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: Benjamin Collins Safety Officer: Andrew Koehler
System Overview
Vehicle Criteria
Vehicle Dimensions • Overall vehicle length: 90.5” • Nose cone l ength: 19.75” - Shoulder: 3.25” • Length of parachute compartments: - Drogue: 13” - Main: 16” • Booster system l ength: 40.75” -Booster body tube l ength: 40.25”
Vehicle Dimensions • Upper airframe body l ength: 26.1” • Airframe tubing OD: 4.014” • Coupler: 15.5” -Coupler tube: 15" -Switch b and: 7.1” - Shoulder: 3.9” • Exterior Payload Hole: 6 ”L X 2 ”W • Interior Payload Hole: 6”L X 1.5”W
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
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
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
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 h eight of 0.457”
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
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
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
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
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
Upper Airframe Subsystem • Contains main parachute and main parachute shock cord during flight • Polypropylene plastic nosecone -Lightweight -Aerodynamic ogive shape -Team experience with material
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
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
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 Number of Shear Pins (Main) Drogue 1.5 2 Main 2 3
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
Launch Vehicle Verification: Mass Statement • Ballast added following construction • Total mass predicted with component breakdown Mass Breakdown: • Using manufacturer specs. or prior Booster: 13.3 lbs measurements Coupler: 4.7 lbs Upper Airframe: 3.5 lbs • Mass prediction: 22.51lbs Total Mass: 21.5 lbs • ~1lb below CDR design mass • Limited future mass growth
Static Stability Margin cont. Locations: Stability Margin: (Cp-Cg)/D • Marked on Booster Tube • Recommended: 2-2.5 • Cp : 71.3” from nosecone • <1, Under stable • Cg: 63.1” from nosecone • >>2, Over stable • Constructed Value: 2.04 Calibers
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
Full Scale Test Flight • Completed March 18 th • 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
Full Scale Test Flight Results
Full Scale Test Flight Results
Full Scale Test Flight Results
Main Deployment
Launch Vehicle Verification: Kinetic Energy Test Flight Kinetic Energy Upon Landing: Booster 61.2 ft*lbf Coupler 29.2 ft*lbf Upper Airframe 21.6 ft*lbf • No vehicle section is expected to approach 75 ft-lbf of kinetic energy Terminal Descent Rates: Main (safe between 10-25 ft/s): Drogue (safe under 100 ft/s): Simulated: 18.7 ft/s Simulated (15”) : 91.6 ft/s Hand Calculation: 18.4 ft/s Hand Calculation (15”): 88.3 ft/s Test Flight: 20 ft/s Test Flight (20”): 80 ft/s
Launch Vehicle Verification: Drift Wind Open Speed Rocket • Drift predictions done with a 0 degree launch [mph] Prediction angle as specified by NASA [ft] • All distances are well within 2,500 ft. limit 0 7 5 312.5 • Worst case real flight scenario still results in satisfactory drift of 2,490 ft. 10 675 • 5 degree launch angle, along 20 mph winds 15 1,125 20 1,600
AGSE
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
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
Electromagnet • Requires 12 V • Needs to be switched on and off • Run through relay • Relay controlled by Arduino 3 • 2”x1 8 ”x1”
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
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
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
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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