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UNIVERSITY OF NORTH DAKOTA FROZEN FURY UNIVERSITY STUDENT LAUNCH INITIATIVE PRELIMINARY DESIGN REVIEW NOVEMBER 5, 2014 2
TABLE OF CONTENTS I) Summary of Flight Readiness Review 4 Team Summary.4 Launch Vehicle Summary.4 AGSE Summary.....5 II) Changes Made Since Proposal......5 Changes Made...5 III) Vehicle Criteria..5 Selection Design and Verification of Vehicle....6 Major Milestone Schedule.6 Design Overveiw...7 Motor Selection..11 System Reveiw...13 Scale Launch..16 IV) Launch Operation Procedures.17 Preparation of Recovery System....17 Altimeter Bay.18 Motor Preparation...19 AGSE Setup...19 Igniter Insertion...20 Launch Processes...21 V) Safety and Failure Modes.....22 Failure of Propulsion System...24 Failure of AGSE...25 Material Safety. 27 Environmental Concerns..30 VI) AGSE Concept Features... 32 VII) Activity Plan.34 Plan 34 Budget....35 Educational Engagement...37 VIII) Conclusion..38 3
Preliminary Design Review Report I) SUMMARY OF THE PDR A. Team Summary Name: University of North Dakota, Frozen Fury Location: Grand Forks, North Dakota 58202 Team Mentors: Dr. Tim Young Team Members: Xuchu Xu Gregory Foote Ryan Knutson Nicholas Petronio Jacob Teffs Rebecca Larson Emeke Opute Sydney Porter Cameron Bush Nicole Fitzgerald Scott McDaniel Sofiane Chaieb Connor Jaford Jeffrey Gendreau Haylee Archer Micheal Zepeda Chirstian Johannes Kyle Pletan Sushil Shrestha B. Launch Vehicle Summary Size/Vehicle Dimensions: Unloaded mass: 13.75 lb Loaded Mass: 17.38 lb Length: 7.59 ft Diameter: 6 in Span: 13.5 in CP: 64.06 in CG: 56.39 in Margin: 1.28 Fin Dimensions: Root: 12.32 in 4
Motor Choice Tip: 6.16 in Sweep length: 3.22 in Semi Span: 3.75 in Aerotech K513FJ Recovery Three Part System Drogue: 6 sided, 24 in Main 1: 6 sided, 84 in Main 2: 6 sided, 44 in C. AGSE Summary The AGSE will be compromised of three systems. The first is the payload grabbing apparatus that will use a slide rail and claw to move the payload from the ground to the rocket. The next system will use a linear actuator to raise the rail to an angle of 85. The last system will have a wire wrapped around a coil that will unravel and feed into the rockets motor to prepare for the ignition. II) CHANGES MADE SINCE PROPOSAL 1. At the time of the proposal, the plans for the AGSE were in debate. In the weeks following the proposal, the several rough drafts we had for the AGSE have been narrowed down to one system that will be explained and detailed in this PDR. Further, since the plans were not finalized, any possible risks due to the AGSE were not assessed. See section III. 2. The size of the parachute was determined using Rocksim and guidance from our mentor Tim Young. 3. We will be using PerfectFlite Stratologger altimers. III) VEHICLE DESIGN CRITERIA A. Selection, Design, and Verification of Launch Vehicle 1. Mission Statement, Requirements and Mission Success Criteria: MISSION: 5
The primary objective of the 2014 2015 University of North Dakota Frozen Fury rocket team is to design and construct a safe, stable rocket along with an automated ground support system. The ground support system is designed to secure a sample that is to be loaded into the rocket. REQUIREMENTS/MISSION SUCCESS CRITERIA: AGSE An autonomous payload retrieval, vehicle erection and ignition insertion system will constitute successful launch readiness. Rocket launch A successful rocket launch will consist of reaching an altitude of 3000 feet above ground level (AGL). The launch will be performed autonomously. Rocket recovery A successful recovery of the rocket will consist of the recovery system ejecting at the appropriate time and altitude and recovering the rocket on the ground such that it is deemed reusable for future launches B. Major Milestone Schedule Design 1. Scale Construction November 22nd December 3rd 2. Scale Test Launch December 4th 3. Make possible design changes 4. Full Scale construction 5. Full Scale test February 6. Final Adjustment 7. Competition Launch AGSE 1. Obtain guidelines 2. Design 3. Construction (ongoing since start of project to be finished in January) 4. Programming 5. Testing 6. Changes based on test results 7. Test Launch Late February 8. Changes basted on test launch 9. Final Launch 6
Outreach 1. Ideas 2. Contact Schools 3. Plan Programs 4. Construct programs 5. Present programs 6. UND Physics Day (In Progress) C. Design Overview 1. Flight Profile/Simulation (Above: 3D Design of rocket) 7
(Above: 3D Design of Payload Securing) (Above: RockSim Simulation) 8
(Above: RockSim Radial Stability Simulation) (Above: 3D design of AGSE) 9
2. Size/Vehicle Dimensions: Unloaded mass: 13.75 lb Loaded Mass: 17.38 lb Length: 7.59 ft Diameter: 6 in Span: 13.5 in CP: 64.06 in CG: 56.39 in Margin: 1.28 3. Fin Dimensions: Root: 12.32 in Tip: 6.16 in Sweep length: 3.22 in Semi Span: 3.75 in 4. Simulation Projections (Mission Performance Predictions) Projected max altitude: 3372 ft Max Velocity: 530 ft/s (Mach 0.48) Max Acceleration: 249 ft/s² Time to apogee: 15 s Velocity at deployment: 5.5 ft/s Altitude at deployment drogue: 3372 ft (Apogee) Altitude of deployment of the two Main: 1000 ft 10
(Above: RockSim Flight Graphical Representation) D. Motor Selection: 1. AeroTech K513 54mm a) Manufacturers Information: 11
