NASA USLI Preliminary Design Review · 2020. 1. 22. · Vehicle: The rocket will deliver the payload to an altitude of approximately 4800 ft., descend safely and within the Mission

NASA USLI Preliminary Design Review Univers i ty of Alabama in Huntsvi l le

Charger Rocket Works

November 7 th, 2018

Agenda• Introductions and Team Overview

• Mission Objectives

• Flight Overview

• Testing Plan

• Vehicle Fabrication

• Payload Overview

• Safety

• Outreach

• Budget

•Requirements Compliance

• Questions

Friday, November 2, 2018 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS 2

Introductions• Zachary Ruta, Program Manager

• Hope Cash, Safety Officer

• Marcus Shelton, Chief Engineer

• William Hankins, Vehicle Sub-Team Lead

• Colton Connor, Payload Sub-Team Lead

• Tanner Schmitt, Deputy Safety Officer

• Jade Kirkwood, Vehicle Safety Lead

• Connor Gisburne, Payload Safety Lead

• Dr. David Lineberry, Faculty Advisor

• Mr. Jason Winningham, NAR/TRA Team Mentor, Level III Certification

• Ms. Vivian Braswell, Graduate Student Mentor


Mission Statement The objective of the Charger Rocket Works (CRW) team is to construct a safe and successful Level 2 high powered rocket with deployable unmanned air vehicle as a payload through applying engineering judgement and skills. Additionally, CRW will engage with the community in STEM education events and promoting rocketry to diverse groups.


Mission Objectives Vehicle: The rocket will deliver the payload to an altitude of approximately 4800 ft., descend safely and

within the Mission Performance Requirements set by NASA, and be recovered in a reusable state.

Payload: The payload will deploy from the rocket, fly to a target location, and drop a beacon on target zone all while meeting the desired NASA requirements for the USLI competition.

Safety: Comprehensive safety methods will be implemented in all aspects of fabrication, testing, andlaunches of hardware using in-depth analysis and written procedures and checklists.

Outreach: The CRW team will meet a minimum of 200 students through hands-on activities as per the request of NASA and will promote STEM and rocketry to diverse groups.


Team Organization


Vehicle


Vehicle Overview


Summary of Vehicle Characteristics


Parameter Value

Vehicle Length 119 in

Body Tube Diameter 6.17 in

Motor Selection L1520T-P

Major Vehicle Materials Fiberglass, Aluminum, ABS Plastic

Center of Gravity Location 69.5 in

Center of Pressure Location 82.9 in

Upper Airframe Overview


•The length of the upper body tube is 52 in

•The major inner diameter is 6 in

•The length of the nose cone is 26 in

•The payload volume is 24 in long

•The main parachute packs at the aft end of the upper airframe

•The tracker is mounted in the nose cone

Upper Airframe - Nose Cone•The nose cone is an ogive profile

•The bulkhead was designed to withstand 200 lbf

•The tracker is a custom CRW-built device

•The tracker mounts on the bulkhead inside the nose cone

•Shear pins attach the nose cone to the upper body tube


Upper Airframe - Main•The parachute shock chord will be attached to the eye bolt at the center of the upper airframe bulkhead

•The upper airframe main bulkhead was designed to withstand a pulling force on the eye bolt of 500 lbf

•The payload lies between the nosecone and main parachute bay

• The payload is allotted 24 inches of tube volume and 10 lb mass


24.00in

Avionics Coupler•Houses primary and redundant altimeters

•Black powder charge Wells for both main and drogue parachute

•Provides 6 inches of shoulder length per side of the switch band

•Eye-bolts on each bulkhead for main and drogue shock cords


Avionics Coupler


Black Powder

Charge Wells

Stainless Steel

I-Bolt

Primary and

Redundant Arming

Switches

Primary Stratologger CF

Altimeter

Primary 9V Lithium

Battery

Redundant 9V Lithium

Battery

Redundant Stratologger CF

Altimeter

Lower Airframe OverviewRequirements:

• Reach an altitude of 4,800 feet

• Maintain a stability margin of 2 calibers throughout ascent

• Houses the motor and recovery subsystems

• Removable fin can assembly


Fins and Fin Can• Fins:

• Adjust CP for stability

• G10 fiberglass sheet

• Fabricated in-house

• Fixed to fin can with 4 #4-40 bolts (each)

