MSD P18102: Hybrid Rocket Engine Detailed Design Review Presented - - PowerPoint PPT Presentation

MSD P18102: Hybrid Rocket Engine

Detailed Design Review

Presented by: Ryan Chojnacki • Amy Guthrie • Ozzy Castillo • Trevor Mothersell Zack Rizzolo • Tim Frey • Matthew Sisson • Doug Moyer

Agenda (w/ Approximate Time Allocations)

• Team Member Introductions (2 min)
• Project Background (8 min)
• System Overview (15 min)
• System Requirements
• System Architecture
• Thrust Classification
• Propulsion (60 min)
• Thermal (10 min)
• Feed System (20 min)
• Break (15 min)

2

• Electronics (35 min)
• Controls
• Power Distribution
• Structures (15 min
• Test Plans (25 min)
• Project Summary (15 min)
• Risk Analysis
• Budget
• Schedule
• Purchasing
• Mass and Power Allocations
• Questions and Feedback (20 min)

Total: 4 hours (1:00 - 5:00)

Team Introduction & Roles

Goals of this Review

• Validation of finalized system and subsystem level requirements
• Validation of finalized design decisions
• Verification of feasible component acquisition plan
• Validation of test plans (feasible and well designed)
• Identification of potential blind spots and/or additional risks

4

Customer: RIT Launch Initiative

• Student organization that

explores the various aspects

• f rocket design and

construction for research and competition

• Currently working on a

solid-propellant rocket to compete at 2nd Annual Spaceport America Cup in New Mexico in June 2018 (10,000 ft class)

5

Project Overview

• Develop a propulsion system to deliver a 10 lb payload to 30,000 ft to compete in 3rd Annual

Spaceport America Cup (June 2019)

• Propulsion System of choice: Chemical Hybrid Rocket Engine
• Many benefits to hybrid-propellant rocket

○ Altitude accuracy ○ Safer to handle propellants compared to solid engine ○ Less mechanical complexity than liquid rocket engine

• Assumed total vehicle weight for design: 140 lb
• Vehicle Max Diameter: 7.5 in
• Design thrust: 1300 lb
• Max total impulse: 9,209 lb-sec

6

Example Hybrid Rocket Engine Schematic:

System Overview

7

System Architecture

8

Thrust Classification

9

Thrust Classification Procedure (Thrust Curve)

10

Thrust Classification Procedure (Aerodynamics)

11

Thrust Classification Procedure (Altitude Results)

12

Rocket Specs: Wet Mass: 140 lb Dry mass: 98 lb Length: 15 ft OD: 7.5” Stability: 2.2 c Drogue: 6 ft Main: 25 ft

Thrust Classification

• Through means of fluid mechanics, monte carlos, NASA CEA, and Roger’s

Modified Barrowman equations, our thrust was classified

13

Propulsion System

14

Chamber Assembly

15

Combustion Chamber Casing

• Aluminum 6061-T6
• McMaster PN: 9056K43
• Or 5 Schedule 40 pipe from SMC Metals
• 5.5” OD, 37” Long
• Bored out to 5.00” & 5.25” IDs
• Estimated Mass
• 6-10 lbm (2.7-4.5 kg)
• Maintains a FoS of 2 up to:
• 500 psi internal pressure
• ~ 5000 °F Combustion temperature
• 327 °F (164 °C) (for thinnest wall

thickness)

16

Regression Rate Analysis - Boundary Layer Theory

17

• The engine ballistics for a hybrid rocket engine are governed by boundary layer theory
• The rate at which the solid fuel burns or regresses is governed by the boundary layer on the

surface of the fuel grain as shown below

Regression Rate Analysis

• Regression rate analysis is highly complex and has multiple dependencies as

shown below:

• The regression rate of a hybrid fuel grain in its simplest form is governed by

the following equation: Where a and n are the engine ballistic coefficients.

• From empirical results for Paraffin and N2O: a = 0.155 mm/sec, n = 0.5

18

Regression Rate Analysis

• For a cylindrical port, the regression rate changes over time which affects the

thrust developed.