Manufacturer: AeroTech Entered: Nov 19, 2007 Last Updated: Jul 22, 2014 Mfr. Designation: Common Name: Motor Type: Delays: Diameter: Length: Total Weight: Prop. Weight: Cert. Org.: K513FJ K513 reload L 54.0mm 41.0cm 1647g 974g Tripoli Rocketry Association, Inc. Cert. Date: Jun 9, 2007 Cert. End: Jun 30, 2012 Average Thrust: 556.8N Maximum Thrust: 658.3N Total impulse: 1496.3Ns Burn Time: 2.8s Case Info: Propellant Info: Availability: RMS 54/1706 Fast Blackjack regular 12
b) ThrustCurve.org Profile/Graph The engine file provided by AeroTech for the K513 is shown below. This graph is from ThrustCurve.org, an online, user submitting database of motor information. This graph was done with the Rocket Altitude Simulation Program (RASP). The impulse of the rocket has an average of 556.8 Newtons of thrust. The horizontal blue line marks the average thrust, and the vertical blue line denotes the end of the engine burn. E. System/Subsystem Review/Rationale 1. Airframe Material The 2014 2015 Rocket design is projected to have an airframe composed of either fiber glass or a carbon fiber composite. Simulations of both material types have been conducted using RockSim for a 6 inch diameter and 99 inch rocket. The simulations project a peak altitude around 3000 ft with both a carbon fiber and fiber glass rocket (approximate unloaded weight 13.75 lb) using a mid level K size motor. Due to unknowns concerning the mass of the payload component, the team feels it is prudent to move forward with the current 13
fiber glass design despite its inconsistency with the mission success criteria max altitude of 3000 ft. Fiber glass will provide the air frame with added strength that could potentially take the stress of a higher impulse motor if the need arises with further simulations and tests with true component weights. Two scale launch tests are scheduled for early December and post winter break to test both carbon fiber and fiberglass constructions. A definitive material will be chosen after this testing is completed. This dual scale launch will also familiarize the team with the material of choice prior to the construction of the full scale rocket in the Spring of 2015. 2. Fin Material Fins will be constructed out of the same material as the airframe (i.e. Carbon Fiber/ Fiber glass). The innate strength of the material will ensure that the fins will not break upon landing, which is something the Frozen Fury Team experienced last year. 3. Bulk Head Material Internal Bulkheads will be constructed out of ¼ in. cabinet quality birch plywood purchased from a Grand Forks, ND local hardware retailer. The rationale behind choosing birch plywood is that it has a very clean face and very few knots. The use of higher grade wood ensures the bulkheads and fins will have uniform wood grain and will be structurally strong in order withstand the stress of flight. Bulkheads are cut from the plywood using a table saw, and then sanded to fit securely in the 6 in diameter rocket body tube. The bulkheads are affixed inside the airframe with West Systems epoxy on both the superior and inferior edges for added strength. The plywood bulkheads make certain the rocket structure is rigid throughout its entire length. 4. Motor Type The current simulated motor type used for the 2014 2015 Frozen Fury Rocket is a AeroTech K513. This motor has a moderate impulse and projects the design s max altitude at approximately 3372 ft. This motor type is still under discussion due to the payload component weights being unknown. 14
It was also verified that the AeroTech K513 motor was not of the Skid mark/metal filing variety so there would be no additional fire hazard with its use. 5. Workmanship The quality of work is very important to maintain a successful program. The team has plans to stay neat in the construction process and all tools and components will put away at the end of the day. This is propelling the team toward success by keeping our workspace clean day to day, which helps expedite work. 6. Recovery Sub System The rocket will utilize a drogue parachute deployment at apogee, and a main parachute deployment at 1000 ft AGL. The drogue chute is a 24 in nylon round parachute. This allows the rocket and payload to descent at a velocity of 22.5 ft/s. This has been considered fast enough for recovery area purposes. The first main parachute is an 84 in PML chute with a 12 inch spill hole. The payload parachute is an 44 in PML chute with a 12 inch spill hole. The spill hole lets the rocket descend in a more stable fashion while maintaining a relatively safe descent rate of 5.8 ft/s. The parachutes will be connected to a rip stop nylon shock chord. They will have quick links attached at each end for ease of assembly and removal. The quick links will also be attached to eye bolts which are epoxied into place on the altimeter bay s bulk head. The shock cord s length will be large enough to ensure that none of the rocket s structural components will collide during decent. Sheer pins will be used in conjunction with small amount of friction fitted tape at the separation points. 7. AGSE The rocket will begin on a metal frame. The metal frame has our payload grabbing apparatus that will be comprised of belt driven sliding rail. The moving platform on the sliding rail will have two 15
