Presentation 3 Vehicle Systems - Phoenix
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- Godfrey Hunt
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1 Presentation 3 Vehicle Systems - Phoenix 1
2 Outline Structures Nosecone Body tubes Bulkheads Fins Tailcone Recovery System Layout Testing Propulsion Ox Tank Plumbing Injector Chamber Nozzle Testing Hydrostatic Cold Flow Hot Fire System Validation Test data presentation Trajectory System Operating space (altitude) Flight Profile (engine test) 2
3 Overview Design & Analysis Construction Validation 3
4 Nose Cone Design -Materials: Carbon fiber sheet 60 minute cure epoxy resin -High tensile and compressive strength FR = 3:1 Analysis - Half-Power profile -y = R x L - Fineness Ratio -STAR-CCM+ Mach 0.8
5 Nose Cone Construction -Low-density foam core from CNC -Carbon fiber vacuum bagged over foam core -Foam dissolved out with acetone Flight Performance -Withstood flight loads as expected -No damage throughout flight
6 Body Tubes Analysis +45 /-45 weave angle Fiber/matrix modeling difficulty Expected Load ~725 lbf Proven via flight results Construction Older Tubes 2 layers Newer tubes Compression fit tape 1 layer Validation 90 (axial) Resistant to longitudinal bending 90 (hoop): Resists internal/external pressure 45 Ideal to resist pure torsion - 4 Main Body Tube sections 6
7 Bulkheads Design Commonalities Material: Aluminum 6061-T6 Considerations Attachment methods Well nut Nut/bolt Rivets JB weld Loading Ease of Assembly Layout 4 main bulkheads Electronics Bay Connections: Recovery well nuts Bay doors bolt/nut Payload bolt/nut Body Tubes JB weld Joint Bulkhead Connections: Body Tubes JB weld Thrust Bulkhead Connections: Body Tubes JB weld Top - well nut Bottom Nut/Bolt Tail Cone Connector Connections: Body Tubes JB weld Tail Cone - Rivets 7
8 Bulkheads E-bay Bulkhead Analysis Buckling Factor Expected Critical Load ~2870 lbf Estimated Critical Load ~3800 lbf Length 12 in Material 6061-T6 Yield Strength 7.99x psi Rod thickness in Design Analyze Build 8
9 Bulkheads Thrust Bulkhead Need for Quick Disconnect feeds Prefilling tank with oxidizer posed a safety hazard Remote and removable filling system needed to be developed Original engine bulkhead needed to be redesigned to fit said system Design Restrictions Little internal space. Original rocket was not designed to house a detachable mechanism for feeding line. Check-valve needs to fit between QD and oxidizer tank Original Dimensions Rocket External Radius 3.25 in Distance from plumbing to bulkhead 2.63 in Distance from cross to body tube 2.38 in Female QD length* 2.5 in *Requires 2 in of solid tubing after QD 9
10 Bulkheads Thrust Bulkhead Discarded design Ideas Placing female QD internally at an angle Placing male QD directly at cross QD system will not fit inside rocket. System needs to sit outside rocket 10
11 Bulkheads Thrust Bulkhead External feeding lines Quick disconnect placed behind fins to reduce drag Rubber plug centers line and reduces vibrations Clamp on tail-cone secures bottom Bulkhead redesign Ease assembly Machined from single piece of metal General Specifications Bulkhead material Aluminum 6061-T6 Bulkhead weight 1.90 lb Fill line material Stainless steel Fill line external length 20 in Fill line outer diameter 0.25 in 1050 lbf 11
12 Fins & Stability Airfoil Design NACA 65A-010 CFD optimization Planform Design OpenRocket optimization Geometric constraints Dynamic Stability RASAero w/crosswind 12
