relevant team members on important rules. For all outdoor activities involving tests and launches, the test team will formulate a detailed document with step-by-step procedures, safety precautions, perimeters, and methods to minimize environmental impacts. Table 29 identifies potential hazards, provides emergency procedures, and lists necessary contingency equipment to address each potential hazard. The safety officer and safety team will review the procedures prior to the activity to ensure all regulations are followed and environmental impacts are minimized. Table 29: Environmental Hazards and Solutions Hazard Cause Effect Items free falling from high altitudes 1) Failed deployment of the recovery system on rocket 2) Items becoming loose during flight May damage the ground and any other area where the item lands. Pre- RAC 3C Mitigation Ensure that all components are secured as designed and that recovery systems are assembled correctly. Verification Testing is actively ongoing to confirm an improved technique for packing the payload parachute. Post- RAC 3D Vehicle landing in trees, roofs, or other high locations Public interference The rocket drifts unexpectedly far or in a different direction than intended. Loud noises and startling other people Possible damage to shingles, tree cover, or residential lawns Due to lack of knowledge on the 4C 4B 1) Make drift predictions before launches. 2) Ensure that the launch site and conditions are optimal to avoid these situations. Speakers will be used at all launches to Low drift profile validated using open rocket simulation. Observers were made aware prior to both the 4D 4D 72

82 Littering Causing fires Hazardous materials being spread into the environment Significant greenhouse gas emissions If small parts come loose or if a part goes missing Rocket motors, black powder charge, failed batteries. Non-natural materials such as fiberglass, epoxy, and batteries getting in unwanted places Transportation with motor vehicles releases carbon dioxide emissions which are harmful to the environment subject, people may be afraid. The parts may not be biodegradable and could affect the natural wildlife. Fires will damage the area and can be very dangerous. Depending on the material the impact can vary anywhere from negligible effects to poisonings. Greenhouse gas emissions and burning of fossil fuels pollutes the air and is said to cause climate change. 3B 2B 1D 2C alert the public to an upcoming rocket launch. 1) Check over all components before launch to ensure they are not loose. 2) Survey the ground postlaunch to check for and recover any loose debris. No flammable material will be located near a launch site or test site. All nonnatural materials will be regulated to ensure they do not get into the environment. The team will minimize the number of vehicles being used by carpooling subscale and full-scale test launches. All garbage was collected and disposed of prior to leaving launch sites. No section was damaged enough to spread debris. Fire safety procedures validated during full-scale test flight. No flames were observed at the launch pad after the vehicle s departure. All hazardous materials were properly stored or disposed of at launch sites. Only the minimum number of cars required (three) were taken to each launch. 3D 2D 1E 2D 73

83 4.7 Project Risk Analysis In the size and scope of the Student Launch competition, there are a variety of risks and concerns when it comes to the project itself. The viability and affordability of the project requires a certain level of investment in both labor and dollars that if not met, could results in setbacks or even in the failure of the project. In order to best alleviate these kinds of risks, the team manager has performed an analysis into factors that could affect the project and ways to mitigate these risks. This analysis is presented below as Table 30. In all aspects of the project, the team lead and sub team leads will strive to implement the suggestions discussed in this analysis. Experience in the previous years of Student Launch has shown that the key to project success lies in strong leadership, effective organization, and committed team members. Table 30: Project Risk Analysis Risk Cause Impact Mitigation Team loses knowledge in some particular area The team runs out of money for the project The team does not have enough time to finish the project The full scale test flight is not successful Team member leaves project The anticipated funding does not come in Underestimation of what is left to complete Instability or failure of the recovery system Team must divert efforts from current design problems onto relearning material. The team will not be able to buy all the components necessary to compete in the competition. The vehicle or payload may not be able to be completed in enough time for a full-scale launch before FRR. The vehicle may not be able to be fixed or rebuilt in time to fly another test flight before the competition. Ensure more than one member is knowledgeable about each section of the project and in doing so ensure a redundancy in team knowledge. The team applies for more funding then what is needed to complete the project in case some of it does not come through. The team will start building as early as possible to make sure it is finished in time. Care will be taken to make sure the rocket is stable at all times and that the recovery system is properly constructed. RAC w/ Mitigation 3C 2E 3D 2D 74

84 Membership decreases substantially The team loses its lab space to construct the rocket The CIA loses its launch location Interest in the project fades, school becomes more difficult The university takes away the workspace available to us The owners of the properties decide to stop allowing the launches There may not be enough people working on the project to successfully complete all the papers and the vehicle. New projects or construction cause the team to lose their lab space to build the rocket and payload. There will be no local locations for the full-scale test launch. The team lead works to keep everyone interested in and involved with the project. There are no known plans for construction or projects that would cause the team to lose access to the lab. The team will have to travel further away to locations such as Princeton Illinois or Northern Indiana 3D 2E 4D 75

85 4.8 Preliminary Checklists Final Assembly The checklists included in this PDR give all required steps to prepare vehicle and payload for a safe launch. In the days prior to launch the team will rehearse these checklists to ensure a safe and successful flight. Some steps may seem trivial and will be performed without thought, however, nonetheless the ISS Student launch team has written down all steps to guarantee nothing will be forgotten during launch preparation that could lead to delay or errors for flight Recovery Preparation 1. Prepare Recovery Electronics a. Assemble avionics bay payload sleds, check that all connections are secure i. Altimeters should be wired to switches, batteries, and two terminal blocks ii. Insert and connect fresh batteries b. Lock altimeter switches in off position c. Attach e-matches to altimeters via terminal blocks d. Turn on altimeters and check continuity (3 beeps required for continuity), then switch off e. Slide avionics sleds into couplers and attach bulkheads i. Insert sleds so that the altimeters face the key switches ii. Thread a nut and washer on each bulkhead on each rail (4 total nuts and washers) f. Check that altimeters are off, and attach ejection charges to terminal blocks 2. Pack drogue parachute a. Packing Procedure to be determined through assembly, testing, and practice 3. Insert Drogue parachute into booster airframe a. Attach quick link to eyebolt on motor case, confirm quick link is closed (hand tightened) b. Insert wrapped shock cord into booster tube, pack snug but not fastened c. Push packed drogue parachute into booster tube, with the protector facing upwards d. If the parachute is too tight, adjust packing to make the package wider and/or longer as necessary e. Attach the upper quick link to the bottom eyebolt of the avionics bay, ensure the link is closed (hand tightened) 4. Pack main parachute and flame retardants a. Packing procedure to be determined through assembly, testing and practice 5. Insert main parachute into airframe a. Attach quick link to avionics bay, confirm quick link is closed (hand tightened) b. Insert wrapped shock cord into airframe, pack snug not fastened c. Push packed main parachute into airframe, with the protector facing downwards d. If the parachute is too tight, re-adjust packing to make the package wider or longer as necessary. 76

86 Motor Preparation Adapted from Manufacturer's instructions 1. Assemble Forward Closure a. Apply lubricant to all threads and O-rings. b. Insert the smoke charge insulator into the smoke charge cavity. c. Lubricate one end of the smoke charge element and insert it into the smoke charge cavity. 2. Assemble Case a. Deburr the inside edges of the liner tube. b. Insert the larger diameter portion of the nozzle into one end of the liner, with the nozzle liner flange seated against the liner. c. Install the propellant grains into the liner, seated against the nozzle grain flange. d. Place the greased forward seal disk O-ring into the groove in the forward seal disk. e. Insert the smaller end of the seal disk into the open end of the liner tube until the seal disk flange is seated against the end of the liner. f. Push the liner assembly into the motor case until the nozzle protrudes approximately 1-3/4 from the end of the case. g. Place the greased forward (1/8" thick X 2-3/4" O.D.) O-ring into the forward (bulkhead) end of the case until it is seated against the forward seal disk h. Thread the forward closure assembly into the forward end of the motor case by hand until it is seated against the case. i. Place the greased aft O-ring into the groove in the nozzle. j. Thread the aft closure into the aft end of the motor case by hand until it is seated against the case Launch These checklists display the steps the team will follow for pre-launch and the day of launch Day Before Launch 1. Check that mentor has: a. Correct Aerotech L1300R-P b. Correct charge size for each separation event. Charge sizes to be determined. 2. Check that all the following flight hardware is stored for transport to launch site: a. Booster Airframe b. Motor casing c. Motor Adapter (three pieces) d. Motor Forward Seal Disk e. Main and Drogue Parachutes (x2) f. Main and Drogue shock cords (x2) 77

87 g. 8 quick links h. Coupler (assembled with sled, end-cap bulkheads, and altimeters) i. Flat Screwdriver for Rotary Switches j. Upper Airframe l. Payload fairing (assembled with electronics) m. Shear Pins n. Motor retainer ring 3. Check that all backup equipment and tools are prepared to complete any necessary final alterations: a. Phillips screwdriver for screws b. Small screwdriver for altimeter contacts c. Adjustable wrenches d. Allen wrenches/keys 4. Check that all ground support equipment is packed a. Ground Station Antenna b. Laptop with ground station software c. Micro USB Cable d. GPS tracker e. Binoculars 5. Check that all team members have read or heard safety briefing and are informed of their responsibilities Day of Launch Pre-Launch 1. Pack equipment for travel, as listed above 2. Travel to launch location 3. Unpack equipment at launch site 4. Assemble avionics bay and hatch payload sleds, check that all connections are secure a. Altimeters should be wired to switches, batteries, and two terminal blocks each b. Insert and connect fresh batteries 5. Lock altimeter switches in off position 6. Attach e-matches to altimeters via terminal blocks 7. Turn on altimeters and check continuity (3 beeps for continuity), then turn off altimeters 8. Slide avionics sled into coupler and attach bulkheads: a. Insert sled so that the altimeters face the key switches b. Thread a nut and washer on each bulkhead on each rail (4 total nuts and 4 washers) 9. Check altimeters are off, and attach ejection charges to terminal blocks 10. Pack drogue parachute. Packing procedure to be determined through assembly. testing and 78

