Illinois Space Society Flight Readiness Review University of - - PowerPoint PPT Presentation

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Illinois Space Society Flight Readiness Review University of - - PowerPoint PPT Presentation

Aug 26, 2022 345 likes •790 views

Illinois Space Society Flight Readiness Review University of Illinois Urbana-Champaign NASA Student Launch 2015-2016 March 30, 2016 Team Managers Project Manager: Ian Charter Structures and Recovery Manager: Stephen Vrkljan AGSE Manger:

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SLIDE 1

Illinois Space Society Flight Readiness Review

University of Illinois Urbana-Champaign NASA Student Launch 2015-2016 March 30, 2016

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SLIDE 2

Team Managers

Project Manager: Ian Charter Structures and Recovery Manager: Stephen Vrkljan AGSE Manger: Benjamin Collins Safety Officer: Andrew Koehler

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SLIDE 3

System Overview

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SLIDE 4

Vehicle Criteria

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SLIDE 5

Vehicle Dimensions

  • Overall vehicle length: 90.5”
  • Nose cone length: 19.75”
  • Shoulder: 3.25”
  • Length of parachute compartments:
  • Drogue: 13”
  • Main: 16”
  • Booster system length: 40.75”
  • Booster body tube length: 40.25”
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SLIDE 6

Vehicle Dimensions

  • Upper airframe body length: 26.1”
  • Airframe tubing OD: 4.014”
  • Coupler: 15.5”
  • Coupler tube: 15"
  • Switch band: 7.1”
  • Shoulder: 3.9”
  • Exterior Payload Hole: 6”L X 2”W
  • Interior Payload Hole: 6”L X 1.5”W
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SLIDE 7

Booster Subsystem

  • Includes:
  • Motor, fin, and rail button subsystems
  • Blue Tube construction
  • 40.75” length, 4.014” outer diameter
  • Functionality:
  • Ascent stage of flight
  • Houses motor assembly
  • Mounting point for rail buttons
  • Fins constructed of fiberglass create stability
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SLIDE 8

Motor Selection and Justification

Motor: Aerotech K1000T-P

  • Highly reputable
  • Team experience
  • Quickly reaches maximum thrust
  • Rail exit velocity of 74.5 ft/s
  • Meets target altitude
  • Thrust to weight: 10.69
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SLIDE 9

Motor Subsystem cont.

  • Centering Rings
  • Ensures motor mount tube and casing are centered
  • Three rings composed of plywood
  • Motor Retainer
  • High strength aluminum
  • Prevents motor from moving forward or aft during flight
  • Employs a body and screw cap design
  • Permanently affixed to lower centering ring
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SLIDE 10

Fin Subsystem

  • Fins:
  • Provides aerodynamic restoring force
  • 3 trapezoidal fins spaced 120 degrees apart
  • Fiberglass construction
  • Root chord: 11.8”
  • Tip chord: 6.25”
  • Height: 5.25”
  • Sweep Length: 4.5”
  • Thickness: 0.25”
  • Attached between centering rings
  • Fin tab height of 0.457”
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SLIDE 11

Rail Button Subsystem

  • Rail Buttons:
  • Holds vehicle to rail during first stage of flight
  • 1515 standard rail buttons
  • Designed for a 1.5” slotted rail
  • Secured to vehicle’s centering rings
  • Mounted via a plywood block with T-nut for

removability

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SLIDE 12

Recovery Subsystem

  • Includes:
  • Parachutes (main and drogue)
  • Parachute ejection charges
  • Attachment hardware
  • Avionics bay with altimeters
  • 1 Telemetrum & 1 Stratologger
  • Functionality:
  • Most important for safety of flight
  • Must properly deploy both parachutes
  • Armed through switches on exterior of rocket
  • Isolated environment for recovery electronics
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SLIDE 13

Recovery Subsystem

  • Drogue Parachute
  • Fruity Chutes 15” elliptical parachute
  • Deployed at apogee
  • Backup 2 seconds after
  • Stowed in booster tube
  • Main Parachute
  • Iris Ultra 60” Parachute
  • Deployed at 550’ AGL
  • Backup at 450’ AGL
  • Stowed in upper airframe
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SLIDE 14

Robustness of Recovery Subsystem

  • Includes:
  • Zinc Plated U-bolt attachments
  • Steel quick links
  • 0.5”, tubular, Kevlar shock cords (520,000 psi)
  • Ripstop nylon parachutes
  • Functionality:
  • U-bolt to withstand loadings
  • Quick links sealed with threaded cap for robust sealing
  • Safely return all components with less than 75 ft-lbf of KE upon impact
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SLIDE 15

