Flight Readiness Review Presentation Vanderbilt Aerospace Design - - PowerPoint PPT Presentation

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Flight Readiness Review Presentation Vanderbilt Aerospace Design - - PowerPoint PPT Presentation

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Flight Readiness Review Presentation Vanderbilt Aerospace Design Lab Vanderbilt Aerospace Design Lab: FRR 3/6/2017 Meeting Agenda Mission Overview Vehicle Design & Verification Payload Design & Verification Launch Results Ground

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Vanderbilt Aerospace Design Lab: FRR 3/6/2017

Flight Readiness Review Presentation

Vanderbilt Aerospace Design Lab

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Vanderbilt Aerospace Design Lab: FRR 3/6/2017

Meeting Agenda

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Conclusion Project Plan Mission Overview Vehicle Design & Verification Payload Design & Verification Launch Results Ground Based Testing

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Mission Overview

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Vehicle Objectives

  • Reach desired apogee with

minimal overshoot

  • Recover flight vehicle

Payload Objectives

  • Perform roll induction via cold

gas thruster actuation

○ Achieve 4π radians of rotation ○ Halt all rolling motion for remainder

  • f flight
  • Develop roll control system

algorithms

○ Utilize ground-based testing

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CDR Questions

What will be done to increase thrust?

  • Tank pressure increased to combat inherent regulator droop
  • Purchased higher flow regulator to further combat droop

Late parachute time for subscale vehicle

  • Full scale design offers improved avionics bay and parachute storage
  • Drogue deployment time at 1 second post apogee, 2 second backup

Solenoid Factor of Safety

  • Detailed description of solenoid needs and waiver request can be seen in

FRR appendix

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Meeting Agenda

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Mission Overview Vehicle Design & Verification Payload Design & Verification Launch Results Conclusion Project Plan Ground Based Testing

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Vehicle Overview

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Full Scale Properties Value at CDR Current Value Mass 30.3 lb 34.0 lb Length 94.75” 99” Center of Gravity 50.4” 52.2” Center of Pressure 62.3” 65.6” Static Stability Margin at Exit 2.29 2.43

Launch Vehicle Weight By Section

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Vehicle Sections

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Kinetic Energy and Stability Information

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Component Weight (lb) Landing Energy (ft-lb) Nosecone/Payload 14.75 (14.0 dry) 49.6 Avionics 7.00 24.8 Tail 12.25 (9.16 dry) 32.5 CP 65.6” from nose CG 52.2” from nose Static Stability Margin = 2.43 (launch pad)

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Vanderbilt Aerospace Design Lab: FRR 3/6/2017

Loki L1400

  • Burn Time: 2.0 s
  • Total Impulse: 2842.9 N-s
  • Weight: 2.540 kg
  • Max Thrust: 1906.4 N
  • Avg. Thrust: 1421.4 N

Motor Selection

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Requirements

  • Short burn time
  • Reasonable acceleration
  • Reach target altitude
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Avionics Section

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Recovery System Redundancy

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Ensure Proper Testing of Equipment

  • Altimeter Testing
  • Deployment Testing
  • Check Conditions of the Parachutes
  • Check Quality of Shock Cords
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Recovery System

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Avionics Bay Big Red Bee Radio Transmitter

Parachute Drogue Main Diameter 18” 96” Shape Elliptical Toroidal Cd 1.5 2.2 Source Fruity Chutes Fruity Chutes Deployment Altitude Apogee +1s 750 ft Descent Speed 74 fps 15.1 fps Shock Cord Length 15’, 25’ (40’) 18’, 25’, (43’) Shock Cord Material Kevlar Kevlar Kinetic Energy of Heaviest Section 500 lbf-ft 60 lbf-ft 4F Black Powder Charge Mass 1.5 grams 4.50 grams Backup Charge Mass 2.0 grams 5.00 grams Fire Retardant Blanket Nomex Nomex

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Vehicle Performance Predictions

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Flight Simulations - Vehicle Flight Analysis

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Flight Simulations - Wind Speed Effects

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Meeting Agenda

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Mission Overview Vehicle Design & Verification Payload Design & Verification Launch Results Conclusion Project Plan Ground Based Testing