88 practice 11. Insert Drogue parachute into booster airframe a. Attach quick link to eyebolt on motor case, confirm quick link is closed (hand-tightened) b. Insert wrapped shock cord into booster, pack snug but not fastened c. Push packed drogue parachute into booster, with the protector facing upwards d. If the parachute is too tight, adjust packing to make the package wider or longer as necessary e. Attach the upper quick link to the bottom eyebolt of the avionics bay, ensure the link is closed (hand-tightened) 12. Attach coupler and insert shear pins for drogue parachute a. Refer to labeling on coupler (This end down, shear pin alignment marks) b. Push coupler into booster airframe c. Rotate as necessary to line up shear pin holes d. Insert three shear pins 13. Pack main parachute and flame retardants. Packing procedure to be determined through assembly, testing and practice 14. Attach upper airframe to coupler a. Refer to alignment marks b. Insert screws 15. Insert main parachute into upper airframe a. Attach quick link to avionics bay, confirm quick link is closed (hand tightened) b. Insert wrapped shock cord into airframe, pack snug but not fastened c. Push packed main parachute into airframe, with the protector facing downwards d. If the parachute is too tight, readjust packing to make the package wider or longer as necessary 16. Insert nosecone parachute into nosecone a. Attach quick link to eyebolt on lower nosecone bulkhead, confirm quick link is closed (hand tightened) b. Insert wrapped shocked cord into nosecone, pack snug but not fastened c. Push packed main parachute into airframe, with the protector facing downwards d. If the parachute is too tight, readjust packing to make the package wider or longer as necessary 16. Attach nosecone to upper airframe a. Refer to alignment marks b. Insert four shear pins 17. Insert motor into booster airframe 79

89 a. Attach the adapter rings (three pieces) b. Insert into motor mount c. Screw on retainer ring, confirming the motor is secure 18. Bring rocket to RSO for safety inspection 19. Make changes as specified by RSO Day of Launch Launch Time 1. After RSO approval, wait for range clear 2. When range is clear, move rocket to pad safely 3. Lower launch rod and mount rocket on the rod a. Ensure team members are supporting the weight of the rocket b. Rail button should slide easily along rail. If not, don't apply pressure, rather rotate the rocket 4. Raise rod and rocket to upright position, be sure to support the rocket while lifting 5. One at a time, turn the key switches; listen for continuity, settings check a. Payload altimeter: i. Verify the altimeter turns on b. Payload computer: i. Verify ground station receiving from transmitter c. Primary altimeter: i. 3,1, 10, 10,10 beeps for main deployment altitude ii. Series of beeps for last flight data iii. Series of beeps for battery voltage (Volts, tenths of Volts) iv. Three quick beeps for continuity d. Secondary Altimeter i. 4,9,0,0 beeps for main deployment altitude ii. 5 second siren for apogee delay iii. Series of beeps for last flight data iv. Series of beeps for battery voltage (Volts, tenths of volts) v. Three quick beeps for continuity 6. Check pad power is off and attach igniter to pad controller 7. Insert igniter into motor and plug 8. Leave range and wait for launch 9. Acquire signals from GPS transmitters and camera system before launch 10. Launch rocket 11. At apogee, wait for separation 12. Wait for rocket to land 13. Upon range clear: retrieve rocket, check for undetonated charges and remove 14. Return to safe area 80

90 Day of Launch Post Launch 1. Remove altimeters from coupler and collect data 2. Turn off all avionics and store for transport a. When travel is finished, clean all dirty components, remove power sources from avionics, and store all materials for future flights. 4.9 Compliance The team will comply with the related safety codes and requirements as laid out in this section. The Safety Officer will brief the team as a whole on all referenced codes and requirements, such that design and construction are conducted with safety in mind. Each member has to sign a document stating that he/she agrees to follow the safety related measures. This document is attached in Appendix B: ISS Tech Team Safety Policy NAR High Power Safety Code In order to follow correct safety procedures, the ISS Student Launch team s Safety Officer will ensure that all regulations laid out in the NAR s High Power Rocketry Safety Code are followed. These regulations and the respective sections that cover them are included in Table 31 here. All launches are conducted through NAR chapters, and event organizers follow the rules laid out by the NAR. The NAR HPR Safety Code will also be included in Appendix E: NAR High Power Rocket Safety Code. Table 31: NAR Safety Code and Mitigation NAR HPR Code 1 NAR HPR Code 2 NAR HPR Code 3 NAR HPR Code 3 NAR HPR Code 4 NAR HPR Code 4 NAR HPR Code 5 All high power rockets flown or motors purchased will be within the scope of user certification and licensing. Only lightweight materials will be used for the construction of the rocket. Only certified, commercially available, and untampered rocket motors will be utilized. The will be used only for the purposes recommended by the manufacturer. There will be no smoking, open flame, or heat sources within 25 ft. of the motors. The rocket will be launched with an electrical launch system. This system will activate electric motor igniters installed in the motor after installation on the launch pad. The function of onboard energetics and firing circuits will be inhibited except when the rocket is in launch position. If the rocket misfires, the battery of the launch system will be disconnected and a Event Organizers Event Organizers Event Organizers

91 NAR HPR Code 6 NAR HPR Code 6 NAR HPR Code 6 wait period of 60 seconds will be initiated until the team can retrieve the rocket. A 5-second countdown will be used before launch. Those at the event will be warned in the event that there is a problem. No person will be closer than listed in the Minimum Distance Table. NAR HPR Code 6 When onboard firing circuits are being activated, there will be no one except safety personnel and anyone required for the arming sequence. NAR HPR Code 6 The stability of the rocket will be checked prior to flight and will not fly if it is unstable. NAR HPR Code 7 The rocket will launch from a stable device that provides rigid guidance until the rocket achieves a safe and stable speed in any weather condition. The rocket will also be launched within 20 degrees of vertical. NAR HPR Code 8 The rocket will not contain any amount of motors that have more than 40,960 N-sec of total impulse. NAR HPR Code 8 The rocket will have greater than a 1 to 3 weight to thrust ratio at launch. NAR HPR Code 9 The rocket will not be launched into clouds, near airplanes, over spectators, or beyond launch site boundaries. NAR HPR Code 9 There will be no flammable or explosive payload onboard the rocket. NAR HPR Code 9 The rocket will not launch if wind speed is in excess of 20 mph. NAR HPR Code 10 The launch site will be outdoors in a nonhazardous zone where it will not interfere with trees, power lines, occupied buildings, and persons not involved with the launch. NAR HPR Code 11 The launcher will be 1,500 ft from the nearest occupied building or public NAR HPR Code 12 highway. The rocket will use a recovery system such as a parachute so that all parts of the Event Organizers Event Organizers Appendix G: Minimum Distance Table Event Organizers 5 Event Organizers Event Organizers Event Organizers

92 NAR HPR Code 12 NAR HPR Code 13 rocket return safely and undamaged and can fly again. Only flame-resistant or fireproof recovery wadding will be used to protect the parachutes or other components. The team will not attempt to recover the rocket from power lines, tall trees, other dangerous places, or attempt to catch the rocket as it descends Federal Aviation Requirements The team will comply with all laws and regulations set forth by the FAA that pertain to using airspace for test launches and quadcopter flights. The team s safety officer will be responsible for educating all members of these same laws and regulations regarding the use of airspace applicable to this project: Federal Aviation Regulations 14 CFR, Subchapter F, Part 101, Subpart C; Amateur Rockets, Code of Federal Regulation 27 Part 555: Commerce in Explosives; and fire prevention, NFPA1127, Code for High Power Rocket Motors. ; as well as all other applicable laws. ISS will contact the FAA before any and all test flights, but only with approval from the local range safety officer. All flights are suborbital, remain in the United States, and will be evaluated and deemed safe for all members of the team and community. A copy of this code is located on the shared team Google Drive and will be posted on the team website once complete Range Safety Officer Authority The team will comply with the range safety officer at the competition launch and any test launches for the vehicle. All team members present at the test and competition launches will be instructed to listen to all instructions given by the range safety officer. They will understand that the officer has the final say on whether the rocket flies or not. Members will be given a briefing before attending launches. This will be given by the safety officer and other experienced rocketry personnel and will cover field expectations and safety protocol. All team members will have exposure and experience with the procedures list prior to any launch. 83