13 Fins Design Materials Aluminum High Density Foam Carbon Fiber Cloth Epoxy New Considerations Light Weight Easy Attachment Resist Fin Flutter Construction CNC aluminum bases CNC fin mold Cast foam fin cores and insert all thread Fuse core and base with epoxy Vacuum resin transfer process Attach to body with all thread Bondo fillet Old Design New Design
14 Tail Cone Design Requirements Lightweight & aerodynamic Impact & heat resistant Material: Ultem 9085 thermoplastic 3D printed by Stratasys Analysis CFD in STAR-CCM+ stagnation region 1.1 calibers calibers 14.5
15 Recovery System Overview (3) Apogee (2) Coast Dual-Deployment Recovery System Key Features: Dual Deployment design to minimize drift Single point of rocket separation Integration of Advanced Retention Release Device to release main (ARRD) (4) Drogue Deployment at Apogee, 80 ft/s (1) Motor Ignition (5) Main Deployment at 1500 AGL, 15 ft/s (6) Landing 15
16 Recovery System Overview Drogue Parachute Configuration Main Drogue 5 Tubular Nylon 15 Tubular Nylon Shock Cord Main Parachute Configuration 28 Tubular Nylon + 6 Kevlar Y-Harness = 34 16
17 Current Recovery System Recovery Bulkhead: Top View U-Bolt U-Bolt Ejection Pod Showing E-match to Pyrodex Charge Binding Posts connect E-Match to Electronics Bay Recovery Bulkhead Redundant Ejection Charges connected with binding posts to electronics bay 5 gram Pyrodex P charge 4 x (4-40 Shear Pins) 2 (U-Bolts) distribute opening force across entire bulkhead ARRD mounted through bulkhead ARRD 17
18 ARRD (Advanced Retention Release Device) ARRD implemented as alternative to line cutters Link between drogue and main parachute from apogee to 1500 AGL Activated by pyrodex P charge Installed through the recovery bulkhead Advantages of ARRD vs. Previous Designs Main parachute is kept in the recovery bay Electronic wire no longer required to run from bulkhead to main parachute Utilization of deployment bag keeps the recovery bay organized ARRD Key Dimensions Length w/o shackle Diameter Weight 2.75 oz Pyrodex P Charge.25 grams 18
![Opening Force [lbf] Opening Force Calculation Impulse Momentum Theory Transfer of momentum between vehicle and displaced air mass provides opening force Function of inflation time Force as a function](/docs-images/93/112220675/images/19-3.jpg "of inflation time Deployment inflation window: 100 ft/s Estimate Opening Force: 270-340 lb f 900 800 700 600 500 Opening Force vs. Inflation Time Parachute Inflation Window Recovery System Max.")
19 Opening Force [lbf] Opening Force Calculation Impulse Momentum Theory Transfer of momentum between vehicle and displaced air mass provides opening force Function of inflation time Force as a function of inflation time Deployment inflation window: 100 ft/s Estimate Opening Force: lb f Opening Force vs. Inflation Time Parachute Inflation Window Recovery System Max. Load Ratings Tubular Nylon Shock Cord Fruity Chutes Swivel 4000 lb 3000 lb 3/8 Quick Link 6000 lb Kevlar Y-Harness 6000 lb Time [s] ARRD 2000 lb 19
20 LN-350 Helios III Summary Specifications I SP m Prop Burn time Peak Thrust Average Thrust Impulse 213 s 1.08 lbs/s 10.6 s (6.9 liq) 350 lbf 230 lbf 2434 lb-s Competition Engine 40% FR 20% Hydrotest Verified 20% Cold Flow Verified Currently in Static Testing Phase 1
21 10 lbs of Nitrous 2 lbs HTPB Current OF Ratio is too high Actual OF Ratio ~ 11 Ideal OF Ratio ~ 6.5 Propellant
22 Mass (lb) Tank & Plumbing 25 Maximum N 2 O (l) Mass v. Temperature Composite Overwrapped Pure Aluminum Temperature ( F) Luxfer T84A Tank Specifications Phoenix needs Service Pressure 4500 psi 1000 psi 12.5 lbs. vs lbs. Volume 550 in 3 - Max Nitrous Mass (@ 95 F) 11.7 lb (0.02 lbm/in 3 ) 10 lb