F. Scale Launch servos mounted on it that face the ground. The servos will control a claw that will pivot at the claw s base and then the other servo closes the claw. The claw moves up the slide rail which then drops the payload into the rocket. Our rocket will be raised using a linear actuator. Our rocket will be connected to the launch rail which will start horizontally. The linear actuator will be mounted below the rail and under the top plane created by the metal frame. The actuator will be positioned at an angle and will extend out to raise our rocket to the 85 degree angle. The last process for our AGSE to complete will be the insertion of ignition wire. Our ignition insertion system work by unraveling the wire which is wrapped around a coil. The coil will be on an electric motor which will unravel the wire. The wire will have a guide system that leads to the motor of the rocket. The coil will unravel until the wire is fully in the motor. 1. Launch Dates Two scale launches are projected to take place on Dec. 4 2014, and early January 2015 to test the strength/flight feasibility of a fiberglass vs. carbon fiber airframe. 2. Scale Information I. The scale model will be based off of a kit rocket purchased from LOC/Precision. The kit used will be the LOC Caliber ISP model. Modifications will be made during assembly to make a better scale of our actual rocket. We will base our scale off of the 3 diameter size that this rocket comes in and then cut the length to make the width to length ratios equivalent. Along with this, the fins on the kit will not be used as we will be constructing fins based off of the design of the launch rocket. This will be launched using a first class G motor and the actual specifications of the rocket with a 3 diamter are shown in the picture below. II. We are using a kit to model our rocket because building it will introduce the new members of the group o the different procedures of building the rocket without creating unrealistic time demands on the members. This helps the new members get accustomed to the shop equipment, the names of the parts used to assemble the rocket, the placement of the parts, the handling procedures of a motor, and the use of a payload. 16
Launch Operation procedures Preparation for rocket launch: I. Preparation of the recovery system Checklist A. Equipment for Main Parachute Main parachute 84 inches with 12 inch spill hole Large deployment bag 3 large quick links Main shock cord B. Equipment for Payload Parachute Main parachute 44 inches with 12 inch spill hole Large deployment bag 3 large quick links Main shock cord C. Equipment for Drogue Parachute 17
Drogue parachute 24 inches Small deployment bag 2 large quick links 1 small quick link Drogue shock cord D. Folding parachute Main parachute a. When the parachute is already folded as a half circle, and as flat as possible, at least 3 people begin to lay out the chute. b. One person holds the lines to prevent them from becoming tangled. c. The other two individuals hold the parachute along the folded edges. d. The chute is folded in half three times. e. Starting from the top, it is folded into thirds by folding the tip of the chute to the middle, then folding down again. f. The chute is placed into the bag. g. The chute s rip cords are connected to the large quick link in the middle loop of the main shock cord. h. On the top of the chute, but still in the bag, the parachute rip cords and some of the shock cord are carefully placed, to ensure they do not become tangled. E. Folding parachute Drogue parachute a. The drogue is spread between the three people in the same manner as the main parachute. b. While one team member keeps the cords untangled, two members fold the chute in half three times, and then fold it into thirds length wise. c. The parachute is placed in the small bag. d. The rip cord of the parachute is connected to the middle loop in the drogue shock cord using the small quick link. e. The rip cords and part of the shock cord are folded in a manner that doesn t tangle the cords, and are placed on top of the parachute inside the bag. II. Altimeter bay A. Equipment for Altimeter Bay Altimeter 2 9V batteries 8 washers 4 wing nuts Battery holder B. The altimeter is calibrated, making sure that all parachute deployment numbers are correct C. Two new 9 V batteries are placed on the altimeter board and secure them 18
D. Charges are placed in the charge cups, threading the electric matches through the holes. The charge for the main is 2.5 g and should be placed on the bottom altimeter bay cup. The charge for the drogue is 1.66 g and should be placed in the top altimeter bay cup. E. The wires are connected to the altimeter making sure the positive and negative wires are in the appropriate places. F. The batteries are attached. G. The altimeter board is slid into place and secure with wing nuts. H. The area is cleared of unnecessary personnel and continuity is checked for using the switch on the exterior of the rocket. If there is good continuity, two beeps will be heard after the initial set of beeps. If the continuity is not good there will be double beeps after the initial set of beeps. I. The appropriate side of the main shock is attached to the bottom of the altimeter bay using a large quick link. J. The appropriate side of the drogue shock cord is attached to the top of the altimeter bay using a large quick link. III. Assembly A. The appropriate side of main shock cord is attached to the fin can. B. The appropriate side of drogue shock cord is attached to the payload bay. C. The main bag is attached to the bottom of the altimeter bay. D. The drogue bag is attached to the bottom of the payload bay. E. The rocket is pushed together. IV. Motor Preparation A. Equipment for Motor Motor casing Motor grain Motor retainer 3 screws Electric match B. Our engine will come pre assembled, and will be left in the cardboard tube that it came in until the rocket is ready to be placed on the launch rail C. The motor is placed into the metal casing, making sure the motor is placed fully in its casing, and the motor closure is tightened. D. The casing is inserted into the motor mount tube, being careful since a vacuum is created. E. The rocket is secured with the motor retainer and the three screws F. The red safety cap is left on until the rocket is placed on the launch pad V. AGSE Setup 19