93 5 PAYLOAD CRITERIA 5.1 Rover Selection Process The payload consists of the rover that must travel 5 feet and deploy solar panels to meet the competition requirements. This rover must fit into a six-inch body tube and be able to be reused for multiple flights. The following criteria have been set forth to narrow down which rover design choice the team will pursue. 1) Modularity and weight, 2) Rover complexity 3) Orientation complexity, 4) Greatest accuracy. Design 1: The first design considered was called the X-Rover. This rover was designed to eliminate orientation as a problem. This rover has legs protruding out from the center body radially in four so that it would have at least two legs on the ground regardless of landing orientation. Because the front and back of the rover must be supported, the rover would have a total of eight legs, with a pair of legs in each of the four radial directions. The wheels would be attached to the leg on a ball-in-socket joint, so the wheel could adapt to the landscape without tipping the rover. The cross-section of the rover is an X, giving the rover its name. Each leg would require a motor, so the rover would have eight separate motors. The system as a whole would only require one Arduino that would activate remotely by the team and would not require an orientation mechanism. Design 2: The second design considered was called the RHex rover. This system contains an orientation mechanism, the rover, as well as a locking mechanism for the rover. The orientation mechanism is a gear based Lazy Susan that contains an Arduino and a gyroscope. The rover is designed in three segments to allow for traveling in uneven terrain. The rover s wheels are pinwheel shaped to allow for the rover to have a grip into the terrain. The rover also contains an Arduino and gyroscope within the three sections. The top of one section will have the solar panels attached to it. The horizontal position determined by the gyroscope triggers the rover to exit the vehicle in the proper orientation. This design requires orientation before rover deployment. Design 3: The third design considered by the team was a tank design. This design consisted of a flat piece of plywood with four wheels attached to axles on its side. The wheels would be hemisphere wheels, which would allow for the rover to re-orient itself if the rover exits the vehicle in the wrong orientation. The electronics and solar panel would be attached on either side of the plywood sled. Table 32: Rover Mechanism Trade Study Design Modularity and Rover Orientation Accuracy Weight Complexity Complexity 1 Small Complex None Intermediate 2 Small Intermediate Intermediate Large 3 Minimal Simple Simple Small 5.2 Payload Overview The team decided to pursue design 2 as a baseline design for the rover. This design had minimal complexity when it comes to the rover and the orientation system as a whole. The overall mass 84

94 and modularity of the system was minimized and the rover has been designed to be able to function well in uneven and unknown terrain. This design is not the simplest design, but the team believes it will be the most optimal and can be successful with testing. The rocket payload consists of a 3.4 lb. 12 x 3.2 x 4.4 custom RHex rover that will be stored in the upper airframe of the rocket. The MORRT-E (Miniaturized Off-Road Remote Terrain Explorer) is 12 in. long and divided into three segments to facilitate maneuvers over peaks and furrows in the landing site. Two wheels will drive each individual segment, resulting in six wheels on the rover with a separate motor for each. During the launch, MORRT-E will remain fixed in place with an active servo-controlled locking mechanism during flight that will prevent translational and rotational motion. Once landed, a Lazy Susan will rotate the rover into the correct orientation using input from a gyroscope and output of a continuous rotation servo. The locking mechanism will then release the rover, and it will travel for a fixed time that will allow its distance from the rocket to be greater than 5 ft., and then stop. A servo will then deploy the solar panels, and the rover will await retrieval by the team. In order to ensure the rover does not get tangled with a shock cord while exiting a rocket, the payload bay will be in the upper airframe of the rocket just below the nosecone. A charge will eject the nosecone during the descent, and a nosecone parachute separate from the rocket main parachute will slow the descent of the nosecone. This will remove the need for a shock cord to run around the rover, and it will be able to exit the rocket without interference. After landing, the rover will be oriented using a Lazy Susan mechanism and gyroscopes. The rover will then exit the rocket unimpeded and move for a predetermined amount of time, stop, and deploy the solar panels. The solar panels will be mounted on spring-loaded hinges near the front of the rover. A servo will be active through the entire flight to keep the hinges closed. When it is time to deploy the panels, the servo will rotate approximately 60 degrees and release the hinge. The rover will remain in that configuration until the team retrieves it. Table 33 provides references to how the Illinois Space Society team s payload complies with the requirements set out in the handbook. Table 33: Payload Requirements Requirement Each team will choose one design experiment option from the following list. Teams will design a custom rover that will deploy from the internal structure of the launch vehicle. Requirement Source Experiment Requirements 4.1 Deployable Rover Verification Method The team has chosen to design a solar panel equipped rover. The team will design and 3D print a custom rover. The rover will exit of the Section Addressed Payload Design Payload Design 85

95 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. Deployable Rover Deployable Rover rocket will be programmed to open at landing. The rover will have Arduinos attached to HC- 12 transceivers. One the signal is received, the internal locking mechanism will unlock The Arduinos will be programed to turn the motors on the rover once the unlock signal is received. A battery will supply power to the motors for the necessary amount of time needed to clear 5 ft. Communications & Launch Vehicle Integration. Motors Once the rover has reached its destination, it will deploy a set of foldable solar cell panels. Deployable Rover The Arduino will be programmed to open folded solar panels via servos after the rover has cleared 5ft and stopped. Solar Cell Deployment 5.3 Payload Success Criteria There are a select number of requirements the team has identified to ensure the success or failure of the deployable rover. These requirements have been made as specific as possible, stating specific thresholds when necessary. Table 27 below lists these requirements chosen by the team and specific verification processes to determine if the criteria was met. 86

96 Table 34: Rover Success Criteria Requirement The rover will have a clear path out of the rocket upon landing with the correct orientation before beginning to drive out. The rover runs autonomously and only have the push of one button activates it. The rover will achieve a distance of at least 5 feet away from any part of the rocket before the solar panels deploy. The solar panels will be functional once opened. Verification Strategy The rover docking bay will rotate to the upright orientation so the rover can travel out of the rocket. The Arduino will have the locking mechanism unlock, and the rocket open. The Lazy Susan is programmed to have the rover be upright with a 5 degree uncertainty, which will allow the rover to exit the rocket without tipping. All the code will be written to ensure the rover can run autonomously once notified to run by the push of the button. The onboard Arduino will be programmed to begin driving once it is unlocked from the Lazy Susan. The motors are all individually controlled and will be programmed to move simultaneously away from the rocket. The rover will weigh around 3lbs, be around 12in long and 5in wide. Tests will be run on the motors to determine how much the rover can travel per second and the rover will then be programmed to run for at least that long to ensure it makes the 5-foot requirement. The six motors will provide enough force to overcome most obstacles, and retain their average speed. Testing to determine the time needed for the motors to turn the wheels will most likely take place in a harsher terrain than in the actual competition, so as not to underestimate the time needed to clear its first steps. Although not specified in the NASA handbook, the team will use the solar panels to light up an LED when the panels are opened, provided sunlight is not blocked. The solar panels will also be attached to the Arduino, which will be able to record and store voltage readings. 87

97 5.4 Payload Design The rover has a 12 long body separated into three segments. One segment can be found in Figure 38. Each segment is 5 x 2 x 4.3, and they are connected with a rod that threads through the back of one segment and the front of the next. A nut will be screwed on one side to ensure a tight fit and prevent the rod from falling out. The attachment point does not allow translation of one segment with respect to the other, and rotation is only allowed along the axis perpendicular to the length of the rover. The rotation points will allow the rover shape to conform to the landscape, reducing the risk of getting stuck or caught in the troughs or peaks of the furrows in the field. Each segment has a lateral hole for the motors to be placed. The width of the body is long enough to hold two motors, allowing each wheel to be powered by its own motor. Small holes will run up from the motor hole to the main chamber to allow wires to connect to the Arduino. The main chamber is a hole that is open to the top of the rover and will hold the rover computer and sensors, which include an Arduino Micro, a 9V battery, and a Three Axis Gyroscope Accelerometer Sensor Module. The center segment will hold the accelerometer and Arduino, and the back segment will hold the battery. The motors in the front and back segments will have wires go over the top of the rover and into the center segment chamber. The overall rover circuit is shown in Figure 37 The wires will be bounded with electrical tape to prevent risk of exposed wire during flight and protect the wires from pinching. The attached segments can be seen in Figure 38. The front and back segments of the body will have loops that will serve as an attachment point for the locking mechanism during the flight. Figure 37: Rover Circuit Schematic 88

98 Figure 38: Single Segment of Rover Body The rover wheels are 3 in diameter and are designed to adapt to changing landscape and obstacles in the terrain. The team initially discussed treaded tires or tracks to grip onto the dirt and maximize the friction that pushes the rover forward. A potential problem with this design is dirt and grass could get caked in the crevices between the treads, especially if the field is moist from recent rain. This could increase the risk of tangling in a tuft of grass and reduce the grip that the treads were designed to produce. The team decided to use a three-pointed star design to avoid these problems. The wheels will be made of flexible plastic with a rubber coating where they will make contact with the ground. The curve of the wheel will prevent tangling with the terrain, and the small mass allows it to be lighter than a regular wheel. The rover will have six independent wheels to allow the rover to continue moving even if one wheel stops or is lifted off the ground. Additionally, the flexible plastic will allow the wheel to adapt to the shape of the ground and maximize the contact area. Figure 39 shows the wheel design, and Figure 40 demonstrates the integrated rover, electronics, and wheel assembly. 89

99 Figure 39: Rover Wheel Figure 40: Rover Assembly with Solar Panels, Arduino, Gyroscope, and Motors Communications On board the rocket, there will be two Arduino Micro boards, one on the rover and one attached to the back of the rover platform. Each Arduino will have a HC-12 wireless transceiver connected to it. The setup can be seen below in Figure 41 and Figure 42. The sender module that is with the team will have a button that is pressed once that activates both receivers and tells the Arduino to start executing their respective programs. The HC-12 transceiver will have a spring antenna soldered to them. To ensure the rover can be contacted upon landing, the team chose the HC-12 because it has a 1.1 mile range. Assuming the rover lands within the square mile field, the receiver should have sufficient range. The frequency range of the transceiver modules is from to MHz. The dimensions of the HC-12 wireless transceiver modules are 1.09 in x 0.57 in x 90