23 Tank & Plumbing Minimize Weight Length Leaks Plumbing Cross Specifications Minimum Thickness Working Pressure 4950 psi Weight 1.02 lb BVA system is transferrable between propulsion systems
24 Injector Specifications Orifice Area in 2 Peak oxidizer mass flow 1.8 lbs/s
25 Combustion Chamber Specifications Operating Pressure Test Pressure Length OD Thickness 325 psi 400 psi 21 in 4 in 0.25 in Factor of Safety >2
26 Nozzle Specifications ε 4.3 A t in 2 V e m 7473 ft/s 2.26 lb/s
27 Nozzle Failure (Video)
28 Hydrostatic Testing Results Issues during tests: Bowing of injector coin FEA analysis thicker coin needed Inconsistent tightening of injector housing bolts Set standard torque to 145 in-lbs Old Coin Overuse of gaskets Replaced all gaskets after 5 cycles Stripping of Yor-lok & NPT threads Reduce need for disassembly New Coin Verified October psi (Tank to Injector) 400 psi (entire system)
29 Test 1-1: January 29 th, 2017 Static Engine Testing Results (Video)
30 Static Engine Testing Results (Data) Test 1-1: January 29 th, 2017 (Successful Ignition) Composite Tank Specifications Peak Thrust 130 lb Burn Time 12.7 s (~4 s liquid) Impulse 785 lb-s NOS weight 8 lb Fuel Burned ~1 lb Only load cell data acquired Incorrect loading on load cell FEA showed ~40% thrust lost through wood block
31 Thrust Comparison Testing Data Simulated Curve 31
32 Test 1-2: February 3 rd, 2017 (No ignition) Low NOS supply in fill tank slow/stopped fill during testing Tank tracking and constant weight checks enforced Static Engine Testing Results (Data) Test 1-3: February 18 th, 2017 (No ignition) Igniter failure due to high resistance Resistance check implemented into procedure 2 hour complete vent
33 Test 1-4 & 1-5: February 18 th & 23 rd, 2017 Static Engine Testing Results (Video)
34 Static Engine Testing Results (Data) Test 1-4 & 1-5: February 18 th & 23 rd, 2017 (Misfires/Cold Flows) Fill Stopped (700 psi) Ignition attempt, valve open (500 psi) Oxygen fire issues Tube and igniter are blown out/fall out before valve opens Filling data acquired lost 200 psi in 2.5 min idle period min idle time
35 Test 1-6: February 26 th, 2017 Static Engine Testing Results (Video)
36 Static Engine Testing Results (Data) Test 1-6: February 26 th, 2017 (Successful Ignition) Composite Tank Specifications Peak Thrust 87 lb Burn Time 16.8 s (~11.3 s liquid) Impulse 1191 lb-s NOS weight 10 lb Fuel Burned 1.53
37 Static Engine Testing Results (Data) Composite Tank Specifications Initial weight 3.15 lb Final Weight 1.62 lb Fuel Burned 1.53 lb 37
38 Phoenix Performance OVERFILL
39 Phoenix Performance RAIL EXIT CRITERIA OVERFILL
![10k Target Flight SpacePort, NM Phoenix [Helios] 100 MC Value ±1σ Loaded Weight Mass N2O 93.](/docs-images/93/112220675/images/40-3.jpg "26 lb - 13 lb - Apogee 9804 ft ±4.7% Peak Mach Peak Accel. 0.56 ±3.4% 2.59 G ±2.")
40 10k Target Flight SpacePort, NM Phoenix [Helios] 100 MC Value ±1σ Loaded Weight Mass N2O lb - 13 lb - Apogee 9804 ft ±4.7% Peak Mach Peak Accel ±3.4% 2.59 G ±2.3% Rail Exit 60 ft/s ±3.6%
![10k Target Flight SpacePort, NM Phoenix [Helios] 100 MC Value ±1σ Loaded Weight Mass N2O 93.](/docs-images/93/112220675/images/41-3.jpg "26 lb - 13 lb - Apogee 9804 ft ±4.7% Peak Mach Peak Accel. 0.56 ±3.4% 2.59 G ±2.")
41 10k Target Flight SpacePort, NM Phoenix [Helios] 100 MC Value ±1σ Loaded Weight Mass N2O lb - 13 lb - Apogee 9804 ft ±4.7% Peak Mach Peak Accel ±3.4% 2.59 G ±2.3% Rail Exit 60 ft/s ±3.6%
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