○ The engine dynamics over time can be further explained by the following:

Combustion Port Radius Fuel flow rate O/F Ratio Total fuel consumed

• Using the above equations, the regression equation, and the empirical engine

ballistics coefficients, the hybrid dynamic behaviour was simulated

19

Engine Dynamic Results (Regression Rate)

20

Engine Dynamic Results (Burn Area)

21

Engine Dynamic Results (OF Ratio)

22

Engine Dynamic Results (Fuel Mass Flow Rate)

23

Fuel Grain

• Using the results from the engine

dynamics and ballistic, fuel grain was designed

• Cylindrical port (Paraffin Wax)
• Diameter margin added to account for

uncertainties

24

Volume [in^3] 376.54 Weight [lbs] 12.6 Height [in] 23.5 Outer Diameter [in] 5 Port Diameter [in] 2 L/D Ratio 4.7

Nozzle Design - PDR Review

25

Chamber Wall Phenolic Insulation Nozzle Lip Force Ring

Nozzle Design Revisions

26

Rev 2: Chamber Wall Lip Rev 3: Chamber Wall - No Lip

Nozzle Design Parameters

27

Volume [in^3] 60.51 Weight [lbs] 4.95 Height [in] 5.06 Billet Diameter [in] 5 Throat Diameter [in] 1.48 Area Ratio [-] 5.8 Exit Diameter [in] 3.56 Radius of Curvature (Converging) [in] 1.5 Rt Radius of Curvature (Diverging) [in] .382Rt

Nozzle Attachment: Threaded Retention Mechanism

• Nozzle slides in, ring screws in
• Internal threads on casing,

external threads on ring

28

Threads

Nozzle/Force Plate/Insulation Integration

29

Phenolic Insulation Combustion Chamber Casing Paraffin Fuel Grain Graphite Nozzle O-ring grooves High-temp Seal

• All layers butted-up against each
• ther
• Retaining ring will squeeze

everything into place and reduce any gaps

• High temperature seals used in

between phenolic insulation to prevent hot gasses escaping to combustion chamber walls

• Fire-Retardant High-Temperature

Silicone Rubber Sheet

• McMaster PN 1282N17

Nozzle Design - Next Steps

30

• Grade of Graphite
• We have reached out to MWI for more information of oxidation resistant grades
• Grade G330 preferred if we don’t get a recommendation
• Chosen for its very high temperature capabilities & strength
• Finishing
• Lapping or polishing preferred for smooth surface finish on interior faces of nozzle
• Weight Reduction
• Output pressure mapping from CFD analysis (StarCCM+)
• Import/map data into FEA analysis (Femap)
• Determine necessary wall thickness at elevated temperature (FoS of at least 2)

Nozzle - CFD

31

Static Pressure Volume Mesh Velocity Magnitude Temperature Exit Velocity [m/s] 2298 Exit Mach Number 6.76 Exit Mach Number (Relative) 2.25 Inlet Pressure [psi] 520 Exit Pressure [psi] 12.1 Inlet Temperature [K] 3020 Exit Temperature [K] 1429 Axial Thrust [lbf] (Sea Level) 1278

Thrust Verification - CFD

32

Thrust Verification - CFD

33

Pressure Mapping

34

Pressure Mapping

35

FEMAP → Model → Load → Map Output From Model...

Igniter Design

• Some hybrids use pyrotechnics as a thermal valve around fill tube
• Our fill tube is elsewhere
• Need igniter near injector
• Remote start
• Also needs to be timed to start hybrid engine
• Wired at top of chamber, relay controlled, with 3 external signals
• 2 physical, 1 logical
• IREC requires 2
• Considering power through

injector/chamber

• Or chamber/ground
• Loaded before grain

36

Injector Design

• Flow rate models

○ Single Phase Incompressible ○ Dyer: Non-Homogenous Non-Equilibrium Model

• Criteria

○ Deliver desired flow rate ○ Avoid backflow ○ Atomize → Vaporize

• Port Geometry, Sizing, & Layout

○ Manufacturing with drill and reamer ○ ↓D = ↑ΔP ○ Inlet fillet radius ≥ 0.14 / D → No vena contracta

