Flight Readiness Review University of Alabama in Huntsville Charger - - PowerPoint PPT Presentation
NASA USLI Flight Readiness Review University of Alabama in Huntsville Charger Rocket Works March 13, 2019 Agenda Introductions and Team Overview Mission Objectives Changes Since CDR Vehicle Overview Payload Overview
University of Alabama in Huntsville Charger Rocket Works March 13, 2019
Introductions and Team Overview Mission Objectives Changes Since CDR Vehicle Overview Payload Overview Program Management Safety Testing and Verification Outreach Budget
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Zachary Ruta, Program Manager Hope Cash, Safety Officer Marcus Shelton, Chief Engineer William Hankins, Vehicle Lead Colton Connor, Payload Lead Tanner Schmitt, Deputy Safety Officer Brooklyn Kirkwood, Vehicle Safety Lead Connor Gisburne, Payload Safety Lead Dr. David Lineberry, Faculty Advisor Jason Winningham, NAR/TRA Mentor, Level III Certified Bao Ha, Graduate Student Teaching Assistant
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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.
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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, and launches of hardware using in-depth analysis and written procedures and checklists. Outreach: The CRW team will meet a minimum of 200 students through hands-
diverse groups.
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Parameter Value Vehicle Length 124in Body Tube Diameter 6in Vehicle Weight 50.095lb Motor Selection L1420R Predicted Apogee 4982ft
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Pre-Launch Launch
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Drogue Deployment at Apogee Main Deployment
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Landing
Rocket assembled Rocket placed on pad Drogue deployment charge at apogee Backup drogue deployment charge at apogee plus 1 sec Motor ignited Vehicle accelerates Main parachute deployment at 600 ft AGL Backup main deployment at 550 ft AGL Payload deploys Rocket recovered
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Key Switch has been added to nose
cone such that nosecone avionics can be powered on externally Conserves battery life and ensures signal will not be lost during flight Tracker bracket redesigned to allow more mounting surface for the avionics Is now a 3D printed part 3D printed component infill increased from 25% to 35% to increase strength
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Body tube cut from 60in G12 fiberglass tube via wet-saw Metal tipped 4:1 ogive nosecone purchased from Madcow Bulkhead and key switch holes hand drilled
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Upper airframe bulkhead functions as recovery retention system and payload attachment bulkhead Drogue parachute attaches to upper airframe bulkhead via eyebolt Nosecone Bulkhead functions as nosecone avionics and payload attachment bulkhead Diameter: 6 in Aluminum thickness: 0.25 in Fixed to body tube with six #4-40 screws CNC machined from 6061-T6 Aluminum
Nosecone Bulkhead Upper Airframe Bulkhead
Coupler 13 in. long with 1 in. switch band cut from excess body tube G12 fiberglass bulkhead holes drilled using 3D jig and drill press SPST key switches used to power avionics on pad Keys not removable when system powered off Key locks printed to prevent accidental powering during transport to pad
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Cut from a 60in G12 fiberglass tube on a wet- saw Fin slots cut using plunge router Holes for bulkhead and fin can were hand drilled
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Functions as recovery retention system Main parachute attached via eyebolt Diameter: 6 in Aluminum thickness: 0.25 in Fixed to body tube with 6 #4-40 screws CNC machined from 6061-T6 Aluminum
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Fins: Adjusts CP for stability G10 fiberglass sheet Cut with wet saw Through-wall mounting Installed with eight #4-40 bolts per fin Fin Can: 3D printed in-house with PLA Fixed to airframe with eight #4-40 bolts
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Transfers force from motor CNC machined from 0.190 in. 6061-T6 Aluminum
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Load Path: Boost phase Motor case Thrust plate Body tube Coast phase Retention ring retains motor
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3D printed from ABS plastic Retained the motor during coast phase of the flight Attached to the fin can using 2 #4-40 screws
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Drogue Parachute FruityChutes CFC-18 1 in. tubular nylon, 50 ft. Terminal Velocity: 83.1 ft/s Main Parachute FruityChutes IFC-144 1 in. tubular nylon, 50 ft. Terminal Velocity: 11.2 ft/s
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Two Stratologger CF Drogue: Apogee / Apogee + 1s Main: 600 ft. / 550 ft. Inertial Measurement Unit (IMU): Features accelerometer, gyroscope, magnetometer, and pressure sensor Located in nose cone Featherweight Raven3 altimeter Records pressure (altitude), acceleration, and temperature Located in nose cone
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XBee-Pro S3B Radio Transmitter with Antenova GPS Located in nose cone Powered by CR123 lithium ion battery Used with success on previous CRW flights Transmitting frequency: 902 to 928 MHz Transmits to distances up to six miles away
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Wet Mass: 50.095 lbm Burnout Mass: 39.995 lbm Difference from CDR estimates: 2.874% Some 3D prints strengthened with greater infill percentage Added nose cone tracker and avionics assembly
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Predicted Apogee: 5012 ft. Max Velocity: 582 ft/s Max Acceleration: 249 ft/s2 Velocity off Rail: 57.6 ft/s Thrust to Weight Ratio: 6.91 Time of Flight: 99.7 s Time to Apogee: 18.4 s
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Variable Wind Speeds: 5 MPH: 5009 ft. 10 MPH: 5021 ft. 15 MPH: 5006 ft. 20 MPH: 4963 ft.