A. Equipment for Launch Rail Extension cord (200 ft) Launch pad 6 foot tube 2 launch rails (2 Allen bolts already attached) 1 Allen bolt ½ inch bolt (through angle iron and launch rail) 2 hex nuts (both on 2 inch bolt) Stand 3 legs 6 wing nuts Support angle iron Bracket for support angle iron 2 / 2 inch bolts 2 hex nuts Rocket stop Flat back 2 / 2 ½ inch bolts 2 hex nuts Blast plate Shims Ballast for stability B. One of the removable legs is attached to the stand using two wing nuts. C. The 6 foot tube is attached to the bottom launch rail using 2 inch bolts and hex nuts. D. The top launch rail and the bottom launch rail are slid together. The allen bolt is used on the top hole, and the 2 inch bolt with one hex nut in the bottom hole. E. The blast plate is placed on top of the base. F. The tube is screwed into the base, making sure that the support rail is aligned with the leg. G. The support beam is attached to the launch rail and secured with a hex nut. H. The support rail is secured to the leg of the stand with the brace. I. The rocket is placed on the rail. J. The rocket stop is put on the rail at the appropriate height K. The remaining two legs are attached to the base with wing nuts. L. The stand is leveled. VI. Igniter Insertion A. Equipment for igniter Gear motor Funnel Igniter guide cylinder 20
Igniter wire B. The funnel is placed on the AGSE structure in order to guide the igniter inside the motor. C. The gear motor will insert the igniter wire into the motor through the guide cylinder. VII. Launch procedure A. Check to see if the altimeter is turned on and has the right number of beeps and is functioning properly. B. We will place rocket onto rail. C. Activate AGSE VIII. Main steps of flight VIII. Post Flight Inspection 21
A. We check to make sure no fires were started by the rocket and launch site, or at the landing site. B. The area is examined for harmful debris. C. Must ensure that the ejection charges are spent before handling. D. Check to make sure the motor casing is still in the rocket. Safety and Failure Modes Safety Officer Safety Officer is Jacob T. Provide a Preliminary analysis of the failure modes of the proposed design of the rocket, payload integration and launch operations, including proposed and completed mitigations. The following table shows potential failure modes and their effects. The table is a representation of an available Failure Modes and Effect Analysis (FMEA) table available Quality Training Portal website. The following table contains markings within the actions taken section due to use prior to launch of the scale test flight. This table clearly aided the team towards a successful test. It should be pointed out that no paint was applied to the scale rocket and the payload onboard was just a mockup, it did not function/. Testing of the payload will be conducted in the coming months. Potential Failure Modes and Effect Analysis of the Rocket Analysis of Current 22 Analysis of Item of Function After
Item of Function Item or Function Battery Wiring Potential Failure Model High Level, altimeters fail, and parachutes never deploy Potential Effect(s) of Failure Unsafe return results in damages or injuries S e v e r i t y 10 Potential Cause Wiring from the batteries to the altimeters wiggle loose over the flight E x p e c t e d O c c u r r e n c e 5 Preventati ve Solder end of wires, and use bindings to keep the wires from wiggling during the flight Actions Taken Recommen ded Action Shake test, and addition of hot glue over joints C o m p l e ti o n A c t i o n T a k e n? N e w S e v e ri t y Friction Fit or Sheer Pins High level, if the sheer pins or friction fitting is too tight, the rocket will not separate. Unsafe deployment of parachute results in damages or injuries. 10 The friction fitting is too tight, or too many sheer pins 3 Utilize techniques to ensure the rocket is properly friction fit, and the sheer pin amount will break properly. The lifting test for friction fitting, and a blast test for sheer pins Structural Failure High level, if any of the fins or structure of the rocket fail. Energetic deconstructi on. 10 Failure to inspect gluing surfaces, 3 Supervision of gluing surfaces. Pairing of new team members with old 23