100 0.16 in. Each full setup will take up roughly a square whose sides are 3.25 in. plus having a height of roughly 1.75 in. Figure 41: Arduino Sender Module Figure 42: Arduino Receiver Module Figure 43 displays the order of events that will take place once the vehicle has landed. The team will hit the button that will activate both Arduinos. The Arduino on the Lazy Susan will begin to rotate the platform until the rover and platform are within 5 degrees of the horizontal. The rover Arduino starts to run once the platform is within 7 degrees of the horizontal. The Arduino is set to wait 5 seconds once it is within 7 degrees of horizontal to ensure that Arduino activates, but it does 91

101 not start the motors until the locking mechanism has released the rover. Once it has reached the 5 degrees, the platform motors unlock the rover. The motors are then turned on and the rover begins to move for 20 seconds. Once the 20 seconds have been completed, the rover s motors stop and the solar panels are deployed. Figure 43: Program Procedure Solar Cell Deployment As part of the competition requirements, MORRT-E will be equipped with a pair of solar cells. The cells cost $3 each and are about 2 by 3. The cells will be folded into the front section of the rover on spring-loaded hinges. Under favorable conditions, they will produce four volts each. The panels will be latched down using an HK15298B High Voltage Coreless Digital MG/BB Servo controlled by an Arduino. Further testing on the rover is still required to determine whether to deploy based on a fixed time or on an external sensor stimulus. Most likely the team will opt for deployment after a fixed time, but testing is required to determine what that time should be. The solar panels will be connected to the Arduino to record voltage onto an SD card and make sure the cells are properly functioning. As a team-mandated requirement, a 5mm LED will be 92

102 connected in series to the solar panels to visually demonstrate from a distance that the solar cells are functioning properly. A simple circuit is shown in Figure 44 with the approximate specifications of the solar cell electronics at maximum output, 4V. The LED operates the best at 20mA. It has a maximum voltage drop of 3.5V and there must be a 4.5V drop across the first resistor at 20mA. The resistor has to be 225 ohms, modeled in this schematic seen below. Figure 44: Solar Panel Schematic Launch Vehicle Integration Since the rover will be exposed on the descent once the nosecone has disconnected, a locking mechanism to keep the rover in place is necessary. On the front edge of the first and third body segments of the rover will be a loop with an outer edge.2 inches away from the body segment as seen in Figure 46. On the platform will be two HobbyKing Coreless Digital HV/MG/BB Servos that are connected to an aluminum hook that will latch onto the loop on the rover. Figure 47, Figure 48, Figure 49, and Figure 50 show different views of the rover and hook layout with the hook activated, and Figure 51 and Figure 52 show different views of the rover and hook layout with the hook deactivated. The torque of the servo is 1.3 ft-lbs. The maximum torque that the servo will encounter is 0.98 ft-lb, so this should be sufficient to move the hook and endure forces during flight. During flight and descent, the servo will be activated. The position of the hook when the servo is deactivated will have the protruding rod at an angle of 28 degrees below the horizontal. When activated, the servo will rotate the hook 110 degrees counter-clockwise so that the loop is positioned at the corner of the hook. Once the rocket has landed and the platform is positioned 93

103 correctly, the locks will be deactivated and return to 28 degrees below the horizontal. The rover will drive out over the servos and deactivated hooks. The clearance from the top of the servo and hook and the bottom of the rover segment is.18 inches ensuring that nothing will get into the way of the rover as it drives out. The payload section will be held in place with an aluminum bulkhead that is shown in Figure 45. The bulkhead has six evenly spaced threaded holes around the circumference. To attach the bulkhead to the rocket, six screws will screw in from the outside of the rocket into the six threaded holes in the bulkhead. This attachment mechanism will allow the entire Lazy Susan and rover assembly to be removed from the rocket. This will allow the team to test that each electronic is on and functioning prior to launch and align the locking mechanism after turning on the Arduino. The bulkhead is made of aluminum for strength so the six attachment points do not fail. Large holes are present in the bulkhead to reduce weight. Figure 45: Aluminum Bulkhead with Threaded Holes 94

104 Figure 46: Loop on Rover Body Figure 47: Rover Locking Mechanism with Hook Activated Figure 48: Front Locking Hook 95

105 Figure 49: Back Locking Hook Figure 50: Side View of Rover Locking Mechanism with Hook Activated 96

106 Figure 51: Rover Locking Mechanism with Hook Deactivated Figure 52: Front View of Rover Locking Mechanism with Hook Deactivated 97

107 Figure 53: Side View of Rover Locking Mechanism with Hook Deactivated Orientation Mechanism Once the rocket has landed, it is necessary to orient the rover so that it can drive out of the rocket smoothly. The Lazy Susan mechanism orients the rover from the landing angle to be right side up before exiting the rocket. The Lazy Susan mechanism consists of a bulkhead, an aluminum bulkhead gear, a platform, and the servomotor with a plastic gear attached. The bulkhead will be screwed into the rocket body so that it cannot move relative to the body tube. The bulkhead gear will be epoxied to the bulkhead and will serve as a contact point for the servomotor gear. The platform will thread through the center of the bulkhead without attaching to it so that it can rotate freely with respect to the bulkhead. The servomotor is attached to the platform and holds the platform in place using the attachment between the servo gear and bulkhead gear. The configuration is shown in Figure 54. The servomotor will actively hold the platform in one orientation until activated by the team s communication system. Once activated, the servomotor will turn on and begin rotating the platform relative to the rocket body tube. The Arduino will use input from an accelerometer to determine the current angle relative to the ground. Once the accelerometer detects that the platform is within 5 degrees of horizontal, the servomotor will stop, and the Arduino will command the locking mechanism to unlock the rover. The circuit with the battery, Arduino, servomotor, and 98

108 accelerometer is shown in Figure 55. The entire platform and Lazy Susan assembly is shown in Figure 56. Figure 54: Lazy Susan Rotation Mechanism 99

109 Figure 55: Lazy Susan Schematic Figure 56: Platform with Lazy Susan Mechanism 100

110 5.5 Maneuverability MORRT-E will be equipped with six motors, one for each wheel, which will all be programmed to the same speed via the onboard Arduino. The motors will be an Adafruit Continuous Rotation DC Motor Servomotor and will require 5V. The system will be powered by a 9V battery. The Arduino program tells the motors to rotate the wheels for 20 seconds to exit the rocket and achieve a distance of 5 feet. When there is no resistance, the motor can achieve 56 rpm, but the new rpm will have to be calculated when testing is started. Each motor weighs.088lbs and can provide lbf of torque. The motors will be programmed to go for a set amount of time that will be determined after testing the speed the rover moves at. The dimensions of the motors are 1.5" x 2.1" x 0.8" and will be 3" apart. The connector wire length will be 11.8". This length is very excessive and most of the wire will be kept stuck on or near the motor to avoid the wires from catching on the rocket while exiting, on debris while roaming away from the rocket, and on the wheels. Since the rover body is designed to bend to some extent, the wires will not be completely stuck, and instead have a few inches loose. The adjacent motors will be different lengths from the center of the rover, so that the wheels are alternating in distance from the rover body. This will minimize the risk of the wheels interfering. Since the motors are not too powerful, there is a chance that if a wheel is against a difficult obstacle, the motor will not be able to conquer it. This another reason the body is in sections, so that the other five motors have wheels on the ground turning, and together they will be able to assist the struggling motor. 5.6 Prototyping and Testing Testing will begin the week of October 30 th. The payload team will 3D print the rover body, wheels, platform, and gears, and bulkhead. The team will begin constructing the payload and testing the motors with simple commands to test maneuverability, speed, power usage, and other variables. Assembly and the majority of testing will take place in Talbot Lab. Once the hardware has been assembled, the team will write code and test the electronics and maneuverability of the rover. The area outside Talbot Lab has areas with minimal hills, so a test terrain of gravel and dirt will be created to assess the rover movement on different slopes and materials. By testing the limits of the rover safely and discovering which parts of the rover are weak, the team will deal with problems as they arise. By December, outdoor testing will be unlikely, as snow and extreme cold might damage the rover's electronics. Indoor testing will continue through December to test the rover's ability. The team will launch a subscale rocket in December to test the rocket and payload. The rover will not be included in the subscale launch. Only the Lazy Susan mechanism will be present on the subscale launch, including two gears, the bulkhead, the platform, and one motor to prevent rotation of the platform during flight. The bulkhead will be epoxied on the inside of the rocket tube with the 2.4 in gear attached to it. The platform will be hinged through the center of the gear and can rotate with respect to the bulkhead. The motor fits in the cutout on the back of the platform and 101

111 holds the smaller gear. The teeth of the smaller gear will be aligned with the 2.4 in. gear. The purpose of the test is to assess whether the gears can remain aligned and test the strength of the components in real flight vibration and landing impact environments. Because the purpose of the subscale launch is to assess the ability of the Lazy Susan to endure the loads during flight, no computer will be present on the flight, and the Lazy Susan will not orient the platform. Separate tests will be performed to assess the functionality of the other systems, including the communication system, Lazy Susan orientation mechanism, the locking mechanism, movement across the terrain, and solar cell deployment. Each component will be tested individually in worstcase day of flight conditions until it can reliably perform successfully. Success criteria for each component is described in Table 35. After the components are determined to work consistently, an integrated test with each system will be done. The final test will simulate the rover deployment process from landing to solar cell deployment. The communication system will be tested for reliability and range. The published range is 1.1 miles, so the team will take the receiver and transmitter apart and test the maximum range that can still reliably send a signal in open ground. The communications will then be tested with various obstructions that may be present on the flight, such as trees. The testing requirements for the communications system is shown in Table 35. The Lazy Susan will undergo extensive testing because it presents the highest probability of failure in the payload deployment. The system can be broken down into 6 components: the platform, the motor, the Arduino, the accelerometer, and the two gears. The success requirements for each component is shown in Table 35. Each item will be tested extensively at a component level to ensure all performance specifications are met. After component testing, the Lazy Suzan will be tested at a systems level to evaluate the functionality of the entire system. The bulkhead with the Lazy Susan attached will be inserted into a spare piece of 6 diameter blue tube and screwed into place. The Arduino program will run with a team member holding the blue tube to simulate landing. The orientation process will be observed by the team under a variety of different starting orientations to test the adaptability and reliability of the mechanism. Testing of the Lazy Suzan will begin the week of October 30 th, and will continue until December 21 st. The locking mechanism is vital to holding the rover in one place so it does not get damaged during flight or fall out when the nosecone ejects from the upper airframe. The locking mechanism will first be tested separately to ensure the hook rotates throughout the correct angle. Then, the rover and locking mechanism will be placed on the platform. The team will test the stability of the hook when attached to the rover, the rotation and translation allowances, and the clearance of the open 102