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Rocksim: 5012 ft. OpenRocket: 4963 ft. RASAero II: 4999 ft. Custom Code: 4982 ft.
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Variables: Motor Impulse (±1%) Rocket Mass (±0.25 lbf) CD Error (±0.04) Temperature (±15 oF) Wind Speed (±2 MPH) Normal Distribution Average: 4982.7 ft. 27.5% fall outside CRW Requirement 0% fall outside SLI Requirement
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CP location: 91.1 in. CG location: 77.2 in. Stability Margin: 2.25
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Vehicle Component Mass [lbm] Kinetic Energy [lbf-ft] Upper Airframe 17.56 34.20 Coupler 4.35 10.47 Lower Airframe 15.85 30.87
Vehicle Flight Demonstration: Total descent time: 80s Apogee was 5017 ft. Competition Launch: Expected descent time: 78.5s Apogee Target: 4982.7 ft.
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Total descent time: 80.0 s Drift under 20 MPH: 2340 ft. Assumes: Apogee occurs over launch pad Wind is 1D and constant Parachute opening times are considered
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February 9, 2019 at 12:37pm Mean Temperature: 42 °F Party Cloudy Winds: 9 MPH NNE Predicted Apogee: 4664 ft Aerotech L1420 used
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Apogee reached: 5017 ft Drogue deployed at apogee Main deployed at 600 ft AGL Descent velocity 83.1 ft/s under drogue 11.2 ft/s under main Drift from rail to landing: 924 ft Time to apogee: 18.3 s Time of descent: 80 s Rail to landing drift: 924 ft
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Predicted apogee was low due to inaccurate drag coefficient Raven3 accelerometer resolution was too low to accurately estimate drag coefficient Estimated drag coefficient equal to 0.375 using Rocksim
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y = 3E-05x + 34.378 R² = 0.6311 10 20 30 40 50 60 50000 100000 150000 200000 250000 300000 350000 400000
Acceleration (ft/s2) Velocity2 (ft2/s2)
1000 2000 3000 4000 5000 20 40 60 80 100 120
Altitude (ft) Time (s)
Preflight Actual
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Beacon Release
Use video feed to confirm location Send command to release beacon
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UAV Flight Vehicle Landing Pre-Flight
Wait for affirmation to deploy Check for GPS lock Check for Ground station connection Check video feedback Autonomous flight to the FEA (100 ft Ascent, flight to the GPS location of FEA) Piloted landing on to the FEA Fail safe return to last way point when communication loss
Payload Deployment
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Send command to fire black powder charges Piston: Pushes the deployment sheath and the nose cone out of the body tube Deployment sheath: Houses the UAV and unfolds to allow UAV to fly when pushed out of the body tube by piston
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Piloted flight away front the FEA
Fly away
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Mounting plates printed from PLA instead of machined aluminum UAV operates under one battery instead of two Deployment sheath has a carbon fiber beam instead of aluminum Added spring steel
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Mounting plates printed out of PLA Heat-set inserts to reduce amount of hardware PLA reduces weight compared to aluminum Act as UAV structure All electronics and brackets connect to the plates Upper mounting plate dimensions are 5.125 x 9.7 inches Lower mounting plate is 2.25 x 5.5 inches
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Bent from aluminum sheet metal Attaches to the upper mounting plate Located at the bottom of the UAV Encases the undercarriage of the UAV Houses most electronics and wiring Bracket is 2.5 x 6 inches
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Turns off UAV during vehicle flight Cuts radio transmission to the UAV Reduces power loss by UAV Normally closed switch powers on after deployment as the arm unfolds Pressing of the arm against the switch powers of the UAV
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Located on the side of the upper mounting plate Spring system is activated when UAV is deployed Arms are pulled apart when they are clear of the sheath Stopping posts align the arms for flight Spring helps lock the arms into place
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Located on the back of the UAV Beacon holder restricts horizontal movement Solenoid restricts vertical movement Solenoid fires, releasing beacon from the UAV on command
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Flight Computer Electronics Speed Controllers Beacon Release Solenoid FPV Video System Telemetry Transceiver