Payload Containment

  • Payload will be attached to hatch door and placed on rocket
  • Hatch will be guided and held via 4 side magnets
  • Mortice latches will lock hatch into place
  • Thin tab and holes will be added to allow for removal
  • Payload section isolated from rest of coupler
  • No damage in unlikely event gripper loses payload
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SLIDE 16

Upper Airframe Subsystem

  • Contains main parachute and main

parachute shock cord during flight

  • Polypropylene plastic nosecone
  • Lightweight
  • Aerodynamic ogive shape
  • Team experience with material
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SLIDE 17

Test Plans and Procedures

  • Dimensions and weights verified on arrival of components
  • Components and hardware inspected for quality and manually load tested
  • Electronics and connections tested and inspected
  • Parachute pull test
  • Hatch door lock mechanisms will be tested for durability and functionality
  • Integration with AGSE system
  • Loading vehicle on rail, inserting hatch, erecting launch pad, and inserting igniter
  • Full scale test flight
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SLIDE 18

Staged Recovery System Testing Plan

  • Ejection charges and parachutes loaded in the same manner as on launch day
  • Ballast mass used to replace fragile components
  • Setup to allow remote deploy: wire 

E-match  remote firing system

  • Shear pins determined by actual weight and predicted accelerations
  • Electronic testing: power lifetime, functionality, and interference
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SLIDE 19

Ejection Charge and Shear Pin Testing

  • 1. Number of shear pins chosen based on expected forces
  • 2. Safety margin of ~1.5 applied
  • 3. Then determined black powder sizes to break shear pins

Joint Grams of Black Powder (Main) Number of Shear Pins Drogue 1.5 2 Main 2 3

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SLIDE 20

Launch Vehicle Verification and Overview

  • Verification implemented through:
  • Simulations
  • Full Scale Test Flight
  • Inspection
  • Rigorous ground testing of hatch door, recovery equipment, AGSE integration
  • Overview: Combination of simulations and Hand Calculations to solve for the following
  • Velocity predictions
  • Altitude verifications
  • Kinetic energy predictions
  • Drift
  • Descent rates
  • Launch rail exit velocity
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SLIDE 21

Launch Vehicle Verification: Mass Statement

  • Ballast added following construction
  • Total mass predicted with component breakdown
  • Using manufacturer specs. or prior

measurements

  • Mass prediction: 22.51lbs
  • ~1lb below CDR design mass
  • Limited future mass growth

Mass Breakdown: Booster: 13.3 lbs Coupler: 4.7 lbs Upper Airframe: 3.5 lbs Total Mass: 21.5 lbs

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SLIDE 22

Static Stability Margin cont.

Stability Margin: (Cp-Cg)/D

  • Recommended: 2-2.5
  • <1, Under stable
  • >>2, Over stable
  • Constructed Value: 2.04 Calibers

Locations:

  • Marked on Booster Tube
  • Cp: 71.3” from nosecone
  • Cg: 63.1” from nosecone
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SLIDE 23

Launch Vehicle Verification: Flight Profile

  • Simulated at average wind speed (10 mph)

Predicted Apogees:

  • OpenRocket: 5,360 ft.
  • Custom Sim: 5,370 ft.
  • Wind speed negligibly affects apogee
  • Simulations agree on a time to apogee of

17.3 s

  • Drag parameters adjusted to increase

accuracy

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SLIDE 24

Full Scale Test Flight

  • Completed March 18th
  • Flew fully loaded vehicle without operational hatch
  • Upward stability was optimal
  • Apogee at 5472ft
  • Recovery Events occurred as designed
  • Used 20” Drogue for test flight
  • Iris Ultra took a few seconds to fully deploy

Photo taken by Greg Smith, CIA

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SLIDE 25

Full Scale Test Flight Results

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SLIDE 26

Full Scale Test Flight Results

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SLIDE 27

Full Scale Test Flight Results

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SLIDE 28

Main Deployment

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SLIDE 29

Launch Vehicle Verification: Kinetic Energy

Test Flight Kinetic Energy Upon Landing:

  • No vehicle section is expected to approach 75 ft-lbf of kinetic energy

Booster 61.2 ft*lbf Coupler 29.2 ft*lbf Upper Airframe 21.6 ft*lbf Terminal Descent Rates: Drogue (safe under 100 ft/s): Simulated (15”): 91.6 ft/s Hand Calculation (15”): 88.3 ft/s Test Flight (20”): 80 ft/s Main (safe between 10-25 ft/s): Simulated: 18.7 ft/s Hand Calculation: 18.4 ft/s Test Flight: 20 ft/s

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SLIDE 30

Launch Vehicle Verification: Drift

Wind Speed [mph] Open Rocket Prediction [ft] 7 5 312.5 10 675 15 1,125 20 1,600

  • Drift predictions done with a 0 degree launch

angle as specified by NASA

  • All distances are well within 2,500 ft. limit
  • Worst case real flight scenario still results in

satisfactory drift of 2,490 ft.

  • 5 degree launch angle, along 20 mph winds
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SLIDE 31

AGSE

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SLIDE 32

Crane System

  • 2 Stepper Motors
  • 360 degree rotation
  • 4” steel turntable
  • Chain
  • 1’x1’x2’ aluminum
  • 1’x1’ square aluminum plate
  • Wooden shelf below for electronics
  • 14” reach
  • Carbon fiber makeup
  • Vertical and horizontal arms 1” square

tubes

  • Horizontal arm 20” length
  • 0.25”x2 crane rods 40” length
  • Pulley system
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SLIDE 33

Hatch and Clip

  • Electromagnet
  • Hatch door
  • Blue Tube
  • 0.03 lbs
  • PLA plastic clips
  • Magnets at corners
  • Steel strip
  • 3”x1”x0.10”
  • 0.02 lbs
  • Guide piece - arc of steel

above Blue Tube

  • 0.20 lb
  • Mortice latches
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SLIDE 34

Electromagnet

  • Requires 12 V
  • Needs to be switched
  • n and off
  • Run through relay
  • Relay controlled by

Arduino

  • 2”x1

3 8”x1”

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SLIDE 35

Rail System

  • 18” Stroke
  • 12 Volt DC Motor
  • 0.60 Inches per Second
  • Tip placed 20.1” along rail
  • Base placed 4.6” in front of the

hinge

  • 24.25” below base plate
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SLIDE 36

Rail System Cont.

  • Maximum force required 82.75 lb
  • Rest length at 28.8”
  • Extended length of 39.1”
  • Gives 5° off vertical
  • Approximate runtime of 17 seconds
  • 8’ rail of 80/20 aluminum
  • 10.8 lb
  • Center of mass (C.O.M.) 4’
  • Weight of rocket is 22.51 lb
  • Combined gives C.O.M. to be 41.6”

from the pad end of the system

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SLIDE 37

Ignition System

  • 35 lb. Force
  • 5 degree angle
  • 12 Volt DC Motor
  • 24” stroke
  • 25” light wooden rod
  • 0.60 inches per second
  • 40 second runtime
  • Guide funnel
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SLIDE 38

Electronics

  • 3 cell LiPo battery
  • 2 Stepper motors
  • Motor Controllers
  • 2 Linear Actuators
  • 2 LEDs
  • 2 Limit Switches
  • 1 Relay
  • Pause Switch
  • Master Kill Switch
  • Arduino Mega
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SLIDE 39

Electronics Cont.

  • 12 V Battery
  • 60 A
  • Idle power draws 0.25 A
  • Arduino
  • Crane operation draws 3.75 A
  • Arduino + electromagnet + stepper x2
  • Linear actuators draw 5.25 A
  • Arduino + actuator (one at a time)
  • Arduino shield allows 5 V Arduino

to power 12 V motor

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SLIDE 40

AGSE Structure

  • Volume at initial position: 157 ft3
  • Lowered height: 42.80 in
  • Raised height: 120.12 in
  • Max width: 50.90 in
  • Max length: 124.80 in
  • Estimated mass: 100.55 lbs
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SLIDE 41

AGSE Verification

  • Results of Testing
  • Securing the payload in the clip
  • Crane can hold the hatch and payload

during motion

  • Gears, chains, and belts function

properly, do not fall off

  • Rocket can be lifted by linear actuator

to correct positon

  • Estimated AGSE run time: 3 minutes
  • 2.5 minutes for crane, 17 seconds for

rail system, 36 seconds for ignitor

  • Launch pad does not tip over
  • Igniter smoothly enters motor
  • System can be paused
  • Reliable and repeatable
  • Correctly functioning

electronics

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SLIDE 42

Questions?