Flight Readiness Review University of Illinois at Urbana-Champaign - - PowerPoint PPT Presentation

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Flight Readiness Review

University of Illinois at Urbana-Champaign NASA Student Launch 2017-2018

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Overview

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Launch Vehicle Summary

Javier Brown

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Flight Profile

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Current Launch Vehicle Design

1) Ejection charge at apogee 2) Drogue deployment at apogee 3) Nose cone separation and parachute deployment at 1000 feet

Nose cone Upper body tube Coupler Booster tube

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Vehicle - Major Dimensions

• Total Length: 130’’
• Total Mass: 43.5 lb.
• Nosecone: 30’’
• Upper Airframe: 48’’
• Payload Bay: 14’’
• Avionics Coupler: 16’’
• Booster Frame: 48’’
• Outer Diameter: 6’’
• Root Chord (Fins): 12’’

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Vehicle - Mass Statement

• Mass of rocket increased due to heavier nosecone and ballast

– Heaver nosecone required ~1 lb of ballast in top centering ring for stability

Mass Breakdown Subsystem Mass (lbm) Structures 17.62 Recovery 8.32 Motor 9.32 Rover 2.02 Platform 3.42 Total 40.7

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Vehicle - Stability

• Stability @ liftoff:

2.48 calibers

• Current CP location:

97.064’’

• Static CG location:

81.974’’

• Ballast utilized just above top most centering ring to guarantee and ideally stabilized vehicle.

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Vehicle - Propulsion

Motor: L1420R-P

• Diameter: 2.95’’ (75 mm)
• Max thrust: 374 lbf
• Total impulse: 1038 lbf･s
• Burn time: 3.18 s
• T/W ratio: 8.49
• Off-rail speed: 61.4 ft/s
• ⁄

3 8’’ Aircraft grade

plywood centering rings

• RMS 75/5120 Casing

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Airframe - Recovery

• U-Bolt connections for strength
• 1/4”-20 T-nuts/Bolts for “permanent”

attachments

• Two rotary switches
• Parachutes
• Main: Iris Ultra 96”
• Drogue: Fruity Chutes Elliptical 18”
• 1/2” Tubular Kevlar shock cord
• Redundant altimeters
• 1 TeleMetrum altimeter for altitude and location

tracking

• 1 StratoLogger altimeter for altitude tracking

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Nosecone - Recovery

• U-Bolt connections for strength
• Two rotary switches
• Parachute
• Nosecone: SkyAngle 40’’

1/2” Tubular Kevlar shock cord

• Redundant altimeters
• 1 Telemetrum altimeter for altitude and

location tracking

• 1 StratoLogger altimeter for altitude

tracking

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Ejection Charges

• Number of shear pins based on section weights, accelerations, and

shear pin maximum forces

• Black powder charges calculated with pressures and forces applied

to the bulkhead

Joint Max Accelerati

• n

Mass Above Joint [lbm] Max Shear Force [lbf] # of Shear Pins Required 1 8.17g 22.92 407 4 2 32g 8.25 264 5 3 32g 10.33 331 6 Joint # of Shear Pins Diameter [in] Length [in] Area [in^2] Force [lbf] Pressure [psi] Grams of FFFFG Black Powder 1 4 5.973 21 28.02 280 9.9992 3.0 2 5 5.829 22 26.69 350 12.96 4.5 3 6 5.973 14 28.02 420 14.98 3.0

Joint and Shear Pin Properties Amount of Black Powder Needed

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Vehicle Verification Plan

• Full vehicle verification plan found in FRR
• Major verification tasks

– Verified aerodynamics and construction procedure with subscale creation and flight – Increased simulation accuracy – Small-scale and large-scale testing of components – Verified vehicle design and manufacturing during fullscale test flight

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Kinetic Energy

• Predictions determined using OpenRocket.
• Terminal Velocities

– Nosecone – 14.92 ft/s – Upper Airframe and Booster Frame 1st separation:

• Drogue – 103/85 ft/s
• Main – 14.97 ft/s
• Kinetic Energies

– Booster Frame – 50.25 ft ･lbf – Avionics Coupler – 11.67 ft ･lbf – Upper Airframe w/ Payload – 40.81 ft ･lbf – Nosecone – 14.95 ft ･lbf

• All kinetic energies are within specified threshold of 75 ft ･lbf

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Drift Predictions

• Predictions determined using OpenRocket. All predictions are well

within the stipulated threshold of 2640 ft.

Section​ Drift in 0 mph winds (ft)​ Drift in 5 mph winds (ft)​ Drift in 10 mph winds (ft)​ Drift in 15 mph winds (ft)​ Drift in 20 mph winds (ft)​ Booster and Upper Airframe​

9.3​ 590​ 1041.4​ 1614.3​ 2335.32​

Nosecone​

9.3​ 349.1​ 791.1​ 1430​ 2117​

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Computational Fluid Dynamics

• CFD performed to

verify integrity of pressure readings for nosecone altimeters

• Full 3D simulation

done with ANSYS

• Results show that

pressure at nosecone shoulder is very close to pressure along body

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Full Scale Test Flight

• Launched on February 17th, 2018 in Princeton, IL
• Launch, ascent, and descent was successful

– Ineffective deployment of nosecone parachute – Damage to nosecone shoulder and threaded rod

• Altimeters successfully reported data

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Figure of StratoLogger vs OpenRocket

• Nosecone and coupler avionics data match well

– Further proof of integrity of nosecone pressure reading

• Actual flight data
• ver-performed

compared to OpenRocket predictions

– Motor over- performance – Overestimated mass

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Full Scale Test Flight – Ground Track

• TeleMetrum GPS

location superposed

• nto Google Earth

ground image

• Drift distance of

2137 ft., which is below competition requirement of 2500 ft.