Exterior paint failure Low level, the paint could strip off due to high velocities. Striping of paint from the rocket. 1 High velocities over the rocket skin, and an uneven coat of paint 1 Even coats of paint, and consider limiting velocity of rocket Parachute events High level, if the parachutes fail or tangle. Unsafe return results in damages or injuries 10 Improper folding of parachutes, and stuffing into rocket 5 Experienced members handle parachute folding and stuffing. Pair new team members with old Quality Training Portal FMEA Resources Potential Failure Modes of the Propulsion Systems Propulsion Risks Propulsion Mitigations Status Propellant failure would cause the delay of the launch. Double check prior to launching Motor casing failure can cause the rocket to burn up or not reach anticipated height and would cause a delay of the launch. Double check the structure of the motor casing prior to installing the engine in to the Igniter failure could cause a delay in the launch because either the igniter burned out or was not connected properly to the system. If the Motor mount fail to do its intended job, the motor could fly out the top of the rocket and cause the rocket to have a rapid deconstruction mid flight Reloadable motor rocket system failure could stem from the propellant not fitting properly in to the motor casing and could fall out the back. rocket Double check it to be fully installed prior to launch and if the ignition does burn out wait the approved time before approaching the rocket to replace the igniter. Check that the mount is properly installed during construction and installation. Make sure that the propellant cells are of the right size and fit properly into the casing 24
with out sliding on launch day Potential Failures of the AGSE AGSE Failure Mitigation Status Unscheduled ignition of motor due to errant currents. Battery failure Wire damage Damage of electrical components from heat and force of blast Payload doesn t fall properly into the rocket s payload area Payload Door doesn't completely close Rocket erector failure Shielding as well as seperating the ignition system as much as possible from rest of electronics Make sure batteries are properly charged and no damage to any of their components Careful inspections of wiring will be done prior to and after launches. Make appropriate blast plates and protection enclosures Careful testing and guide system to insure payload gets properly captured Careful testing in a labratory enviroment. Keeping batteries properly charged. When testing, making sure to test a fully loaded rocket to take in account the full rocket payload and not just the safer labratory usage of an empty rocket. Launch day, and launch travel provide a lot of risks, below is a table outlining some of the risks that could be associated with those events. 25
Launch risks and their accompanying consequence Traveling failure, like a flat tire would cause the team to arrive late, thus having a late start setting up and launching the rocket Launch failure would cause the rocket to malfunction while on the pad If the incorrect weight was calculated for the rocket the designated height might not be reached along with the safety margin might not be correct Parachute failure would cause the rocket to fall uncontrollable towards the ground Dual deployment failure could cause the rocket to fall faster than desired and potentially have a hard landing Structural damage while traveling down to launch site could cause a recovery failure along with damage to the payload section Motor/Propellant problems could cause the rocket to fail to reach projected altitude or be under powered Mitigations for consequences Plan for such events and adjust travel plans in advanced if possible Conducting test launches to get all of the kinks out of the system would be beneficial Adequate test simulations and rocket components weights taken while building Double check that the recovery system on launch day and how the parachute is folded to make sure it will not tangle Double check the altimeters on launch day to make sure all wires are hooked up correctly Double check the rocket for any damages or cracks on launch day to ensure that the integrity is still there Simulations be conducted to make sure that the correct engine is use and do safety check on launch day to insure the motor is still useable Status If there was an ignition failure on launch day it would cause the rocket to stay on the pad after the go button was pushed Double check that the igniter is install properly and that all wires are hooked up while exiting the launch area 26
Wind conditions on launch day could cause the rocket to drift in dangerous direction towards a group of people If the weather is not behaving properly it could cause a launch delay or cancellation of the launch entirely Make sure that the rocket can perform as intended in different wind speeds during simulations Double check the weather while preparing the rocket so it can perform its job safely under the current conditions, If not met scrub the attempt Provide a listing of personnel hazards, and data demonstrating that Safety Hazards have been researched (such as Material Safety Data Sheets, operator s High density filler 404 West Systemsmanuals, NAR regulations), and that hazard mitigations have been addressed and mitigated. Material Safety Data Sheets The MSDS sheets and NAR High Powered Safety Code are posted on the Frozen Fury s website (http://undfrozenfury.org). The safety precautions for most of the materials were found on the West Systems Inc online company page and Science Lab.com. All MSDS sheets are found under the Safety link on the top of the website. Each team member has read and complied to all of these safety codes dictated on the MSDS sheets. Also underneath the MSDS sheets there is a link to a document for the NAR High Powered Safety Code. The MSDS will not be attached to the PDR for paper conservation. The following is a list of the documents is also available on our website regarding safety material: Ammonium Perchlorate Epoxy 105 West systems Fast hardener 205 West Systems Fiber Glass 727 West Systems NAR High Powered Safety Code Paint Example OSHA Power Tools OSHA Power Tools (HTML site) Carbon Fiber 27