112 hook. Requirements of each locking component are included in Table 35, and system-level testing success requirements are shown in Table 35. Because the terrain on the day of flight will not be known, the rover maneuverability on many different terrains will be evaluated, and further steps will be taken to improve the design if necessary. Various testing mediums will be prepared, including concrete, grass, dirt, mud, and gravel. Each course will consist of a flat region followed by a furrowed region to simulate the field terrain. If the rover struggled in any of the testing mediums, the material or design of the wheels will be modified to optimize the maneuverability of the rover. The maneuverability tests will cover the rover speed, efficiency in different environments, motor torque, and motor functionality. The components specific to these tests are the wheels and motors. Testing requirements for maneuverability components and system level requirements are shown in Table 35. The final system tested is the solar cell deployment. The components in this system are the solar cells, an LED, an Arduino, and a High Voltage Coreless Digital MG/BB Servo. The requirements for component testing are in Table 35. The LED function is an internal requirement set by the team independent of the competition requirements. The Arduino and servo will be tested by writing code and utilizing each component with basic functions. The solar cells will be tested by connecting them to the Arduino and measuring the output voltage. The integrated system will be evaluated by writing the Arduino code and operating each component in the sequence that would occur at the competition. 5.7 Testing Deliverables Table 35: Payload Component Test Matrix Component Validation Matrix Testing Requirement HC-12 Transmitter/Receiver The HC-12 Transmitter/Receiver shall be able to transmit a signal with a range of at least one mile without obstructions. The HC-12 Transmitter/Receiver shall be compatible with an Arduino. The button shall commence the transmitting of a signal from the transmitter to the receiver. Button Validation Test The HC-12 Transmitter/Receiver will be activated one mile away from the rover, and a team member will be near the rover to confirm the signal was received. The HC-12 Transmitter/Receiver will be activated and it will be observed if the received signal activates the Arduino. The button will be pressed to observe if the servos begin rotating the platform. 103

113 The hook shall withstand landing and flight loads without signs of stress or deformation. The hook shall hold the rover with less than 1/8 inch allowance of movement in any direction. The hooks shall prevent rotation of the rover while locked. Locking Hook The rover will be locked onto the platform and stress tests will be performed on the rover to determine the strength of the hook. The rover will be locked onto the platform and rotated in all directions to observe if the rover moves more than 1/8 inch in any direction. The rover will be locked onto the platform, which will be rotating to determine if the rover moves while locked in. The hook shall have at least 0.2 in. of clearance The rover will be locked onto the platform, and from the bottom of the rover when opened. the servo will be activated so the hooks unlock from the rover. The distance between the bottom of the rover and the hooks will be measured to determine if there is enough clearance. Locking Servo The locking servo shall actively retain the locked position until commanded to unlock by the Arduino. The locking servo shall rotate 110 degrees from the locked position to the unlocked position. The locking servo shall endure forces and torques during flight without deformation or deviation from the intended position. The locking servo shall lie under the rover with at least 0.3 in. clearance from the bottom of the rover. The program will run from start to finish and it will be observed if the servo activates when it is supposed to, or if it activates at an incorrect time. After the platform is locked into place, the hooks will unlock to determine if they rotate far enough from the bottom of the rover. The rover will be locked onto the platform and pulled in multiple directions to ensure that the hooks can withstand substantial force and movement of the payload during flight. The rover will be locked onto the platform and the distance will be measured from the bottom of the rover to the top of the locking servo to check for a 0.3 in. clearance. Wheels The wheels shall be 3 in diameter and 0.2 in in The wheels will be 3D printed and dimensioned 3 width. in. in diameter and have a thickness of 0.2 in. The wheels shall be able to traverse mud, dirt, and The wheels will be assembled onto the rover and grass terrains. tested by running it over different types of hilled terrain to ensure the rover will not have trouble moving. The wheels shall be able to traverse inclines up to 30 degrees. The wheels will be assembled onto the rover and driven up hills of terrain to ensure the rover can handle an inclined route. 104

114 The wheels shall not get caught in grass or other objects in the landing zone. The solar cells shall produce a voltage that can be measured and stored on an SD card. The solar cells shall open when commanded by the Arduino. One LED shall light up once the solar cells have been deployed. The spring loaded hinges shall open the set of solar panels once commanded by the Arduino. The Solar Cell Servo will actively keep the solar panels closed during the duration of the flight. The Solar Cell Servo will rotate 150 degrees when commanded by the Arduino to open the solar panels. The platform will support the weight of the rover in all orientations without signs of stress of deformation. The platform will survive the rocket landing impact without signs of stress or deformation. The platform will fit within a 6 diameter rocket with at least 0.2 clearance on all sides. Solar Cells LED Spring Loaded Hinge Solar Cell Servo Platform The wheels will be assembled onto the rover and small natural objects such as grass will be intentionally placed in its path to ensure the rover can handle unexpected obstacles. The solar cells will be connected to an SD card and placed outside to ensure they can successfully produce usable data for the rover. After it has been confirmed that the platform can successfully lock in place and the rover is capable of moving the required distance from the landing site, the Arduino will send a signal to the spring mechanism to deploy the solar panels. The Arduino will send a signal to the LED to activate once the signal is sent to deploy the solar panels. The Arduino will send a signal to the spring loaded hinges once the rover has stopped moving and deploy the set of solar panels. The Arduino will be require the servo to remain closed (less than 10 degrees from horizontal) during the flight so that the spring loaded hinges do not deploy the solar panels. The Arduino will send a signal to the Solar Cell Servo to open the solar panels. The rover will be placed on the platform and held above ground, and it will be observed to see deformation or bending. A small scale platform will be placed on the subscale launch, and it will be inspected after landing for deformations. A full scale model will be drop tested to ensure it survives the loads. The platform dimensions will be 14 x 3.4 x 4.5, and the largest cross-sectional dimension will be

115 The motor will take less than 30 seconds to achieve the desired position from any starting point. The motor will endure the maximum torque applied by the platform during flight without signs of stress or deformation. The motor will be compatible with an Arduino Micro and take less than 9V to power. The Arduino will be activated when the team pushes a button. The Arduino will have enough ports to connect a Continuous Rotation DC Motor Servomotor and Three Axis Gyroscope Accelerometer Sensor Module. The Lazy Suzan Arduino will execute a program that takes input from the Three Axis Gyroscope Accelerometer Sensor Module and runs the Continuous Rotation DC Motor Servomotor until the platform is within 5 degrees of the correct horizontal orientation. Continuous Rotation DC Motor Servomotor Arduino Micro and Program The Lazy Suzan orientation will be placed directly upside down and timed to test the time to completely orient the platform. The speed will be adjusted as needed. The platform and rover will be drop tested in the worst-case orientation to maximize torque on the motor and inspected for damage. The motor will be started while connected to a 9V battery. The communication system will be connected, and a button will be pushed to begin the Arduino program. The complete Lazy Suzan circuit will be connected and inspected. 106 The program will be coded, uploaded to the Arduino, and executed with the Lazy Suzan hardware attached. The Arduino will be powered by a 9V battery. The Arduino will be turned on while connected to a 9V battery. Three Axis Gyroscope Accelerometer Sensor Module The Three Axis Gyroscope Accelerometer Sensor Module will detect the current orientation of the platform with an error of less than 1 degree. The Three Axis Gyroscope Accelerometer Sensor Module will be compatible with an Arduino Micro. The Three Axis Gyroscope Accelerometer Sensor Module will have a data rate greater than or equal to 50 Hz. Gears The Lazy Suzan gears will support the Lazy Suzan mechanism without signs of stress or deformation. A protractor will be used to measure the true angle and compared to the detected angle in at least 20 different orientations. The Three Axis Gyroscope Accelerometer Sensor Module will be connected to an Arduino and turned on. The number of data points over 10 seconds will be counted and averaged to get the data rate. The Lazy Suzan gears will be placed on the subscale flight and inspected after to detect deformation in gear teeth.