•Fin Can:

• Allows fins to be replaced easily

• ABS Plastic for weight and ease of fabrication

• Fabricated in-house

• Fixed to airframe with 8 #4-40 bolts

• Function as centering rings


Motor Retention and Boat-TailDesign:

• Currently an open trade

• 3D printed at UAH

• Reloadable motor casing

Load Path:

• Boost Phase

• Motor case

• Thrust plate

• Body tube

• Coast phase

• Boat-tail retains motor


Aft Bulkhead•Functions as recovery retention system

•Eyebolt attached through center hole

• Diameter: 6 in

•Aluminum thickness: 0.25 in

•Fixed to body tube with 4 #4-40 screws


Vehicle Trade Studies


Motor Trade StudyMotor Manufacturer # of Grains

Velocity off the rail

(ft/s)

Apogee

(ft)

Max Velocity

(ft/s)

Max Acceleration

(ft/s2)

Time to

Apogee

(s)

Stability off

the rail

(cal)

L820-SK CTI 3 44.1 3311 473 163 15.5 1.80

L645-GR-P CTI 3 41.9 4001 492 120 17.4 1.46

L3200 Vmax CTI 3 103 4335 643 734 15.8 2.45

L1150-P Aerotech 3 68.6 4408 584 230 16.9 1.99

L851-WH CTI 3 48.4 4566 569 163 17.8 1.56

L900DM Aerotech 4 49.5 4640 572 167 17.9 1.42

L995-RL CTI 3 61.8 4659 582 224 17.5 1.87

L800 CTI 3 54.4 4748 561 170 18 1.86

L850W Aerotech 3 56.7 4755 569 204 17.8 1.82

L1040DM-P Aerotech 4 52.5 4771 594 209 17.8 1.58

L1050-BS-P CTI 3 57.9 4846 610 211 17.8 2.05

L1720-WT-P CTI 3 74.5 4919 671 360 17.2 2.28

L1520T-P Aerotech 3 70.9 4951 654 306 17.4 2.23

L1355-SS CTI 4 65.9 5109 645 302 17.9 1.65

L1390G-P Aerotech 3 66.2 5178 662 292 17.9 1.95

L1170FJ-P Aerotech 4 61.2 5343 656 237 18.4 1.65

L1350-CS CTI 3 67.4 5817 722 276 18.8 1.93

L1420R-P Aerotech 4 66.5 6114 750 284 19.2 1.62

L1365M-P Aerotech 4 65.6 6316 749 265 19.6 1.53

L1395-BS CTI 4 68.9 6637 794 303 19.9 1.90

L2375-WT CTI 4 86 6751 867 476 19.4 2.06

L1115 CTI 4 61 6834 747 287 20.5 1.86

L2200G-18 Aerotech 4 89 6918 853 556 19.6 1.89


Selected Motor


Hardware RMS-75/3840

Single-Use/Reload/Hybrid Reloadable

Total Impulse (lbf*s)/(N*s) 835.37 / 3715.9

Propellant Weight (lbm) 4.09

Loaded Weight (lbm) 8.05

Weight After Burnout (lbm) 3.96

Maximum Thrust (lbf) 396.9

Average Thrust (lbf) 352.5

Burn Time (s) 2.64

Aerotech L1520T

Flight Profile• Maximum speed: 654 ft/s

• Maximum acceleration: 292 ft/s2

• Apogee: 4973 ft

• Time to apogee: 17.8 s


Trajectory Verification•Comparison of OpenRocket Trajectory Results vs. Self-Derived MATLAB/Simulink package.

•In-house code does not have an accurate value of drag coefficient for the rocket; testing will aid in calculating this value.

•Performs Monte Carlo Analysis


Stability Margin•Static margin of 2.23 off the rail

•Calculated using average weather and launch day conditions.

• Average wind speeds of 5-6 MPH

• 5o minimum rail angle

• Effective rail length

•Values will change as the rocket mass estimates become better.