Translated from the NAR website, under the high powered rocketry safety code, the following information is important both for the scale test flight and full scale test flight. Current plans do not include the use of a motor larger than a L class. Total Impulse (Newton Seconds) Motor Minimum Diameter of Cleared Area (ft.) Minimum Personnel Distance (ft.) 0 320.00 H or 50 100 200 smaller 320.01 I 50 100 200 640.00 640.01 J 50 100 200 1,280.00 1,280.01 K 75 200 300 2,560.00 2,560.01 5,120.00 L 100 300 500 From the High Power Rocket Safety Code on the NAR website. Minimum Personnel Distance (Complex Rocket) (ft.) As given by these rules, all team members were at least 100 feet away from the rocket at launch during the scale flight, and will be at least 300 feet away during the full scale test flight. This is a strict minimum distance. The team will use, at a minimum, three 100 foot long extension cords to run power from the ignition box to the rocket s motor igniter. The following list contains mitigations towards the High Powered Rocket Safety Codes on the NAR website. 1. Certification. Team mentor Tim Y., are certified within the NAR. At least one of them will be present during each and every one of our flights. Tim Y. will handle obtaining the motors for us, as well as assisting in their construction. 2. Materials. I will use only lightweight materials such as paper, wood, rubber, plastic, fiberglass, or when necessary ductile metal, for the construction of my rocket. Our rocket will be constructed of craft phenolic tubing with birch plywood fins. The only metal present will be in the form of small 28
rods, bolts and other small hardware. 3. Motors. The Aerotech K513 motor we will use in our rocket was also used last year. Proper safety will be observed by our team in regards to the motor, supervised by returning team members who handled the motor last year. A mentor will be present during all motor handling phases. 4. Ignition System. Our rocket ignition systems will not be active until it has arrived at the launch site and is adequately prepared for flight. The electric igniter provided with the motor will be the only igniter type used. Misfires. The NAR members present will ensure that the misfire guidelines are followed, as well as the team leaders to ensure that all team members and spectators in the area understand the dangers and will not approach the rocket for any means. 5. Launch Safety. The team will ensure all individuals present at a launch know the dangers present and will treat each flight attempt as a heads up flight. Meaning that, during the countdown and flight, someone will direct everyone to keep an eye on the rocket, and be alert for its descent back to the frozen fields of North Dakota. At least a five second count down will be used, but history of our past flights dictated at least a ten second count down. 6. Launcher. Our rocket will be launched vertically, and we will take necessary precautions if wind speed will affect our launch. We have a steel blast shield to protect the ground from rocket exhaust. Dry grass around our launch pad will be sufficiently cleared away. The rail is long enough, and has been simulated, to ensure the rocket reaches stable flight before exiting. 7. Size. The motor we will use has 2060 N of impulse. Our rocket will weigh 17.8 pounds, well below one third of the 201 pound thrust the motor will provide. 8. Flight Safety. Tim Y. has details on our FAA altitude clearance. We will refrain from launching in high winds or cloudy conditions. There remains many flight paths around Grand Forks due to the UND being a large aviation school. A Waiver and/or NOTAM will be submitted prior to flight to ensure all aviation matters are directed away from our area. 9. Launch Site. 29
Our launch site is of an adequate size for our planned altitude. 10. Launcher Location. Our launch site is 38 miles West of Grand Forks, ND. This location provides an adequate amount of space to satisfy minimum distance requirements. The agricultural area west of Grand Forks provides miles of flat, baron land. 11. Recovery System. We will use a 12 inch parachute for drogue, and a 86 inch with a 12 inch spill hole main parachute in order to ensure rocket recovery. The main parachute and drogue parachute will both be placed in flame retardant Nomex bags. 12. Recovery Safety. Power lines are scarce in the vicinity of our launch site, but we will refrain from recovering it should it happen to land in a dangerous location such as up a tree or tangled in power lines. If such an event happens, the local power company will be notified. Environmental concerns Environmental concerns and their explanations. Dissolution of rocket fuel into open water causes contamination of water source. Mitigations Careful planning of launch locations and recovery area. Status Fume inhalation of hazardous fumes due to proximity to rocket. Ignition produces sparks capable of setting fire to dry grass and other flammable material. Upon recovery, ground destruction may be discovered, such as loose rocket propellant. Potential hazard to wildlife if small rocket pieces are ingested. 30 Observe proper distances for spectators and keep minimum crew around rocket. Keep flammable material away from rocket and ensure the launch rail is metal. Prior to launch, all rocket components will be checked so that all materials are secured and contained to minimize potential ground damage. Team will function as cleanup crew at impact