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Payload Systems Overview

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Sensing - Inertial Measurement Unit (IMU) to monitor acceleration, angular velocity, and orientation Control - Custom software operating on BeagleBone Black computer to control thruster actuation Actuation - Thrusters fed by pressurized air tank to induce roll and counter roll

Cold Gas Thruster System Payload Electronics & Control Systems

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Thruster System

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Cold Gas Thrusters

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Problem Statement

  • A thrust system will be used to

induce and reverse in-flight rotations after MECO and prior to apogee

Solenoid and Thruster Nozzle

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Cold Gas Thruster System Rocket Integration

  • All payload components housed within removable forward section

○ Allows ease of assembly and 360 degree on-pad access

  • Forward section bolted to vehicle for removability and security
  • Nose cone bulkheads and foam supports air tank during flight
  • Thruster couples aligned with exhaust ports for roll actuation
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Cold Gas Thruster System Rocket Integration

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Cold Gas Thruster System Rocket Integration

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Thruster Testing

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Nozzle Thrust Test Stand Arrangement

Air Tank U-bolt Support Data Acquisition Board Load Cell Solenoid and Nozzle

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Higher Pressure Thrust Results

  • Problem - 2000 psi gave low roll performance in initial subscale launch

○ Regulator delivery pressure drops with increased flow rate ○ Leads to lower mass flow → Lower thrust obtained

  • Proposed Solution - Increase tank pressure to combat regulator droop

○ Use N2 in addition to compressed air due to high pressure supply tank availability

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Higher Pressure Thrust Results

  • Result: Increase of 1.5 N

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Tank Pressure (psi) Thrust (N) 2000 ~ 6.5 N 3000 ~ 7.5 N 4000 ~ 8.0 N

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New Regulator Purchase

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Ninja Regulator Orifice CP Regulator Orifice

  • Problem - 4000 psi only achieved 1.5 N increase

○ Regulator droop still a major factor ○ Regulator orifice limiting mass flow

  • Proposed Solution - Purchase higher flow regulator

○ Orifice comparison shown below

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New Regulator Thrust Results

  • Result: Increase of 4 N (5.5 N total)

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Pressure Regulator Thrust (N) 3000 Ninja ~ 7.5 N 4000 Ninja ~ 8.0 N 4000 Custom Products ~ 12.0 N

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Payload Electronics & Control Systems

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Payload and Control System Electronics

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VectorNav VN-100 IMU

  • 3-axis Accelerometer (± 16g)
  • 3-axis Gyroscope (± 2000 °/s)
  • 3-axis Magnetometer (± 2.5 Gauss)
  • Quaternion-based singularity-avoiding
  • utput with Kalman filtering

BeagleBone Black with PCB Shield

  • Miniature Computer
  • Many Inputs/Outputs
  • Internal/External Data Capabilities
  • WiFi Adapter
  • Custom PCB Shield

ROSMOD

  • System modeling environment

in C++

  • Visualization for system

component interactions

  • Used for all software integrated

systems

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Payload Electronics Schematic

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Power Management Data Collection and Processing Solenoid Triggering

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Payload Electronics Layout and Assembly

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IMU

  • Circuit board designed for greater in-flight reliability

○ Eliminated unnecessary potential failure points ○ Improved design of screw switch

  • Payload assembly features lighter sled and batteries
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Software Overview

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High Level Controller State Machine

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Control System Overview

Position-Based Control

  • Oscillation about rotation

setpoint

  • No steady-state error
  • Returns to setpoint after

disturbances Omega-Based Control

  • Maintain zero angular

velocity after setpoint is reached

  • Allows for steady-state error
  • Opposes disturbances

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Payload Performance Predictions

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Payload Simulations - Vehicle Roll Analysis

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Simulation Pulsing Conditions

  • Continuous thrust to roll 720°
  • Alternating thrust to hold 720° position
  • Thrusters turn off as apogee is approached
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Meeting Agenda

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Mission Overview Vehicle Design & Verification Payload Design & Verification Launch Results Conclusion Project Plan Ground Based Testing