37

Injector Design

38

RIT U of Toronto Mass Flow Rate 5.03 lb/s 3.57 lb/s Diameter 0.08 in 0.06 in # of Ports 33 34 ΔP 240 psi 200 psi Inlet Geometry Fillet R = 0.16 * D Square-Edged

39

Injector Design Revisions

40

Rev 0: Threaded injector. Risk of cross-threading. Costly manifold. Rev 1: Threads welded onto

• chamber. Flanged injector bulkhead.

41

Next Steps

• Select material based on:
• Heat transfer MATLAB script
• FEA
• Manufacturing and cost considerations
• CFD on injector to validate MATLAB script
• Manufacturing procedures
• Testing procedure for cold flow tests
• Combustion instability

42

Thermal

43

Thermal Insulation

• Fuel Grain Liner
• 5.25" OD, 0.125" wall thickness
• Pre/Post CC
• 5.00" OD, 0.25" wall thickness
• Material
• LE Grade Phenolic Tubing
• Has great flight history with similar teams
• Sourced from Accurate Plastics Inc.
• Injector insulation being researched

44

* insulation shown in green above

Phenolic/Chamber Heat Flux - Matlab

45

Phenolic/Chamber Heat Flux - CFD

46

Max Phenolic Temperature [K] 2708 Max Chamber Temperature [K] 2325 Max Convection Coefficient [W/m^2-K] 18705

15 Minute Break

47

BREAK WILL RESUME AT 3:10

48

49

50

51

N2O Flow Analysis

52

Parameter Imperial Metric Mass flow rate, ṁ 5.0157 lbm/s Specific Gravity 0.771 Injector Pressure 780 psi 5.3779 MPa Volumetric flow rate, Ṽ 46.7229 GPM 0.0029 m^3 Pipe Diameter, D_pipe ¾’’ Flow Velocity, v 34 ft/s 10.3422 m/s Initial Oxidizer Pressure, P 785.9866 psi 5.4192 MPa Re 2750000 (Turbulent Flow)

N2O Flow Analysis (cont.)

53

Major Loss from SS Hose 15.5 PSI Minor Losses T-Fittings 5.4 psi / T Solenoid Valve 30 psi Check Valve 38 Total Minor Loss 96 psi TOTAL LOSS 111 psi

Pressure Loss for Stainless Hose

https://www.hoseflex.com/wp-content/uploads/2014/07/Stainless-Steel-Hose.pdf

54

Oxidizer Tank Sizing

55

N2O Mass 37.25 lbm Tank Volume 0.85 ft^3 Tank ID 6.5 in Tank Internal Height 46 in Wall Thickness 0.25 in MEOP 900 psi

Nitrogen Pressurant System

Analysis based on ideal gas law, adiabatic, constant pressure through regulator

56

Volume of Tanks & N2O Tank Pressure Volume of Tanks & N2O Tank Pressure Volume and pressure of N2 tank initially

Nitrogen Pressurant System

57

Pressurant Tank

Model Number: CRPIII-161-9.0-30-T Working Pressure: 30Mpa Length: 570mm Diameter: 174mm Water Capacity: 9L Empty Weight: 5.1kg Cylinder Thread: M18*1.5

58

N2 Valve Selection

• 24 VDC
• ¼” Pipe
• 3500 psi N2
• 47 GPM

59

Regulator

Inlet Pressure: 3500-4000 psi Outlet Pressure: 900 psi

60

Feed System Support

• Can utilize an “interstage” as described previously
• Will contain cutouts for
• fill/drain ports
• power/data when testing
• Can act as a support for oxidizer tank
• Will protect feed system
• Materials and Design TBD