Rocket ash can have hazardous effects on the ground below the launch pad. and launch site to ensure all rocket parts are recovered. An adequate blast shield will be used and when clean up occurs proper disposal of the cleaning materials will take place. Electrical Charateristics of Arduino Reference Schematic: 31
Preliminary integration plan The arduino ATmega2560 will be the base of our design. Everything else will be built off of this board. The data logger shield was designed to plug into the arduino duemilanove thus we will not be able to plug it directly into the ATmega so we will be using a separate development board for this. The development board will allow us the freedom to play with the configuration and construct any circuit as necessary. AGSE Concept Features and Definition Creativity and Originality We have decided to build the AGSE based upon an Arduino controller board. As this board is an open source prototyping platform a multitude of projects have already been completed and documented using this board. As our team does not have a background in embedded systems development this will make the design and development of the AGSE more feasible through making the research much easier. With this board we will be using sensors of different output forms. The creativity and originality of this project lies in its uniqueness as this project has not yet been built nor documented using this platform. All of our hardware organization will be unique to this project as will our code that will be developed by the team. Uniqueness or Significance In this project we aim to develop a hardware structure that is most suitable for this project s given requirements. This typical sensor environment has not yet been implemented on an Arduino platform. We will be documenting all of the steps that we take to build this payload and add to the vast amount of documentation available on the open source Arduino platform. Although we will be using this documentation to learn how to log data and read individual sensor values we will have to configure the device into an operable payload using the knowledge we have acquired from research. This unique project is significant for a couple of reasons. One, it will take a large amount of research from the team, adding to our amount of knowledge on hardware organization and coding. Second, it will add to the amount of documentation available on the Arduino, providing aid in the design of autonomous systems. Suitable Level of Challenge 32
Diving into this project, this team has very little experience with hardware organization and software development. By the end of this design the members of the team involved with the payload will have to exercise both of the skills fluently. As our design is completely unique we will have to conduct research and perform tests. Throughout this process we will have to focus on the many different aspects of design efficiency. This constitutes developing a payload that is small, light, and consumes very little power. These variables will be depending on our ability to design and code. With our limited background using these technologies, researching and integrating these technologies will prove to be a difficult task. AGSE Objectives The overall objection of the AGSE is to get the rocket ready for launch. This will be done by four systems of the rocket. The first system will capture the payload and release it into the rocket. The second will secure the payload inside the rocket and close the payload bay door. The third system will lift the rocket s rail to an 85 degree angle from the horizontal. The fourth system will insert the ignition into the rocket. AGSE Success Criteria Our AGSE will be found successful if every system works as planned and without error or damage. It will also be found successful if every process before launch happens in our time allowed. Experimental logic, approach, and method of investigation Our method of investigation will be experiment. We will develop our four different systems, payload retrieval and insertion, payload bay closure, rocket erection, and ignition insertion, and test them individually. After each is found to function properly we will test them in sequence. As doing this does not consume resources we can repeat and fine tune without repercussion. Test and measurement, variables, and controls Our test and measurements for launching will be done mostly on computers. As for the AGSE we will have to test by intelligent design proceeded by trial and error. Preliminary analysis of the failure modes of the proposed design of the rocket, AGSE integration, and launch operations, including proposed and completed mitigations The AGSE has three systems where failure could occur. Mechanical failure of components could happen to each system. To counter this, we must thorough inspection of all the components to make sure they are not damaged and will work properly in the future. Electrical components could fail in each system due to 33