Kinetic Energy CalculationsBody Section Mass (lbm) Kinetic Energy at Touch Down

(ft-lbf)

Upper Airframe 21.14 54.29

Coupler 2.3 5.91

Lower Airframe 10.22 26.25


• Heaviest component under main parachute is upper airframe

• All sections descend at 12.86 ft/s (slower than the necessary 15.12 ft/s)

• Set speeds will be reassessed as mass estimates are refined

Drift Analysis•Made using following assumptions:

• Apogee is over launch rail

• Horizontal wind speed is constant and uni-directional from apogee to touch down

• Parachutes are immediately opened

•Max drift with 20 MPH wind is 2493 feet


Recovery


Recovery System•Drogue:

• Deploys at apogee

• FruityChutes CFC-18 (CD = 1.5)

• Shock Cords: 50 ft in tubular nylon (½ in)

• Connected between aft bulkhead and avionics coupler

• Descent velocity: 103.8 ft/s

•Main:

• Deploys at 600 feet AGL

• FruityChutes IFC-120 (CD = 2.2)

• Shock Cords: 50 ft in tubular nylon (½ in)

• Connected between upper bulkhead and avionics coupler

• Descent velocity: 12.86 ft/s


Avionics•Two Stratologger CF altimeters

• One primary and one redundant

• Independent 9V Battery for each

• Arming key switch on coupler switch band

•Black powder terminals for both Drogue and Main deployment

•Redundant charges will be sized larger than primary


GPS Tracking• Xbee-Pro S3B radio transmitter and Antenova GPS

• Transmits between 902 to 928 MHz

• Transmits to distances up to six miles away

• Powered by single CR123 3V Lithium Ion Battery


Vehicle Fabrication•Manufacturing will be done in Johnson Research Center and UAH Machine Shop

• Body tubes fabricated on X-Winder 4 axis filament winder

• Bulkheads and fin can will be CNC machined

• Avionics fixtures and boattail will be 3D printed

• Fins will be cut from fiberglass sheet


Vehicle Testing Plan

•Black powder charge testing

•Material strength/ stress testing

•Radio frequency interference testing

•Subscale vehicle launch

•Full scale vehicle demonstration launch

•Full scale payload demonstration launch


Payload


Payload Overview .

Overall UAV Design: • Quadcopter

• Mechanically folding arms

• FPV imaging

Deployment: • Sheath design

• Unfolding UAV deployment casing


UAV Mechanical Details

Beacon release system

• Solenoid driven

• One movement release – direct descent

• Actively retained in all direction

• Offset weight of camera assembly


Deployment•Unfolded deployment sheath

•Piston ejects by use of black powder

•Bulkheads and internal vehicle body tube create axial and longitudinal retention

• Unfolding physics of deployment sheath is naturally self-orientating


UAV within Deployment•Folding arms to conserve space

•Retention system:

• Casing restricts vertical movement

• Pegs restrict horizontal movement


Airframe Dimensions


Mass Budget


Trade Study


UAV Electronics Trade Selection

Description Quantity Model/Specification

Flight computer 1 mRo PixRacer R15 32 bit flight computer

FPV camera 1 Caddx Turtle 1080p 60fps Mini HD FPV Camera w/ DVR

GPS 1 mRo GPS u-Blox Neo-M8N

Power module 1 AUAV Power Module (ACSP5) 10S-LIPO

Electronic Speed Controller 4 Airbot Wraith32 V2 BLHeli32 35A ESC

Motor 4 EMAX RS2306 2400KV Brushless Motor 4 Pieces

Battery 2 ZOP Power 11.1V 4000MAH 3S 30C Lipo Battery XT60 Plug

Video transmitter 1 Airy Mini 5848 5.8Ghz VTX

Control/telemetry transceiver 1 HKPilot Transceiver Telemetry Radio Set V2


UAV Block Diagram


Gro

un

d S

tation

Vid

eo R

ecei

ver

2 X Battery (LiPo 3s)

Electric Speed

Controllers (ESC)

Motor + Propeller

Flight Computer

Camera

GPS + Compass

Power Module

Video Transmitter

Tel

emet

ry/C

on

tro

ller

Tra

nsc

eiv

er

Tran

sceiver

11

.1V

Solenoid

5V

Power line

Data line

Legend

UAV Power BudgetComponent Voltage

(V)

Current

(A)

Power

(W)

Duty

Cycle

Supply

Efficiency

Power

Draw (W)