61

Final Equipment List

62 Component Qty Unit $ Total $ Mass [lbm] Growth Mass w/ Growth [lbm] TOTAL $4700 70 7% 77 Oxidizer Tank 1 $800.00 $800.00 28.10 10% 30.91 Pressurant Tank 1 $284.00 $284.00 11.24 10% 12.37 Gas Pressure Regulator 1 $615.00 $615.00 3.09 10% 3.40 N2 Solenoid 2 $120.00 $240.00 2.18 5% 2.29 N2O Solenoid 2 $700.00 $1,400.00 10.00 10% 11.00 Check Valve 2 $350.00 $700.00 3.09 10% 3.40 Relief Valve 3 $100.00 $300.00 9.92 10% 10.91 Stainless Steel Hose 1 $0.00 0.27 10% 0.30 Cross Fitting 2 $54.84 $109.68 0.59 5% 0.62 Tee Fitting 4 $33.16 $132.64 0.93 5% 0.97 Pressure Sensor Adapter 2 $10.98 $21.96 0.55 5% 0.58

Next Action Items

• Source N2O solenoid and check valve
• Create Simscape model of fluid flow
• Purchase valves and regulator
• Initial flow tests
• Order custom N2O tank

63

Safety Considerations

Main Concerns with N20:

• Exothermic decomposition
• Contamination reduces energy threshold
• 2 phase at standard room temperature
• N2O saturating tank and combustion chamber

64

Safety Protocols

Safety through Design

• Operating as a liquid
• Pressure relief valves
• Check valves
• High pressure drop over injector
• Use stainless steel, PTFE, and compatible grease throughout system

Safety through Procedures

• Inject N2O after ignitor has already fired
• Thorough cleaning of all tubes and tanks between
• Fill oxidizer tank at less than 20 psi/sec
• Wear goggles and gloves

65

Controls

66

Microcontroller

• Teensy 3.6 was ordered and received
• Meets basic goals:
• Large pinout
• High speed
• UART, SPI, I2C
• ADC with minimum 8 inputs
• Programming using Teensyduino add-on

for Arduino IDE

• Begun familiarizing ourselves with board and

reference manual

• Next steps: Integrating uC into test circuits

and programming functions

67

GIF demonstrating uC controlling LED

68

Controller Flowcharts

• Controller tasks have been

broken down into various functions and ISRs

• After DDR, we will be

moving to polling rather than ISRs

• Flowcharts are continually

being adjusted, refined, and detailed

• During process of creating

flow charts, also brainstorming how to program safety measures in case something goes wrong

Controls Hardware Block Diagram

69

Communication Diagrams

• Customer requirement for avionics:

RS422

• DB9 connectors and serial cables

acquired, transceiver being selected

• Packet design up to engine team

Potential designs:

○ Standard 8 bit ASCII ○ 16/32 bit data (from engine) ○ Binary commands (from FC)

• Potential framing:

○ Escape character ○ Consistent overhead byte stuffing (COBS)

• Note: Logic Shifter unnecessary with

current 3.3V Transceiver IC (Old picture)

70

Communications Circuit

71

GIF demonstrating full duplex operation

Valve Circuit

72

Not a GIF (But it works!)

Valve Circuit

Changes / Implementations:

• TVS diode opens for transients 3x the
• perating voltage.
• Diode for kickback.
• IGBT to handle high power
• Optocoupler to isolate microcontroller

from high DC and transients.

• Previous optocoupler was inverting
• utput. New optocoupler is uninverting

(high input = high output), rated for more power, and smaller.

73

Pressure Transducer and Thermocouple Circuits

74

• Pressure Transducer is read through ADC. It has an incorporated ASIC which auto-calibrates it, so a

simple op-amp seemed sufficient. Alternately, the Op Amp IC could be removed and the ADC on the Teensy could use differential inputs, if there is sufficient room for the signal lines.

• 12 bit ADC on Teensy 3.6. Analog input LSB resolution is 3.3/10^12 = 0.8mV. Transducer accuracy is

0.25% of 4V full scale = within 10mV, so the ADC should be more than sufficient.