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Damages to Nosecone

• Hard impact to shoulder and

bulkhead of nosecone

• Fiberglass shoulder severely

cracked

• Protruding end of threaded rod

bent

• Bulkhead alignment to nosecone

compromised

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Damages to Body Tube

• Minor delamination on surface of

blue tube

– Caused by snow packed into section from parachute dragging section on ground

• Most fraying near rotary switch

cutout

• Slight swelling and warping near

tips

– Makes fit with nosecone slightly difficult

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Deployable Rover Payload

Ryan Noe and Destiny Fawley

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Payload Requirements

• NASA Student Launch Requirements:

– Teams will design a custom rover that will deploy from the internal structure

• f the launch vehicle.

– At landing, the team will remotely activate a trigger to deploy the rover from the rocket. – After deployment, the rover will autonomously move at least 5ft. (in any direction) from the launch vehicle. – The rover will deploy a set of solar panels once it has traveled the 5ft. Required by the competition.

• Internal Team Requirements:

– Upon landing, the orientation mechanism must be able to rotate the rover to a position in which it can properly deploy. – After the rover has deployed the solar panels, the Arduino will receive readings from the solar panels. – 5 lb. limit – 5.95” diameter x 14.5” length

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Payload Overview

Rover Orientation Mechanism

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Rover Design Iterations

Version 1 (Proposal) Version 2 (PDR) Version 3 (CDR) Final Design

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Wheel Design Iteration

• Windmill wheels
• Five point wheels

– Less jarring – Optimized grip – Improved servo mount

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Rover Overview

• Miniaturized Off-Road Remote Terrain Explorer (MORRTE)
• Consists of 3 segments attached with steel axles
• All 3D-printed components
• Each segment is specific to certain electronics

Front Segment Middle Segment Back Segment

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• 2 solar cells
• Two, five point wheels
• Two servo motors
• Servo-driven hinge
• Orientation system latching loop
• Electronics:

– SD Card Reader – Power Boost – 3.7V Li-ion Battery

Front Segment of the Rover

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Middle Segment of the Rover

• Camera and camera cover mounted
• n bridge
• 2 servo motors
• 2, 5 point wheels
• Electronics:

– Arduino Micro – MPU 6050 – HC-12

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Back Segment of the Rover

• 6V NiCd battery
• Servo connection panel
• Safety bridge
• 2 servo motors
• 2, 5 point wheels
• Orientation system latching loop

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Rover Prototyping

First Round of Prototyping Final Round of Prototyping

Prototyping Changes

• Rover segment

modifications

• Wheel modifications
• Bridge designs
• Solar cells

hinge/bridge assembly

• Camera mount

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Orientation System Overview

• System to ensure rover leaves airframe upright
• Bulkhead screwed to Upper Airframe
• Platform rotated by servo motor
• Controlled by Arduino Micro system

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Orientation System Design Iterations

Version 1 (Proposal) Version 2 (PDR) Version 3 (CDR) Final Design

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• AL6061 Bulkhead
• AL6061 Platform
• 3D-printed electronics Cover
• Aluminum Axle & Gear
• Electronics

– Arduino Micro – Continuous Rotation Servo – 2x Servo – MPU6050 9DOF Accelerometer/Gyroscope – HC-12 Transceiver Module – PowerBoost 500C – 6V Ni-Ca Battery Pack – 3.7V Li-ion Battery

Orientation System Hardware

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Orientation System Prototyping

• Early prototype: change motor speed using orientation
• Successfully used MPU6050 accelerometer data for orientation

Early prototyping changed motor speed based on breadboard

• rientation – critical to the orientation

system

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Electrical Schematics

Orientation System Schematic Rover Schematic

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Payload System Software

• Two systems activated shortly before rocket assembly
• Rover and Orientation System act semi-independently

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Rover Testing

• Successfully tested

– Ambulated from body tube – Maneuvered multiple terrains

• Over a hill
• On grass and dirt
• Regular, tile floor

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Orientation System Testing

• Successfully tested

– Orientation scheme is successful – Latches lock and unlock at the same time

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Full Scale Test Flight

• Payload system flown on full scale test flight
• Rover attached to orientation system bulkhead with Kevlar cord
• Orientation system loaded with functional code, no rover code
• Results:

– Rover survived intact – Solar panels lost upon main chute ejection – Front servo horn pulled from threads, back servo PLA arm sheared

• Rover successfully kept from falling with Kevlar cord

– Power issue prevented orientation system from properly functioning – Orientation system components intact, functional

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Payload Future Work

• Resolve orientation system power issue to ensure battery-only

functionality

• Communications code and capabilities testing
• Construct, program, and test ground station button
• Integrate on-off switch on rover and orientation system
• Demonstrate full payload functionality on second full-scale launch

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Safety

Courtney Leverenz

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Operations Procedure

• Operations Procedure Completed

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Operations Procedure Explanation

Verification (SO/A Team Lead)

Verification of Critical Operation (SO/A Team Lead) Caution of Hazard Procedure for Correct Operation

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Updates

• Environmental Concerns

– Spilt and updated

• Affects to/from project
• Verification References

– Cross-sectioned

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Questions?