Flight computer 5.0 0.045 0.23 100% 90% 0.25

Camera 7.0 0.38 2.66 100% 90% 2.96

GPS 5.0 0.033 0.17 100% 90% 0.18

Transceiver 5.0 0.1 0.50 100% 90% 0.56

Video transmitter 7.0 0.56 3.94 100% 90% 4.37

Solenoid 11.1 0.25 2.78 1% 100% 0.03

Motors 11.1 50.9 564.99 100% 100% 564.99

Total weighted power draw (W) 573.34

Total battery capacity (WHr) 88.8

Run time (min) 9.29


\

UAV Link Budget (Telemetry/Command Deployment)


Dipole Antenna Dipole Antenna

RX

sensitivity

(dB)

Transmit

power

(dBm)

RX

Antenna

Gain (dB)

TX

Antenna

Gain (dB)

Link

Margin

(dB)

RX

Antenna

Loss (dB)

TX

Antenna

Loss (dB)

Maximum

free space

loss (dB)

Frequency

(GHz)

Range

(km)

-117 20 2.15 2.15 12 2 2 125.3 0.915 48

48 km

UAV Link Budget (Video Link)


RX

sensitivity

(dB)

Transmit

power

(dBm)

RX

Antenna

Gain (dB)

TX

Antenna

Gain (dB)

Link

Margin

(dB)

RX

Antenna

Loss (dB)

TX

Antenna

Loss (dB)

Maximum

free space

loss (dB)

Frequency

(GHz)

Range

(km)

-95 20 9.5 2.15 12 2 2 108.5 5.8 1.4

1.4 km

Biquad Antenna Dipole Antenna

Deployment Electrical System


Microcontroller

6V power supply

(batteries)

3.3V power supply

(buck regulator)

XB

eerad

io

Latch actuator

(solenoid)

Dual E-match firing

circuits

Arm

ing

indicato

r

Gro

und statio

n

Contro

ller

Tran

sceiver

Power line

Data line

Legend

12V power supply

(boost convertor)

Payload Propulsion Sub-System


Parameter Value

Maximum thrust (lbf) 7.49

Weight (lbf) 3.53

Thrust-to-weight ratio 2.1

Nominal throttle point (lbf) 4.19

Airspeed (mph) 30.1

Range (mi) in 20 mph headwind 1.44

Flight time (min) 9.29

Deployment Sub-System


Deployment Controller

Retention Latch

Deployment Signal Receiver

• Black powder deploys payload

• Latch secures payload until

deployment

• No transmission from radio

Deployment Piston•Redundant black powder charges

•Piston deploys complex assembly

• Payload

• Orientation sheath

• Nosecone


Payload Testing Plan


Drop Test Ejection Test Video Range TestControl/Telemetry

Range Test

PurposeTo test the durability

of the UAV structure

To test the ejection of

the payload from the

vehicle

To test the range of

the video receiver

To test the range of

the controls

Procedure

Drop the UAV from

a predetermined

height

Load the deployment

system in a body tube

and eject using black

powder

Increase the distance

between the UAV

and ground station

until connection is

lost

Increase the distance

between the UAV

and ground station

until connection is

lost

Desired Result

No damage to the

structure of the

UAV

Full ejection with no

damage to the

deployment or

payload system

Range of the video

exceeds half a mile

Range of the controls

exceeds half a mile

Payload Testing PlanFlight Endurance

TestFlight Range Test Flight Test Retention Test

Purpose

To test the time limit

of flight for the UAV

(find deviation from

presumed limit)

To test the overall

flight range of the

UAV

To test the overall

stability of flight

To test the retention

system of the

deployment system

Procedure

Continuously hover

the UAV until power

is lost

Continuously fly in a

precise circle to

calculate the overall

flight distance

Ascend the UAV,

travel a

predetermined

distance, drop the

beacon, and descend

Lock the deployment

into place, then apply

loads to test retention

Desired ResultFlight time is roughly

nine minutes

Flight distance

covers at least half a

mile

Complete overall

flight control with

working systems

Have complete

retention of the

deployment system

without failure


Key Safety Personnel•Hope Cash, Safety Officer

•Tanner Schmitt, Deputy Safety Officer

•Jade Kirkwood, Vehicle Team Safety Lead

•Connor Gisburne, Payload Team Safety Lead


Hope CashSafety Officer

Tanner SchmittDeputy Safety Officer

Jade K.Vehicle Team Safety

Lead

Connor G.Payload Team Safety

Lead

Training•17 members of the 20 person team have been Red Cross CPR/AED/First Aid certified