• Thermocouple IC calibrates itself and sends data over SPI.

Sensors: Flight Configuration

• Pressure transducers (x3)
• 0 - 2000 psi range (x2)
• 0 - 5000 psi range (x1)
• 0.25% accuracy
• 5V supply voltage
• 8mA supply current
• Metri-Pack 150 Connector
• ~ $100 each
• Thermocouples (x2)
• K-type standard thermocouples
• ~ $75 for 5 pack

75

Sensors: Test Stand Configuration

• Flight configuration plus:
• Primary Load Cell
• PCB Piezotronics S-type Load Cell
• 2000 lbf capacity
• 2.4 kHz resonance frequency
• Secondary Load Cell
• TE Connectivity, 100 lbf capacity
• Accelerometers (x2)
• Considering Sparkfun breakout board
• 3-axis, +/- 2,4,8,16g, up to 3200 Hz
• Other options will be researched
• Microphone
• To be selected (or borrowed)
• Not a critical measurement

76

Power Distribution

77

Battery Sizing

• 14.8 Li-Ion battery needs to be able to

supply 7A, 114W, 14.4 Wh in worst case scenario.

• Potential Battery Selection:

○ AA Power Corp Li-Ion ○ 14.8V working voltage, 4Ah, 59Wh ○ 16.8V max, 11Vmin, 20A max ○ 5.51" x 2.0" x 1.7’, 17 oz. ○ Has integrated balance PCM (easier for us)

78

Example Components Voltage (V) Current (A) Quantity Power (W) Time Teensy 3.6 5 0.5 1 2.5 60 min TI LMV344 Op Amp 5 100u 1 500u 500 sec MAX31856MUD+ Thermocouple IC 5 1.2m 3 18m 500 sec Honeywell MLH Series Pressure Transducer 5 4m 3 60m 500 sec N2 Solenoid Valve 24 0.4 2 19.2 250 sec N2O Solenoid Valve 24 0.66 2 32 250 sec 3.3/5 Regulators 5 ~0 2 500 sec LM2588 24V Regulator 11 (Worst

case)

2.7 (Worst

case)

2 60 500 sec 7A Total 114W Total 14.4 Wh

Worst case scenario assumes: 1. The 24V regulator will be at maximum current draw the entire time. Worst case power is at low battery voltage (which should not be reached) and valves always on with maximum current draw (which will not be true), in which case an extra 2.7A of current is needed. 2. The valves will be at maximum current draw the whole time (in reality, they will only peak when turning on/off)

Battery Input Circuit

79

ADC monitors battery voltage

Battery Input Circuit

• Normally powered by DC jack and brick charger

with current sensing. If charger unavailable, unpopulated resistors can be added to charge the battery from a powers supply to the pins Vin+/Vin- (with careful supervision of battery’s PCM’s fuel gauge).

• When plug is inserted, pin 2 of DC jack is
• disconnected. Power PNP BJT Q3 is off and

IGBT is off, disconnecting the load. LED is powered.

• When plug disconnects, pin 2 connects to pin 3.

Q3’s gate is pulled to ground, opening the IGBT.

• We couldn’t find any p-type IGBTs and are
• pen to a better solution for disconnecting the

load during charging.

80

Voltage Regulators for 5V, and 3.3V

• Dedicated 3.3V regulator for

microcontroller.

• Normally closed push button to

easily power cycle uC during testing.

• The other two LDOs’ enables are

normally pulled down.

81

24V Regulator

82

24V Regulator

• Circuit has been tested in SPICE

minus the input circuit on right.

• Step-by-step start-up:

○ Input from uC (V5) turns on power BJT Q3 which turns on IGBT Q4. ○ The current limiting thermistor causes the large inductors and capacitors to slowly reach line voltage and prevents a large transient spike. ○ Later, 3.3V input from uC (V4) turns on BJT Q1 / IGBT Q2, bypassing the thermistor, and also enables the IC, causing the voltage to charge up to 24V. ○ A TVS diode could also be added, but the spike in voltage/current lasts ~1ms (a long time for a TVS).