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Full Scale Launch

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Full Scale Launch Summary

February 19, 2017: Manchester, TN

  • Successful drogue deployment
  • Successful main deployment
  • Verification of control system
  • Obtained valuable data on

natural roll

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Safety

Types of Hazard Analysis

  • Personnel Hazard Analysis
  • Propulsion/Motor Failure Modes
  • Payload/Control Failure Modes
  • Recovery System Failure Modes
  • Miscellaneous Vehicle Failures
  • Environmental Effects
  • Project Management

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Launch Operations Procedures

For each independent section:

  • Necessary Hardware
  • Assembly Procedure
  • Required Personnel/Signatures

Also included:

  • Troubleshooting
  • Post-Flight Inspection

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Altitude vs. Projection

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Ignition Delay

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Motor Output

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Elapsed Time (s) Acceleration (G’s)

  • Similar Impulse
  • Longer Burn Time
  • Motor performance below manufacturer specs
  • 4% less ≈ 300’ lower
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Increased CD from Launch Angle

CD = 0.27 → 4400’ CD = 0.40 → 4000’ Conclusion

  • High-drag launch

configuration can lead to significant apogee reduction

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Revised Projection

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Full Scale Payload Experiment

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  • 720 degree rotation obtained
  • Control system shows actuation signals sent
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Full Scale Payload Experiment

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  • Lower than expected air tank mass ejection points to natural roll
  • To verify thruster system, electronics were inspected and subscale re-launch planned
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Subscale Re-launch

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Subscale Re-Launch

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Natural Roll

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Subscale Takeaways

1. Electronics performance under high “g” conditions verified

○ Certified full scale electronics error resolved

2. Gained valuable flight data

○ Roll, pitch, yaw, and acceleration data successfully obtained ○ Data will help to refine the drag model for ground-based testing

3. Thruster actuation successful

○ Solenoid successfully actuated by electronics

4. Ability to achieve significant active displacement against natural roll verified

○ >200 degree roll against natural roll with 2800 psi ■ After ground-based thruster performance analysis, 4000 psi will be flown for full scale ○ When combined with natural roll from full scale, verifies thruster system roll capabilities

5. Additional vehicle recovery experience gained by team

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Meeting Agenda

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Mission Overview Vehicle Design & Verification Payload Design & Verification Launch Results Conclusion Project Plan Ground Based Testing

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The FRAME

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Emulate in-flight conditions

  • Freedom of motion about roll axis
  • Vertical orientation
  • Torque input to rocket to simulate in-flight

aerodynamic forces Easily reproducible testing

  • Real-time data collection and visualization
  • Robust construction to eliminate need for

calibration between tests

  • Characterization of system transfer function
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Testing Software

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Testing Flow Chart

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FRAME Integration Test: Varying Axial Flow

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FRAME Integration Test: Varying Axial Flow

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Effect of Motor-Induced Damping

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FRAME Integration Test: Control System Comparison

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FRAME Integration Test Video

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Comparison of Control Systems

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Meeting Agenda

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Mission Overview Vehicle Design & Verification Payload Design & Verification Launch Results Conclusion Project Plan Ground Based Testing

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Future Testing Plans and Procedures

The FRAME

  • Continuous testing of control system will verify its robustness under

aerodynamic disturbances

Full Scale Launch Opportunity 3/18

  • Further data acquisition regarding vehicle, payload system, and recovery
  • Testing of control system and characterization of system dynamics

Finalizing Vehicle Aesthetics

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Requirements Verification

See section 7.2 of the FRR for a complete view of verification status. Vehicle

  • Successful full scale and subscale-relaunch recovery
  • Team now has valuable experience from three successful launches
  • Lower altitude than expected - root causes analyzed and solutions in place

for March 18 and NASA SL Payload

  • Full scale launch verified robust control system
  • Subscale re-launch verified electronics with successful thruster actuation
  • Comprehensive ground-based testing and simulations verify roll capability

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Meeting Agenda

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Mission Overview Vehicle Design & Verification Payload Design & Verification Launch Results Conclusion Project Plan Ground Based Testing

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Conclusion

Designed

  • Subscale payload flight provided essential design considerations for

fullscale launch vehicle Built

  • Full list of construction procedures with detailed photos in FRR

Tested

  • FRAME allows robust testing for full characterization with low risk

READY TO FLY!

  • Excited to get to Huntsville next month and demonstrate our High Roller!

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