•Multiple safety briefings carried out through the year to ensure safety is always a priority

•Each Team member has signed Safety Pledge


Safety Training Schedule

Training Topic Date

CPR/AED/First Aid 10/4/18 – 10/19/18

Basic Emergency Procedures 10/18/18

Black Powder Testing and

Motor Safety10/30/18

Outreach Safety 11/1/18

Launch Checklists and SOPs•Safety Operating Procedures are written, planned procedures intended to guide testing and ensure safe operation throughout the course of the test

•All SOP’s must be reviewed by the Safety Officer, Red Team, and Propulsion Research Center Staff

•Launch Checklists are also made for every launch

•The Launch Checklists make sure that every step in the launch is carried out in the safest manner

•Launch Checklists must also be reviewed by the Safety Officer, Red Team, and Propulsion Research Center Staff


Hazard and Risk Assessment

•The Safety Team analyzed the various risks, hazards, and failure modes present in the Student Launch project


RAC

Probability

Level

Severity Level

1

Catastrophic

2

Critical

3

Marginal

4

Negligible

A – Highly

Probable

1A 2A 3A 4A

B – Likely 1B 2B 3B 4B

C – Moderate 1C 2C 3C 4C

D – Unlikely 1D 2D 3D 4D

E – Improbable 1E 2E 3E 4E

Severity Level

Description Criteria

1 –Catastrophic

Loss of life or permanent injury, irreparable major damage to facilities or hardware, complete project failure.

2 – Critical Severe personal injury, significant damage to hardware or facilities, significant impact on overall schedule.

3 – Marginal Minor personal injury, reparable damage to facilities or hardware, significant impact on immediate schedule.

4 – Negligible Minor personal injury, little to no damage to hardware, little impact on immediate schedule.

Next Steps•Scheduled Black Powder Test – Thursday, November 8th

•Scheduled Sub-Scale Launch – Saturday, November 10th

•Fabrication of Payload – Coming Weeks


Outreach


Past Events•Oct. 12 – Outreach at St. Francis Borgia Regional High School

• CRW Team member: Connor Gisburne

• Rocketry Basics Presentation

• Activity: Estes Rockets built and launched.

• Survey Results:

• Informative: 4.54/5

• Fun:4.69/5


Upcoming Events•Nov. 3 – Girls Science and Engineering Day

• Partnership with Propulsion Research Center Student Association & UAH Society of Women Engineers

• Activities: Stomp Rockets & CD Hovercrafts

• Anticipated number of individuals: ≈200

•Nov. 10 – UAH Society of Women Engineers

• Partnership with UAH Society of Women Engineers

• Activities: Rocketry Basics Presentation

• Anticipated number of individuals: ≈100


Future Events•December 2018: High school outreach

• CRW team members

• Activity: Estes Rockets & Rocketry Basics Presentation Presentation

•Spring 2019: Science Olympiad

• CRW team members

• Activity: Rocketry Basics Presentation

• TBA: Davis Hill Elementary School

• Activity: Propulsion and Vehicle Design

•TBA: Challenger Middle School

• Projectile Motion and Forces


Budget


Budget Summary Totals

Sub-Scale Rocket $667.92

Full-Scale Rocket $2,574.45

UAV Payload $1,328.88

STEM Outreach $400.00

15% Margin $745.69

Grand Total $5,716.93

Total Expenditures as

of PDR$667.92

Requirements Compliance Plan•Vehicle requirements will be verified primarily through testing of vehicle subsystems and the full launch vehicle

•Payload requirements will be verified by testing of the UAV systems during and after full construction and integration

•Safety requirements will be verified via Safety Briefings and the creation of Standard Operating Procedures, Launch Procedures, and Launch Checklists for all testing and launches

• Laws and Regulations are available in the CRW Safety Manual, and the CRW Safety Pledge covers the compliance of all regulations by the CRW team.


Questions


Appendix


Theoretical Recovery Drag Parachute Recovery Systems Design Manual by

Theo Knacke

Drag Coefficients do not exceed 1.0

Values specified by manufacturers are incorrectly derived

Subscale and Full Scale testing will assess the accuracy of these studies with respect to the project


Funding Sources


Documents

NASA USLI Preliminary Design Review · 2020. 1. 22. · Vehicle: The rocket will deliver the payload to an altitude of approximately 4800 ft., descend safely and within the Mission