83

Follow-Up

• Next step is to produce a PCB for the engine control.
• Major concerns / questions:

○ What is the best method for heatsinking this board if only 2 layers are available? ○ If 4 layers are available, is separating digital and analog power and ground necessary? ○ What is the best way to disconnect the load during charging? ○ What is the best way to prevent transient spikes when connecting the battery to the large RCL circuit of the 24V regulator? ○ Vge is a concern on the IGBTs (will the current voltages be sufficient to

• vercome the large IGBT threshold?)

84

Test Plans

85

1 - Proof of Concept Tests

• Mold Paraffin
• Testing for ease of molding, and lack of bubbles/density
• Testing multiple techniques
• Pouring wax vs melting wax in mold
• Concentric circles mold vs machining inside diameter
• Spin molding vs vibration molding vs careful pouring
• Wax cooling speed
• https://www.lonestarcandlesupply.com/blog/heating-pouring-waxes/
• Metal vs PVC mold | Maybe the chamber is the mold
• Hard paraffin vs less hard paraffin
• Controlling Solenoid Valve
• Valve operation and test circuit
• Component hardiness
• Proof of Concept

86

1 - Proof of Concept Tests

• Serial Communication
• Serially communicate with a computer USB-Serial or an Arduino
• Match up and document baud rate, error handling
• Does it work if we connect late
• Disconnect in the middle, etc.
• Base Tank Pressurization
• Just moving N2O or N2
• Loading N2 tank
• Testing how pressure loading works, do we need a pump?
• Manually and electronically
• Benchtop Insulation Test
• Both “will it work” as well as “which works” test
• Firing ablative insulation and testing time until breakthrough
• Acceptance: Yes this works
• Optimization: This took the longest to burn through
• Oxy-acetylene torch testing

87

1 - Proof of Concept Tests

• Prototype Engine
• Set up nitrous/paraffin and try lighting it
• For initial test, likely ignite with paper or a match or something similar
• I just want to see fire

88

2” Schedule 80 Pipe N2O Chamber Orifice Check Valve Pressure Gauge Solenoid Valve Valve Tank

1 - Proof of Concept Tests

• Strain Gauge Calibration
• Use strain gauge to measure test chamber pressure
• Calibrate using shop air or CO2
• Pressure transducer on the other end of the chamber
• Prototype Engine Pressure
• Trying to measure pressure in engine by varying output orifice size and using choked flow

assumption

• Multiple tests, cap pipe with hole drilled in cap to build pressure
• Time to reach pressure as well
• Somewhat verification test, not proof of concept
• Initial Sensor Workings
• Be able to read sensors with control board microcontroller
• We will be using a lot of sensors for this testing
• Likely on a DAQ, but good time to get them working

89

2 - Verification Tests

• Fuel Regression
• Start with a quick variation of parameters test - Nitrous flow rate, Chamber pressure/Outlet

size, Port diameter

• Length/DP same in small scale and full scale
• G * DP is constant (Reynolds #)
• Post combustion chamber allows for full combustion, chemical kinetics >> transport properties
• Nozzle Cold Fire
• Running pressurized CO2 or shop air through the nozzle to test thrust characteristics
• Will need a load cell, as well as a pretty high mass flow rate to keep pressure in the chamber
• Battery Charging/Discharging
• Regulator Tests
• Testing the regulator should happen around the same time as strain gauge calibration
• N2 or CO2
• Verifying both pressure and mass flow rate, as well as some vibration