116 The gears will remain aligned during launch and landing. The gears will be inspected after the subscale launch to detect misalignment. 5.8 Payload Mass Budget Table 36: Payload Mass Budget Rover Component Material Numbers of Components Individual Mass (lbm) Total Mass (lbm) Wheel ABS Plastic Servomotor 5VDC Combination Cotinuous Rotation Front Body Link ABS Plastic Middle Body Link ABS Plastic Back Body Link ABS Plastic Arduino Micro Combination V Battery Combination Three Axis Gyroscope Combination Accelerometer Sensor Solar Panels Combination HobbyKing Coreless Combination Digital HV/MG/BB Servo Hinge Steel

117 Hex Drive Rounded Head Steel Screw Zinc Yellow-Chromate Steel Plated Hex Head Screw Nut Steel Rover Total Lazy Susan Bulkhead Aluminum Bulkhead Gear Aluminum Servo Gear ABS Plastic Servomotor 5V DC Combination Continuous Rotation Platform ABS Plastic Arduino Micro Combination V Battery Combination Three Axis Gyroscope Combination Accelerometer Sensor Hex Drive Rounded Head Steel Screw Lazy Susan Total Locking Mechanism Hook ABS Plastic HobbyKing Coreless Combination Digital HV/MG/BB Servo Locking Mechanism Total Total PROJECT PLAN 6.1 Competition Requirement Verification Plan Satisfying competition requirements is a top priority for the team. The following sections detail the manner in which the team shall fulfill the requirements specified in the NASA Student Launch Handbook Launch Vehicle A complete analysis of the competition requirements for the launch vehicle and recovery systems and the verification method for those requirements is located in Table 4 in Section Payload A complete analysis of the competition requirements for the payload system and the verification method for those requirements is located in Table 33 in Section

118 6.1.3 General Project Table 37 below presents the safety requirements as included in the Student Launch handbook as well as the method in which the team will satisfy these requirements. Table 38 presents the general team requirements as included in the Student Launch handbook as well as the method in which the team will satisfy those requirements. Table 37: Competition Safety Requirements Requirement Each team shall use a launch and safety checklists. The final checklists shall be included in FRR and used during LRR and any launch day operations. Each team must identify a student safety officer who shall be responsible for all items in section 4.3. The safety officer shall monitor all team activities with an emphasis on safety. The safety officer shall implement procedures developed by the team for construction, assembly, launch, and recovery activities. The safety officer shall manage and maintain current revisions of the team s hazard analysis, failure mode analyses, procedures, and MSDS/chemical inventory data. The safety officer shall assist in the writing and development of the team s Requirement Source Safety Requirements 4.1 Safety Requirements 4.2 Safety Requirements Safety Requirements Safety Requirements Safety Requirements Verification Method Demonstration Preliminary checklists are included in this document and will be updated in subsequent documents. Inspection- Brian Hardy will be this year s safety officer. Demonstration Safety officer is tasked with supervising all team activities where safety is a concern. Demonstration Preliminary checklists for launch and final assembly have been made; Assembly procedures will be formalized in the coming month leading up to subscale construction. Demonstration- Hazard analysis has been done and is included in this document. Demonstration- Hazard analysis has been done and is included in this document. Section Addressed

119 Requirement hazard analysis, failure mode analyses, procedures, and MSDS/chemical inventory data. Each team shall identity a mentor who is currently certified by the NAR or TRA. Teams shall abide by the rules and guidance of the local RSO during flights. Teams shall abide by all rules set forth by the FAA. Requirement Source Safety Requirements 4.4 Safety Requirements 4.5 Safety Requirements 4.6 Verification Method Inspection Mark Joseph is this year s mentor and is level two certified by the NAR. Demonstration- Team has agreed to follow the discretion of the local RSO during flights. Demonstration Team has agreed to abide by the rules set by the FAA. Section Addressed Table 38: General Competition Requirements Requirement Students on the team shall do 100% of the project. The team shall provide and maintain an included project plan. Requirement Source General Requirements 5.1 General Requirements 5.2 Verification Method Inspection- Mentor will provide only advice and assist in any energetics handling. Demonstration: Budget and funding plan have been devised and included in this report. Educational outreach updates will be given in each report. Risks and mitigation have been provided and will be updated throughout the course of the competition. Checklists have been included and will be updated throughout the course of the competition. Section Addressed Budget: 6.3 Funding Plan: 6.4 Ed-Out PDR update: 0 Risks and Mitigation: 4.7 Checklists:

120 Requirement Foreign National team members shall be identified by PDR. The team shall identify all team members attending launch week activities by CDR. Team shall engage 200 participants in educational, hands-on STEM activities by FRR. The team shall develop and host a website for project documentation. Team shall post, and make available for download, the required deliverables to the team web site by their respective due dates. All deliverables must be in PDF format. In every report, teams shall include a table of contents. In every report, the team shall include the page number at the bottom of the page. The team shall provide and computer equipment necessary to perform a video telecom. Requirement Source General Requirements 5.3 General Requirements 5.4 General Requirements 5.5 General Requirements 5.6 General Requirements 5.7 General Requirements 5.8 General Requirements 5.9 General Requirements 5.10 General Requirements 5.11 Verification Method Demonstration List will be sent in with PDR deliverables. Demonstration List will be sent in with CDR deliverables. Demonstration Team will include ed-out updates in each report and fill out an activity report for every event. Inspection Team has developed a website that will continue to develop throughout the course of the competition. Demonstration Team will upload deliverable and host them in the deliverables section of the website. Inspection All documentation will be in PDF format. Inspection Table of contents is included in report. Inspection Page numbering starts with section 1 and is included at the bottom of the page. Demonstration Team has access to all equipment necessary for milestone presentations. Section Addressed N/A N/A 0 N/A N/A N/A Table of Contents All N/A 111

121 Requirement All teams will be required to use the launch pads provided by Student Launch s launch service provider. Teams must implement the Architectural and EIT Accessibility Standards (36 CFR 1194) Requirement Source General Requirements 5.12 General Requirements 5.13 Verification Method Analysis All analysis has been done assuming the 12 ft 1515 rail provided by Student Launch s launch service provider. Demonstration The team only utilizes equipment that satisfies the requirements of 36 CFR Section Addressed 0 N/A 6.2 Team Requirement Verification Plan The team has derived a set of additional requirements to go along with the requirements included in the Student Launch Handbook. This process benefited the team by providing a clearer picture of the project design moving forward Launch Vehicle A complete analysis of the team-derived requirements for the launch vehicle and recovery systems and the verification method for those requirements is located in Table 5 in Section Payload A complete analysis of the team-derived requirements for the payload system and the verification method for those requirements is located in Table 34 in Section General Project The team has also derived a set of general project requirements that will ensure mission success and the safety of all participants. These requirements are detailed below in Table 39: General Project Team-Derived Requirements Requirement Active team members will have the opportunity to learn how to operate all machinery and tools Custom printed feedback will be used to improve future ed-out events Verification Method Demonstration The safety team will prepare tutorial sessions on all machinery that will be used throughout the competition before construction begins. Demonstration Feedback was taken from ISD and will be used to improve future ISD s. Section Addressed

122 Requirement Safety officer will teach team management on safe practices to allow for a redundancy in knowledge. Website will include a page with member profiles. Website will include a page with team progress updates. Website will include a page with ed-out events and their location/times. Verification Method Demonstration Safety officer will teach team management so that the safety officer is not require at every build session. Demonstration Web admin will add a page with member profiles sent in by active members Demonstration Web admin will add a page with team updates sent in by team management. Demonstration Web admin will add a page with ed-out updates. Section Addressed 4.1 N/A N/A N/A 6.3 Educational Outreach Update Illinois Space Day Figure 57: Illinois Space Day logo Illinois Space Day (ISD) is an annual non-profit educational outreach event that occurred on Saturday, October 7th Organized through the Illinois Space Society (ISS) and run by its Education Outreach Director, ISD is an all-day event which runs from the morning into the 113

123 afternoon and includes a provided lunch to attendees. The exhibits and presentations at ISD are intended for late elementary to early high school students and their parents. This year the attendance reached approximately 200 participants, including 150 kids and 50 adults, which is approximately 30 more people than the previous year. Increases in attendance were influenced by an increase in the scope of schools with which Illinois Space Society interacts. Other outreach events and advertising allowed members of the team to connect with schools that previously were not attending ISD. Figure 58: Liquid Nitrogen Demonstration Notable examples of the many exhibits at ISD include liquid nitrogen experiments, space shuttle tile demonstrations, and an egg drop competition. The liquid nitrogen and space shuttle tile exhibits demonstrate the temperature extremes of space, while the egg drop competition teaches concepts like drag and offers a more hands-on experience for younger attendees. In the liquid nitrogen presentation, pennies, marshmallows, flowers, and balloons will all be frozen and displayed to the audience. For the space shuttle tile, the thermal capabilities of certain composites required for atmospheric reentry are shown by using a blowtorch to heat the tile. The attendees get to use a thermometer to verify the extreme temperatures from a safe distance, while also observing the presenters holding the tile in a gloved hand to display its insulating capabilities. The egg drop demonstration allows children to build their own capsules in varying fashions with the goal of keeping an egg from breaking from a three story drop. This demonstrates why parachutes are used in rocket launches by introducing participants to the concept of drag. In addition to ISS, other student led organizations hold exhibits during the event. These organizations speak about their experience in various aerospace-related topics such as satellite development, high powered rocketry, astronomy, robotics, and aerodynamics of 114

124 vehicles. The exhibits generally show families the simple science behind concepts like temperatures, aerodynamics, gravity, drag, and balance. Figure 59: Alka-Seltzer Rockets Exhibit This year, marked a year of extreme success for ISD. There were more volunteers, more supplies, and new exhibits available for ISD attendees to experience than ever before. This year the number of volunteers increased to 39 ISS members. 12 of these volunteers acted as group leaders with increased responsibility, and the other 27 had tasks relating to check in, t-shirt distribution, food set up, exhibit organization, leading certain exhibits, and more. Not only did volunteer numbers increase, registration and attendees grew also. This year 200 people attended, with 20% of those who attended being returnees from either ISD 2016 and even ISD Of those who came to the event 34% heard of the event through their child s respective school, which was a direct result of ISS s strong relationship within the Champaign-Urbana school district. In addition to the various science exhibits at ISD, each year a professional in the aerospace industry is also asked to speak at the event. This year Dr. Erik Kroeker spoke to the group for an hour. Dr. Kroeker was a finalist in the Canadian Space Agency Astronaut trials. He spoke about his experiences from training to be an astronaut and also how to get involved with STEM as a kid. Dr. Kroeker is a University of Illinois Aerospace alumni and previous faculty member. His 115