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Latch solenoid Externally accessible power switch Enclosed radio receiver and controller
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Mission Planner, an open source ground controls software used to establish telemetry and command the UAV A joystick mapped to throttle, pitch, roll, yaw to fly the UAV Failsafe for low battery, communication loss and GPS loss in place Easily accessible command option for landing, arming , disarming and beacon release mapped to buttons on the UAV controller (joystick) Camera link established through Ethernet connection to GrandStream encoder
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Payload Demonstrate Flight – March 9 Objective is to retain payload and deploy the UAV No plans to fly UAV off of sheath Plan to verify connection between UAV and ground station through live telemetry; this will also verify that the sheath unfolds, that the arms move to the correct position, and that the UAV receives power Plan to verify ability to command the UAV by using UAV controller to release beacon while on the sheath
Final Safety Training Additional Hazard Analysis of Environmental Concerns Updated Mitigation Verifications for Risk and Hazard Assessment UAV SOP Development for Demonstration and Testing Development and Implementation of Full Scale Launch SOP
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Wednesday, March 13, 2019
Number Training Topic Date
10/4/18 – 10/19/18 1 Basic Emergency Procedures 10/18/18 2 Black Powder Testing and Motor Safety 10/30/18 3 Outreach Safety 11/1/18 4 Sub-Scale Launch Safety 11/15/18 5 Test and Demonstration Safety 1/22/19 6 Full-Scale Launch Safety 2/7/19 7 Basic Lab Safety 2/14/19 8 UAV Safety 2/21/19 9 UAV Laws and Regulations 3/5/19
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Environment vs System Surrounding Land Weather Crowd System vs Environment Pollution/Litter Surrounding Land Airspace
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Wednesday, March 13, 2019
Vehicle UAV Sub-Scale Black Powder Demonstration Deployment Controller Demonstration Sub-Scale Launch Thrust Test Shock Cord Tensile Test Hover Demonstration Fin Can Stress Demonstration Flight Range Demonstration Kinetic Energy Drop Demonstration Deployment Ejection Demonstration Black Powder Demonstration Field Deployment and Flight Full-Scale Prep and Launch Laboratory Checklist: LiPo Battery Charging Procedure
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Section Titles Red Triangle for Immediate Safety Note PPE Reminder Sections to be Conducted in Parallel Red Procedure Note Reminder Effect of Missing a Step Signatures at Completion
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Pre-Travel Preparation Procedures At Field Procedures Upper Airframe Assembly Checklist Ejection Charge Installation Motor Installation Final Checkout Pad Checklist Nosecone Checklist Piston Checklist UAV Checklist Payload Integration Checklist Coupler Checklist Lower Airframe Assembly Checklist Recovery Checklist Drogue Installation (Upper Airframe) Main Installation (Lower Airframe) Post-Flight Checklist UAV FLIGHT OPS Final Checklist
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Post-Flight Checklist Hand Over of Operations to Payload Red Team Deployment Checklist UAV Flight Checklist Final UAV Closeout Emergency Landing Procedures
6 Vehicle Tests Recovery Charge Tests Sub Scale and Full Scale Flight Demonstrations Recovery Harness Tensile Stress Test Drogue Deployment Kinetic Energy Test 5 Deployment Tests Two Electronic Tests Payload Ejection Test Orientation Test Integrated Deployment Test 6 Payload Tests Two Electronic Component Tests One Propulsion System Thrust Test Three Flight Tests
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Test Name Description Status Outcome Subscale Recovery Charge Test Verify black powder deployment charges adequate to deploy parachutes Complete Successful Subscale Flight Test Complete Successful Full-Scale Recovery Charge Test Verify black powder deployment charges adequate to deploy parachutes Complete Successful Recovery Harness Stress Test Determine if the shock chord will maintain structure at flight loading Complete Successful Drogue Deployment Drop Test Determine if deployment system shear pins remain intact during flight loading Complete Successful Fin Can Stress Test Determine if flight forces would cause damage to removable fin can Complete Successful
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Test Name Description Status Outcome Deployment Electronics Test Verify deployment electronics function as commanded. Complete Successful E-Match Deployment Test Verify deployment electronics successfully ignite e-match. Complete Successful Deployment Black Powder Test Verify deployment black powder charge can successfully deploy dummy mass Incomplete Deployment Orientation Testing Verify sheath can orient payload