90

2 - Verification Tests

• Miniature Nozzle Hotfire
• Thrust proportional to port diameter for scaling
• This connected with the coldfire test will verify the nozzle
• The hotfire also allows us to verify choked flow and thrust and mass flow rate
• Injector flow testing
• w/CO2 & N2O
• Ambient & at pressure
• Flow rate, pressure drop tests
• Verifying atomization visually to characterize precombustion chamber length
• Proof Pressure Tests
• Burst Pressure Test
• Plug the nozzle end (Cap without hole in it)
• Pressurize with shop air/CO2 to working pressure
• Sensor Verification
• Basic sensor calibration, will be done mostly alongside the rest of these tests as we use the

sensors

91

2 - Verification Tests

• Acoustics
• Can try small scale tests
• Unsure of scaling right now
• Easy enough to record using a microphone
• Fuel Grain Tensile Test
• Stress test fuel grain
• What happens when it heats up
• Do we need to support the fuel grain at all
• Redundant controller test
• Chamber Pressure Test
• Making sure that we’re aware of all of the factors affecting chamber pressure
• We know we can hit it using different parameters, but will that scale up to the rocket
• IE scaling the regression rate/nozzle/mass flow rate, what is the chamber pressure
• May be a side effect of some other tests.

92

3 - Optimization Tests

• Fuel Grain Manufacturing
• Can we line the mold with something
• Is there a way to automate manufacturing
• How consistent are the fuel grains
• Pre-Combustion Chamber
• We only have a rule of thumb here, and a previous MSD project optimization
• Looking at changing the
• Injector Designs
• Ease of Assembly/Repeatability & Reproducibility
• Nozzle Geometry

93

4 - Integration Tests

• Controlling Solenoids
• w/ fluids with microcontroller
• Igniter Tests
• Controlling the ignition from the controller completely, no human intervention
• Battery lifecycle w/ solenoid valves, microcontroller
• Run it until it’s dead
• Leak test
• General Assembly
• Microcontroller thinking off of sensor data
• Trying to model this using MATLAB or some other microcontroller to fake inputs before

integrating everything together

94

5 - System Tests

• Day of operation
• Prop loading/offloading
• Arming/disarming
• Quick Fire
• Full Hot Fire
• Leak tests (periodically)

95

Test Stand Update

• Aluminum I-beams mounted to

aluminum plate

• Aluminum plate is already in bunker and

secured to floor

• Linear bearing/tracks
• Allow for only axial translation
• Each bearing is rated up to 720 lbf dynamic

loading

• Engine mounting fixture
• Needs to hold engine level and straight
• Sensor wires can be secured to fixture
• Next Steps
• Tank mounting
• Force place/load cell mounting
• Review design for ease of assembly & cost

96

Engine Engine Mounting Fixture I-beams (x2) Linear Tracks (x2) Fixed Aluminum Plate

Test Stand Update

97

• Determined that large oxidizer tank can fit

upright in bunker

• Bunker weatherproofed for winter &

generator is being cleaned up

• Next Steps:
• Design fixture to hold tanks
• Send design to EHS (by January 15th)
• Source materials needed (some already

procured)

Test Space Update

• Have been recently granted shared-access to a BME lab in Institute Hall
• Will use space to work on molding paraffin
• Depending on scale of small-scale testing may be able to use fume hood
• Also have a blast room in the machine shop
• Can do larger scale testing in here (not bunker large)
• This is in the event that BME lab is not equipped for small scale tests
• Entire team is now certified for:
• Lab Safety Training
• Gas Cylinder Training

98

Testing Next Steps

• Start with paraffin molding, as little else can continue without that
• Assemble test combustion chamber and start calibrating gauges
• Acquire Nitrous Oxide

99

Project Summary

100

Mass Allocations

101

Dry Mass Initial Allocation Current Mass Mass w/ Growth Structure 10 lbm 7 9.6 Thermal 2 lbm 3.8 4.2 Propulsion 20 lbm 17 20 Feed System 15 lbm 70 77 Controls 5 lbm 0.5 0.5 Power Distribution 4 lbm 2 2.2 Wet Mass Paraffin Fuel 7.1 lbm 7.1 lbm 7.1 lbm N2O Oxidizer 35.5 lbm 35.5 lbm 35.5 lbm TOTAL MASS 100 lbm 148 lbm 160 lbm