125 relationship with the school and ISS showed throughout his talk, as he knew exactly how to focus his experiences towards the younger kids. By speaking with college-aged participants, children can be exposed to ideas not only involving space exploration, but also how they can make a difference as students. The children and families that attend often return in subsequent years to expand their understanding of space and also see the newest exhibits. Illinois Space Day is ISS s premier annual educational outreach event, and attendance has continued to grow over the last several years. Beyond simply educating children all of the ISS student launch team members were in some way involved with the setup, takedown, and execution of ISD. This ensures all of the team members have experience in the area and can make an impact within the community Upcoming Events Engineering Open House Engineering Open House (EOH) is an event hosted by The College of Engineering at The University of Illinois every spring semester. This event is an opportunity for families with kids of 116

126 all ages K-12 to come and view what The College of Engineering offers to its students and the community. The College of Engineering relies on the Engineering RSOs to provide the main base of the presentations given during this time frame. Traditionally ISS provides at least three different demonstrations for the children to enjoy. These include the orbital simulator, hybrid rocket engine ignition, and liquid nitrogen and space shuttle tile demonstrations. Further, ISS also provides a setup of all the technical projects that occur throughout our academic year, including the rocket built for Student Launch, along with posters detailing the project goals and accomplishments. Many of the demonstrations used for EOH are the most practiced and commonly presented exhibits. The reason for this is EOH is the largest event that ISS volunteers at every year, seeing approximately 20,000 attendees every year. Due to this the exhibits presented must be those that are easiest for the volunteers, while being equally practiced and interesting for the students viewing. This results in the use of the aforementioned demonstrations. Figure 60: EOH Demonstrations (from top left down), Hybrid Rocket Demo, Technical Projects Exhibit, and Liquid Nitrogen Demo Miscellaneous Events The ISS Student Launch team will participate and volunteer in many smaller events than ISD and EOH. These include Boy Scout merit badge clinics, school visits, and more. Each year ISS will host two different Boy Scout merit badge clinics allowing the attending scouts to attain their Space Exploration merit badges. Our volunteers are required to go through training with the Scouts before 117

127 being allowed to teach or administer the merit badges. The requirements for the merit badge include teaching the scouts the basics of space exploration using a presentation, designing an unmanned mission to the outer reaches of the universe, designing a manned mission within our solar system, presenting both missions, building a model rocket in groups of four scouts, and launching the rockets. Typically the rockets will be flown using 1/2A or A class motors purchased from a hobby store. The scouts will not receive their merit badges unless the rocket successfully launches. This event is a great time for volunteers to see their progress with the children and also make a real difference for the scouts who attend. Being able to teach a merit badge clinic is the most regulated of the educational outreach events ISS participates in, but it is a unique opportunity. Figure 61: Boy Scout Merit Badge Clinic One other large portion of educational outreach is classroom visits. In the academic year of there are already five planned classroom visits, each at different local schools, some reoccurring for the span of multiple weeks. Already this semester one visit has been completed. The ISS Student Launch Project Manager Andrew Koehler, the Educational Outreach Director Elena Kamis, and the Illinois Space Society Director Brian Hardy attended The Next Generation Primary School on September 15 th to teach an enrichment class on the basics of the solar system with demonstrations using liquid nitrogen included. The class met for only a half hour, but covered the basics of planetary makeup, sizes, distances, and temperatures. The liquid nitrogen was used to demonstrate the extremes of temperatures on different planets. The event was a success and the society has been asked to return in the future for another presentation. Finally, ISS is frequently asked to provide simple one hour build sessions for model rocketry at events geared towards high school students. One of these events is Little Sisters Weekend where high school female students spend a week on campus with a current female engineering student. On the second night of the weekend, ISS will provide a single hour build session for model rockets where the girls build the rockets and launch immediately afterwards. It provides the girls with a bonding event along with encouraging them to pursue aerospace based RSOs if they choose to attend the university. Educational outreach is a vital part to not only The Illinois Space Society, but also the ISS Student Launch team. All members of the team will volunteer at least once, but the majority of team members will attend most, if not all, of the educational outreach events provided by ISS. Educating 118

128 the next generation of scientists and engineers is something that is extremely important to the society. 6.3 Budget Detailed in Table 40 below are the projected expenses associated with the project. Items marked with the * symbol are already owned by ISS and will not require a purchase. Numbers in parentheses indicate the quantity of items needed. Due to the likelihood of price fluctuation over the span of the project, costs are rounded to the nearest dollar value. In response to this rounding a margin of error will be included in the total projected cost, highlighted in green. Subtotals for each section are highlighted in yellow. Table 40: Project Expenses Item Total Cost [$] Use Structure: 6 x 48 Blue Tube (2) 134 Outer Airframe 0.2 x24 x24 Square Fiberglass 70 Fins Sheet (3) 3 x 48 Blue Tube 27 Motor Mount Tube 75mm to 6 Centering Rings (3) 27 Centering Rings Epoxy and Resin 69 Structural Joints Aeropack Motor Retainer 54 Motor Retainer 48 Length 6 Blue Tube Coupler 67 Avionics and Payload Coupler Tubing 6 Coupler Bulkhead (4) 36 Bulkhead for Coupler Tubing 6 Airframe Bulkhead (4) 36 Bulkhead for Airframe Tubing Fiberglass Nosecone 105 Nosecone Nuts, Bolts, Washers, and 15 Connections Screws* 1515 Rail Button (2) 10 Launch Rail Connection Structures Total Value: 650 Structures Cost to Team: 635 Recovery Equipment StratoLogger CF (2) * 110 Altimeter TeleMetrum 2.0 (2) * 642 Altimeter/Tracker 9V Battery (2) 7.5 Battery for StratoLogger 9V Battery Clip (2)* 2 Attach 9V Batteries to Sleds TeleMetrum Li-Po Battery (2) * 22 Battery for TeleMetrum SkyAngle Model C2 44 * 66 Parachute for Payload Section Iris Ultra 96 * 404 Main Parachute Fruity Chutes 18 Elliptical 53 Drogue Parachute 20-ft. Tubular Kevlar (3) 61 Shock Cord for all Parachutes Quick Links (4) * 10 Attachment Hardware Charge Cups (6)* 1 Black Powder Container 119

129 Item Total Cost [$] Use Nylon Shear Pins* 5 Shear Pins ¼ Threaded Rods (6) 20 Mounts for Sleds 1/8 Plywood Sheet 12 Sleds for Mounting Equipment Right Angle Brackets* 5 Attach Sleds to Rods Terminal Blocks (4) 5 Connect Altimeters to Black Powder Charges Rotary Switches (4) 40 For Activating Altimeters on the Pad Recovery Equipment Total 1726 Value: Recovery Equipment Cost to 331 Team: Motor Equipment L1170FJ-P Reload Kit (2) 416 Motor Fuel Grain RMS 75/5120 Motor Casing 417 Motor Casing 75mm Forward Closure* 102 Closure for Motor Casing 75mm Aft Closure* 80 Closure for Motor Casing Motor Equipment Total Value: 1015 Motor Equipment Total Cost to Team: 833 Payload (Rover) 2 Arduino Micro 40 Rover and Lazy Susan 7 5 VDC Continuous Rotation Servomotors 84 Lazy Susan Orientation and Rover Movement 3 HobbyKing Coreless Digital HV/MG/BB Servo 60 Locking Mechanism and Solar Panel Deployment 3 Rover Body Segments 0 Rover Body 6 Rover Wheels 0 Rover Movement 2 9V Battery 13 Power Arduinos and Servos 2 Three Axis Gyroscope 6 Orient Rover After Landing Accelerometer Sensor 2 Solar Panels 6 Rover Solar Panels 1 Spring Loaded Hinge 3 Solar Panel Deployment 28 1/2 Hex Drive Rounded Head 25 Rover Body Attachment Screw 2 2-3/4 Zinc Yellow-Chromate 13 Motor Attachment Plated Hex Head Screw 2 Steel Hex Nut 12 Rover Body Attachment 1 Bulkhead 50 Payload Orientation 1 84T Aluminum Gear 13 Lazy Susan 1 20T Servo Mount Gear 4 Lazy Susan 1 Platform 25 Lazy Susan 120

130 Item Total Cost [$] Use 2 Hook 75 Locking Mechanism Rover Total Value: 389 Rover System Total Cost to Team: 389 Miscellaneous Costs Subscale Vehicle 250 Educational Outreach 100 Travel Expenses 2,500 Total Misc. Costs to Team: 2850 Margin: 500 Account for Price Fluctuations and Additional Parts Total Value of Project: 6677 Total Cost to Team: Funding Plan All funding for the project will come from the team's parent organization, the Illinois Space Society. The society itself obtains the majority of its funding from five sources: EC, SORF, the AE Department, corporate sponsors, and ISS itself. The Student Organization Resource Fee (SORF) is an on-campus funding organization whose services are available to all registered student organizations. A $5 fee included in all students' tuition goes directly to SORF, which is then allocated to support student organization activities. A maximum of half of a club's expenses may be reimbursed per funding request, with an annual cap of $6,000. ISS initially covers all purchases, then requests funding for those expenses through SORF. The $2,000 estimate from SORF is derived from past Student Launch budgets, as well as a balanced distribution of the maximum allocation amount among the other ISS expenses. Other funding sources for Student Launch include the aerospace engineering department at the University of Illinois, corporate sponsors, and ISS. ISS has requested $1,500 from the aerospace department specifically designated for Student Launch part orders and travel expenses. ISS also receives funding from corporate sponsors for the competition and other societal activities. Corporate sponsorships are pursued from aerospace industry companies and vendors from whom parts are ordered. ISS also contributes its own funds to Student Launch, which are kept in a Registered Student Organization Account. This money originates from campus fundraisers, as well as any surplus money from previous years. Because the funding from the aerospace engineering department and corporate sponsors are less reliable than other sources, funds from ISS will cover any additional expenses for the project. The budget for the Student Launch project will continuously be considered and updated as the project proceeds. ISS and the team will also continue to search for funding sources to assist in the parts and travel expenses of the project. Detailed in Table 41 below are the projected amounts of funding received from each source described above. 121