a variety
landing
Incomplete Integrated Deployment Test Test deployment ejection and payload orientation with payload. Incomplete
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Test Name Description Status Outcome FPV Test Test image quality, transmission range of FPV Camera. Complete Successful Telemetry Range Test Verify telemetry transmits at required distances Complete Successful Integrated Propulsion Test Test thrust level of payload in its flight configuration Partially Complete Partially Successful Flight Test Test tethered and free flight of vehicle Incomplete Flight Endurance Test Ensure payload has sufficient power to meet requirements for flight. Incomplete Flight Range Testing Ensure payload can fly required distance with sufficient battery. Incomplete
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Tested Deployment Ejection System Stepped up charges from 0.5 to 1 to 1.5 to 2.25 grams of black powder Ejected the deployment sheath fully, but caused damage to deployment system
Wednesday, March 13, 2019 Requirement Number Requirement Description Compliance Verification Plan Verification Status
NASA-5.5 Teams will abide by all rules set forth by the FAA. All applicable FAA regulations are accessible to the
responsible for ensuring CRW is in compliance with all applicable FAA regulations. Lists of the applicable FAA regulations are available to the team on the CRW online sharing site. Team Leadership ensures all applicable FAA regulations have been considered when in the design phase of the project. Inspection complete UAH-V-01 The vehicle shall reach an apogee of 4800 feet within ± 250 feet Simulations were used to predict an achieved altitude of 4806 feet. The subcale test flight was used to refine the simulations. Analysis The team will use simulations and hand calculations to confirm that vehicle will reach the required height. Complete The simulations predict the launch vehicle will reach 4806 feet. UAH-V-02 There shall be redundant, increasing black powder charges in the event of initial recovery system deployment failure. Multiple increasingly powerful black powder charges will be installed in the recovery system. Analysis The launch vehicle will incorporate redundant black powder charges. Incomplete The subscale rocket incorporated redundant black powder charges. The full-scale rocket is awaiting assemblly.
Requirement Verification & Compliance
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Verified using the method below Validated through testing, demonstration, analysis, or inspection Example displayed below
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Event Date Status: Purpose Anticipated Number of Individuals
High School
Completed Present Rocketry Basics 37 Girls Science…
Completed Present about Friction and Rocketry Basics 166 First Lego League
Completed Interaction with parents and students 72 Interactive Rocketry at Lexington High School
Completed Present Rocketry Basics 174 Interactive Rocketry at Elkhorn Crossing School
Completed Present Rocketry Basics 147 Eagle River High School
Completed Interaction with Students 26 Canyon Crest Academy
Completed Engineering Design Activity 29 Science Olympiad
Completed Interaction with students 56 UAH’s Take Your Daughters …
Completed Rocketry Basics Activity 90 Hewitt Trussville High School
Completed Present rocketry basics & Open Rocket 212 Ramsay High School
Planned Present rocketry basics 75 Total Impacted 1,084
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Funding sources have not changed since CDR New funding status displayed to the right $550.00 refund to UAH USLI Foundation
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Wednesday, March 13, 2019
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Deployment Re-Testing
March 07 (Huntsville, AL)
Hover Test
March 07 (Huntsville, AL)
Payload Demonstration Flight
March 09 (Huntsville, AL)
Remaining Flight Testing
March 11 – March 15
Test Name Update (12 March, 2019) Deployment Black Powder Test Added 1 inch joint reinforcement to add surface area of epoxy bond between piston bulkhead and piston
powder charge. Issues with solenoid, investigating causes. Deployment Orientation Testing Deployment testing has been
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Test Name Update (12 March, 2019) Integrated Propulsion Test Test thrust level of payload in its flight configuration Flight Test Tethered flight testing has begun. UAV has adequate thrust to lift off. Problems with commanded take off has prevented sustained hover.
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