Mass Allocations

102

Integration Steps

• Design of electronic mounts
• Feed system structural mount for rocket and for test stand
• Wiring of feed system to electronics
• Fill/drain and pressure relief lines to outside of rocket body
• Test Stand integration

103

MSD II High-Level Timeline

104

Proof of Concept Tests 1/1/17 - 1/31/18 Small Scale Verification Testing 1/5/18 - 1/30/18 Redesign/ Manufacture 1/31/18 - 2/13/18 Optimization Testing 2/14/18 - 3/6/18 Design Freeze

3/7/18

Final Components Built/Acquired

3/8/18 - 3/25/18 4/14/18 Test Fire

Imagine RIT

4/28/18

Full Scale Verification Testing 3/26/18 - 4/13/18 Integration Testing 3/26/18 - 4/13/18

Risk Analysis: Technical

105

Risk Probability (1-5) Severity (1-5) Probability*Severity Mass exceeds limit

4 5 20

Heat transfer to combustion chamber walls

3 4 12

Insecure attachment/assembly of propulsion subsystem

2 5 10

Uneven burning of the fuel grain

3 3 9

Erosion/oxidation from N2O

3 3 9

Injector underperforms

2 4 8

Combustion instability

2 4 8

Inability to support the weight of the feed system

1 5 5

Risk Analysis: Resource

106

Risk Probability (1-5) Severity (1-5) Probability*Severity Unable to obtain nitrous oxide oxidizer

3 5 15

Excessive lead time on parts

3 5 15

Key equipment is damaged during testing

2 5 10

Inability to complete project on time due to lack of manpower

2 5 10

Project goes over budget

2 3 6

Project Budget

107

Total Project Funds Source Amount of Money Donations (Roar Day, Quartus, Interpretek) $6,092.01 Roar Day Match Estimate $5,000.00 MSD Boeing Funds $1,500.00 NY State Space Grant (Unconfirmed) $2,000.00 Total Confirmed Project Funding $12,592 Total Including Unconfirmed Grant $14,592

Fund Allocation by Subsystem

108 Project Cost Breakdown by Subsystem Propulsion Structures Power Controller Thermal Feed Test Stand Remaining Funds Total Funds Used Total Amount Allocated by Subsystem $1,073.75 $550.83 $312.00 $1,213.40 $1,175.12 $4,712.36 $508.73 $3,045.82 $9,546.19 Percent of Total Project Funds Allocated by Subsystem of Total Funds 8.5% 4.4% 2.5% 9.6% 9.3% 37.4% 4.0% 24.2% 75.8%

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Summary of Top Expenses

Expense Ranking Item Cost

1 N2O Solenoid $1,400.00 2 Oxidizer Tank $800.00 3 Check Valve $700.00 4 Gas Pressure Regulator $615.00 5 Nitrous Oxide $600.00 6 Combustion Chamber $434.05 7 Fuel Grain Insulation $413.60 8 Pre/Post Chamber Insulation $411.52 9 Primary Load Cell $400.00 10 Printed Circuit Boards $400.00 11 Relief Valve $300.00 12 Pressurant Tank $284.00 13 N2 Solenoid $240.00 14 Paraffin $200.00 15 Injector Insulation $150.00 16 Battery $150.00 17 Tee Fitting $132.64 18 Pressure Sensor Cable $130.10 19 Pressure Sensor $116.03 20 Pressure Sensor $110.28

Procurement

• Still seeking Nitrous supplier
• Big tank for storage, smaller tanks for small scale testing
• Ordering paraffin
• Igniters
• Valves (one or two)
• Sensors (a few)
• Miscellaneous Engine Parts
• Likely locally sourced, things like a large pipe for a “combustion chamber”
• Bolts
• Basic plumbing for feed system

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Special thanks to: Launch Initiative Team

Hunter Collins, Bailey Reid, Mark Saunders

Roar Day Donors MWI, Inc. Quartus Engineering Incorporated RIT MSD

Martin Pepe, George Slack, Professor Gerald Fly Atlas Fibre Co.

Questions/Feedback?