131 Table 41: Projected Funding Estimate Funding Source Requested Amount Engineering Council $ SORF (Student Organization Resource Fee) $2, Aerospace Engineering Department $1, Corporate Sponsors $1, Illinois Space Society $1, Total $6, Project Timeline Table 42: Project Milestones and Expected Completion Dates Milestone Proposal Selection Notification Illinois Space Day (ISD) Team Web Presence Established Preliminary Design Review (PDR) PDR Teleconference Subscale Test Flight Critical Design Review (CDR) CDR Teleconference Vehicle Construction Ejection Charge Testing Full Scale Test Flight Flight Readiness Review (FRR) FRR Teleconference Launch Readiness Review (LRR) Launch Post-Launch Assessment Review (PLAR) Completion Date September 20 th October 6 th October 7 th November 3 rd November 3 rd November 6 th 29 th December 2 nd January 12 th January 16 th 31 st February 10 th February 14 th February 17 th March 5 th March 6 th 22 nd April 4 th April 7 th April 27 th 122

132 Appendix A: Acronyms AGL: Above Ground Level APCP: Ammonium Perchlorate Composite Propellant CAD: Computer Aided Design CDR: Critical Design Review CFC: Chlorofluorocarbons CG: Center of Gravity CIA: Central Illinois Aerospace CP: Center of Pressure EIT: Electronics and Information Technology FAA: Federal Aviation Administration FN: Foreign National FRR: Flight Readiness Review HEO: Human Exploration and Operations ISD: Illinois Space Day ISS: Illinois Space Society LCO: Launch Control Officer LRR: Launch Readiness Review MSDS: Material Safety Data Sheet MSFC: Marshall Space Flight Center NAR: National Association of Rocketry PDR: Preliminary Design Review PLAR: Post Launch Assessment Review PPE: Personal Protective Equipment RFP: Request for Proposal RSO: Range Safety Officer RSO: Register Student Organization SLI: Student Launch Initiative SME: Subject Matter Expert SOW: Statement of Work STEM: Science, Technology, Engineering, and Mathematics TRA: Tripoli Rocketry Association 123

133 Appendix B: ISS Tech Team Safety Policy Illinois Space Society Tech Team Safety Policy All students are to sign and date the present document indicating that they read, understand, and will abide by the contained policy before they enter the Illinois Space Society (ISS). These requirements apply to day to day meetings, construction in and outside of the Engineering Student Projects Lab (ESPL), testing, and any additional meetings that may occur as part of ISS Tech Team activities. The signed forms are to be collected by the team safety officer, recorded, and submitted to the Technical Projects Manager. I. ESPL Rules: Required training to gain access to ESPL General Lab and Electrical Safety training through the U of I Division or Research Safety is mandatory for all individuals before they enter ESPL and participate in Design Council supported projects. Both interactive training modules are online and available at the following link: Upon completion of the training modules the students must print, sign, date each form and give to the designated safety officer who will keep record of their training and then give promptly to ESPL Laboratory Supervisor. It is also required that all students read the present document and sign and date it. Card access to ESPL will be granted after the ESPL Laboratory Supervisor has the General Lab and Electrical Safety training forms and the present document signed and dated on file. Required training to use any tools/equipment in ESPL Students must receive training from The ESPL Laboratory Supervisor and fill out the ESPL General Use Compliance Form and the ESPL Machine Shop use Compliance Form before they use any tool/equipment on the respective forms or any potentially dangerous tools/equipment. Tools shall not be brought into ESPL without the consent of the ESPL Laboratory Supervisor. Any potentially dangerous tools or equipment not listed on the forms should be added to the ESPL General Use Compliance Form list. Students may not work on equipment until the ESPL Laboratory Supervisor has signed and dated the pertinent compliance forms. A student must not use tools/equipment she/he was not trained for. Each student group must designate a safety officer. The name, , and cell phone number of the safety officer must be distributed to each team member. The safety officer must: Make sure that all individuals in the team are working in a safe manner and in compliance with the Design Council Safety Policy. They will keep up to date record of the signed Safety Policy forms for each team member Be familiar with the daily activities of the team Maintain a complete list of MSDS sheets for all potentially hazardous materials and their respective quantities 124

134 All students must abide by the following ESPL General Use Rules: 1. A Laboratory Supervisor will oversee the Engineering Student Project Laboratory, including the Machine Shop. 2. Students may not operate any power tool unless there is somebody else in the same work area of the laboratory or shop. 3. Each student must wear safety glasses with side shield at all times while in any of the ESPL work areas. 4. Hearing protection is required by anyone near loud equipment. 5. When in the work areas one must wear appropriate clothing: closed toed shoes, pants, no loose clothing, jewelry, or hair is allowed that can potentially be caught in equipment. Do not wear ties, rings, or watches. 6. Students must not lift heavy objects without the aid of an appropriate lifting device and hold heavy objects in place using appropriate equipment such as jack stands. 7. When using power tools to cut materials, all parts must be properly clamped in a vise or clamped to a table. Never hold a piece by hand when attempting to cut or drill it. 8. Never leave any tool or equipment running unattended. This includes electronic equipment, soldering irons, etc. When you finish using anything, turn it off. 9. People welding or assisting in welding operations must wear welding masks or yellow tinted safety glasses. You may only watch the welding process if you are wearing a mask. Students who are welding or using grinders must use appropriate shields to protect others. 10. Compressed gases used for welding or other purposes pose several hazards. Users of compressed gases must read and follow the recommendations of Compressed Gas Safety available at Shop doors must not be propped open. 12. Waste chemicals must be properly discarded, See the Laboratory Supervisor. 13. Store potentially hazardous liquids, chemicals and materials in appropriate containers and cabinets 14. Students are responsible for the order and cleanness of their work space and benches according to the rule: If you make a mess, clean it up. The same rule will apply to the common areas of the laboratory including the designated dirty space, paint booth, and welding areas. 15. Work in a clean, uncluttered environment with appropriate amounts of work space and check tools and workspace for problems/hazards before working with them. 16. Know the location of all fire extinguishers, emergency showers, eye rinse stations, and first aid kits. 17. If you fill the garbage can, empty it in the dumpster outside. 18. The Laboratory Supervisor will decide how to proceed in the case of any situations not covered by the preceding rules. 125

135 ESPL Machine Shop Rules (for all students using the ESPL Machine Shop): 1. Any user of the ESPL Machine Shop must read, understand, and abide by the ESPL General Use Rules. 2. The Laboratory Supervisor controls card access to the ESPL Machine Shop. No student can use any machine tool until he/she has demonstrated competence on that machine to the Laboratory Supervisor. 3. No student may enter or remain in the Machine Tool Workshop unless accompanied by the Laboratory Supervisor or a student who is authorized to use the Shop. The authorized user is responsible for the visitor while he/she remains on the Shop. 4. Students may not operate any machine tool unless there is somebody else in the Machine Tool Workshop. 5. Each student must wear safety glasses at all times. 6. When operating machine tools, long hair, long sleeves, or baggy clothing must be pulled back. Do not wear gloves, ties, rings, or watches in the ESPL Machine Shop. 7. When using power tools to cut materials, all parts must be properly clamped in a vise or clamped to a table. Never hold a piece by hand when attempting to cut or drill it. 8. Be aware of what is going on around you. 9. Concentrate on what you're doing. If you get tired while you're working, leave the work until you're able to fully concentrate don't rush. If you catch yourself rushing, slow down. 10. Don't rush speeds and feeds. You'll end up damaging your part, the tools, and maybe the machine itself. 11. Listen to the machine, if something doesn't sound right, turn the machine off. 12. Don't let someone else talk you into doing something dangerous. 13. Don't attempt to measure a part that's moving. 14. Before you start a machine: a. Study the machine. Know which parts move, which are stationary, and which are sharp. b. Double check that your workpiece is securely held. c. Remove chuck keys and wrenches. 15. If you don't know how to do something, ask someone who does. 16. Clean up all messes made during construction a. A dirty machine is unsafe and difficult to operate properly. b. Vacuum or sweep debris from the machine. c. Do not use compressed air. 17. Do not leave machines running unattended. 18. The Laboratory Supervisor will decide how to proceed in the case of any situations not covered by the preceding rules. 126

136 Appendix C: Education Feedback Form Illinois Space Society Student Launch Educational Feedback Form How interesting was the demonstration? (1 Boring, 10 Extremely Interesting) How much did you learn from this demonstration? (1 Nothing, 10 A Lot) How interesting was the presentation? (1 Boring, 10 Extremely Interesting) How much did you learn from this presentation? (1 Nothing, 10 A Lot) What did you enjoy from your time with us? What was your least favorite part of your time with us? 127

137 Appendix D: ISD Brochure 128

138 129