damage from the blast. We must make sure our electrical components will be properly protected from this type of damage. Listing of personnel hazards and data demonstrating that safety hazards have been researched, such as material safety data sheets, operator s manuals, and NAR regulations, and that hazard mitigations have been addressed and enacted Environmental Concerns Explosion of the rocket, which would lead to the batteries on board to be exposed to the environment, would be a form of dropping chemical waste. If the batteries were to explode as well, their contents would have some effect on the environment such as lead, mercury, and cadmium which can lead to toxic metal pollution found in some types of batteries. Other than our batteries, the payload is environmentally friendly. ACTIVITY PLAN A. Timeline Activity Plan #1 Month Day(s) Task Item Status September 11 Request for Proposal (RFP) Complete October 6 Electronic copy of proposal submitted Complete October 17 Awarded Proposals announced Complete October 31 Website released Complete November 5 Preliminary Design Review (PDR) Complete November 12 UND Physics Day Incomplete November 13 21 Scale Rocket Construction Incomplete November 22 Scale Launch Incomplete November 27 30 Thanksgiving Break Incomplete December 15 19 Exams Incomplete 34
December 20 Start of Winter Break Incomplete January 12 Start of Second Semester Incomplete January 16 Critcal Design Review (CDR) due Incomplete January 17 Start Rocket Construction Incomplete January 21 31 CDR Teleconferences Incomplete February 1 4 CDR Teleconferences Incomplete March 16 Flight Readiness Review Report (FRR) Incomplete March 16 20 Spring Break Incomplete March 18 27 FRR video teleconferences Incomplete March 28 Finish Construction of Rocket and AGSE Incomplete April 1 6 Final Preparations Incomplete April 7 Travel to Huntsville, AL Incomplete April 7 Launch Readiness Review (LRR) Incomplete April 8 9 Hardware and Safety Checks Incomplete April 10 Launch Day Incomplete April 12 Back up Launch Day Incomplete April 29 Post Launch Assessment Review (PLAR). Incomplete May 11 Winning Team announced Incomplete B. Budget Expense Quantity Price per Unit Travel 2 $1,500.00 $3,000.00 35
Lodging April 12 18 2014 35 $85.00 $2,975.00 Rocket Supplies 5.5in Fiberglass Air Tube 2 $142.00 $284.00 Centering Ring 3 $7.00 $21.00 Motor Mount Tube 1 $14.00 $14.00 Nose Cone 1 $50.00 $50.00 SeifflyTube 2 $10.00 $20.00 Tube Coupler 2 $8.25 $16.50 Parachute 84 in 1 $90.00 $90.00 Parachute 44 in 1 $52.00 $52.00 Drogue 22 in 1 $18.00 $18.00 1000 Series Rail Beads 2 $2.65 $5.30 Shockcord (per yard) 6 $1.50 $9.00 Motor 4 $113.00 $452.00 Casing 1 $250.00 $250.00 Scale Rocket Kit 1 $78.00 $78.00 PerfectFlite Alitm. 2 $100.00 $200.00 Subcost $1,559.80 AGSE Arduino Mega 2560 3 $65.00 $195.00 Xbee 900 Pro 1 $150.00 $150.00 Xbee 900 Adapter Board 2 $10.00 $20.00 Data Logger Sheild 1 $20.00 $20.00 GPS Module 1 $60.00 $60.00 Box Iron 6 $50.00 $300.00 Rocket Lifting Acuator 1 $200.00 $200.00 Linear Slider 1 $120.00 $120.00 Robotic Claw 2 $12.00 $24.00 Ignitor Lifting Acuator 2 $12.00 $24.00 36
Nuts 20 $0.25 $5.00 Washer 20 $0.25 $5.00 Eye Bolts 4 $1.50 $6.00 Xacto Knife 1 $2.00 $2.00 Batteries 6 $5.00 $30.00 Paint 1 $70.00 $70.00 $1,231.00 Total $8,765.80 C. Educational Engagement The University of North Dakota Physics department holds an annual Physics Day where prospective physics students from area high schools are brought in and are given professor led activities and presentations relating to various areas of physics. The date of this event is November 12th. This will be an Indirect Interaction educational engagement. We expect close to 200 students. As a team, we will give a short presentation on rocketry and UND s involvment in the current NASA USLI event for this year. The UND Physics and Astronomy Department also hold a monthly astronomy talk open to the public. The talk is an hour long and is aimed at a general audience. We are also in contact with the lead of the scheduling for the talks. A rough estimate of the date would be the first Monday of January or February. A rough outline of the talk would include some of the history of UND s involvement in the NASA USLI, the basic physics and science involved in rocketry, and finally the current USLI project. The average attendance for these talks is 30 50 students and other interested parties. We have been in contact with a local high school interested in us mentoring their rocket team. No dates have been set, but their rocket team is likely to visit the university. This would allow our team to have a more in depth discussion of rocketry. We also plan to contact local elementary schools to see if we can attend and give presentations relating to rocketry. Possible examples include water rockets or the aforementioned alka seltzer rockets. 37
CONCULSION The Frozen Fury Team s Participation in the 2014 2015 USLI Competition has started off great. New members are energized and eager to work toward the ultimate competition goal and have been extremely involved in meetings and outreach activities conducted this semester. Already Frozen Fury has begun designing the AGSE components, accomplishing milestone goals, and planning community involvement and education early on in the competition. However, components of the scale rockets have yet to arrive in the shop so construction on the scale rocket is currently at a stand still. Luckily, Frozen Fury has taken this as an opportunity to complete other tasks such as preparing for the Physics Day presentation. 38