NASA SL Flight Readiness Review UNIVERSITY OF ALABAMA IN - - PowerPoint PPT Presentation

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NASA SL Flight Readiness Review UNIVERSITY OF ALABAMA IN HUNTSVILLE CHARGER ROCKET WORKS MARCH 9, 2017 Presentation Summary Project Overview Readiness and Design Summary Key Components Mission Performance Full-Scale Flight

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SLIDE 1

NASA SL Flight Readiness Review

UNIVERSITY OF ALABAMA IN HUNTSVILLE CHARGER ROCKET WORKS MARCH 9, 2017

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SLIDE 2

Presentation Summary

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  • Project Overview
  • Readiness and Design

Summary

  • Key Components
  • Mission Performance
  • Full-Scale Flight Analysis
  • Payload
  • Safety & Procedures
  • Educational Engagement
  • Project Management
  • Questions
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SLIDE 3

Technology Readiness Level

UNIVERSITY OF ALABAMA IN HUNTSVILLE

  • Actual system “flight proven” through

successful mission operations

  • Actual system completed and “flight qualified”

through test and demonstration (ground or flight)

  • Prototype demonstration in a flight environment
  • Payload ground test to verify functionality.
  • Sub-scale model or prototype demonstration in

relevant environment (ground or flight)

  • Component validation through analysis and

experiments as outlined in the component description sheets.

  • Design concept and/or application formulated
  • Basic design principals observed and reported

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SLIDE 4

Launch (0 – 2.4 seconds) Apogee Drogue Primary Fire (18.0 seconds) Coast & Roll Phase Drogue Main 600 ft. (73 seconds) Landing (114 seconds) Drogue Secondary Fire (19.0 seconds) Main Parachute Secondary Fire (550 feet) Main Parachute Primary Fire (600 feet)

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Concept of Operations

UNIVERSITY OF ALABAMA IN HUNTSVILLE

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SLIDE 5

Vehicle Overview

Vehicle Dimensions:

  • Diameter: 6 inches
  • Length: 119 inches
  • Mass: 52.72 lbs
  • Center of Pressure (CP): 89.83 inches
  • Center of Gravity (CG): 76.5 inches
  • No major dimensional changes since CDR

UNIVERSITY OF ALABAMA IN HUNTSVILLE

Payload Briefing:

  • Roll induction and counter roll
  • Proportional Interval

Derivative (PID) updates fin angle to actively control external fins

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CG CP

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SLIDE 6

Changes since CDR

Recovery CDR Main Parachute: SkyAngle CERT-3 XL which yielded a landing kinetic energy of 110 ft-lbf. FRR Main Parachute: Fruity Chute 144” Iris Ultra Compact with predicted landing kinetic energy of 64 ft-lbf. Upper Airframe Removable rivets changed to 4 8-32 screws with nut plates for threaded backing Aluminum all thread changed to steel all thread Solid Aluminum bracket changed to fiberglass with aluminum brackets at each end Lower Airframe Drogue bulkhead thickness changed from 0.25’’ to 0.5’’

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SLIDE 7
  • Tracker Assembly
  • Located in the nose cone
  • Tracker unit communicates with ground

station via laptop to trace vehicle

  • Avionics Bay
  • Houses recovery avionics
  • Two independent Stratologger altimeters
  • Switches
  • Switch mounts
  • 9V batteries
  • 3D printed sled

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Upper Airframe Key Components

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SLIDE 8
  • Fin Assembly
  • Fins were created from fiberglass sheets
  • Fin brackets were machined from stock

2024 aluminum

  • Tail Cone
  • Tail cone printed from ABS plastic
  • Compression proof tested to ~1000 lbf
  • Motor
  • Aerotech L2200
  • Max Thrust: 697 lbs
  • Impulse: 5104 Ns
  • Burn time: 2.3 s
  • Total Weight: 4783 g
  • Propellant Weight: 2518 g
  • Motor Case: RMS-75/5120

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Lower Airframe Key Components

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SLIDE 9

Key Components – Recovery System

  • Drogue Parachute: Fruity Chute CFC-

18

  • Main Parachute: Fruity Chute 144” Iris

Ultra Compact

  • Recovery Harness: 1” Tubular Nylon

(50 ft each)

  • Quick Links: 3/8” Oval-Shaped

Threaded Steel

  • Drogue Nomex: 18” x 18” Cloth Sheet
  • Main Nomex: 36” x 36” Cloth Sheet

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Drogue Parachute Main Parachute

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Interfaces with Ground Systems

  • Tacker
  • 2 XBee radios were configured and linked to the XCTU software via the

use of a laptop.

  • One Xbee radio remained connected to Ground Station while the other

was located in the nose cone.

  • Coordinates were recorded throughout flight and upon landing.
  • Final coordinates were verified by the use of a web mapping service

(Google Maps).

  • Rail Button Placement
  • Structural Ground System Interface
  • Close to CG
  • Close to aft fins

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Mission Performance

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Trajectory Curves

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Flight Predictions

Maximum Velocity 636.73 ft/s Maximum Mach 0.57 Max Acceleration 408.52 ft/s2 Target Apogee 5287 ft T/W 9.38 Rail Exit Velocity 73.79 ft/s Stability Margin 2.18 calibers

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SLIDE 13

Altitude Predictions

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Coefficient of Drag Analysis:

  • Predicted Cd measured from Full-Scale results input to RockSim (0.485)
  • Open Rocket internally derives the Cd without manual input

Wind (mph) Apogee (ft) 5255 5 5281 10 5293 15 5288 20 5266

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SLIDE 14

Descent Calculations

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  • Drogue Parachute: Fruity Chute CFC-18
  • Parachute Diameter: 18 in
  • Terminal Velocity: 87.1 ft/s
  • Main Parachute: Fruity Chute 144” Iris Ultra Compact
  • Parachute Diameter: 144 in
  • Terminal Velocity: 12.8 ft/s

Section Nose Cone Upper Airframe Lower Airframe Mass (lb) 5.8 12.31 25.25 Velocity (ft/s) 12.8 12.8 12.8 KE (ft-lbf) 14.76 31.32 64.24 Section Nose Cone/Upper Lower Airframe Mass (lb) 18.11 25.25 Velocity (ft/s) 87.1 87.1 KE (ft-lbf) 2132.79 2974.49

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Drift Results and Predictions

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  • Worst Case Drift (20 mph) = 2,581 ± 153 ft
  • Max wind speed to meet drift requirement:
  • 18 mph

Wind Speed Drift Distance (ft) 0 mph 5 mph 648 ± 37 10 mph 1289 ± 76 15 mph 1950 ± 114 20 mph 2581 ± 153

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Recovery System Tests

UNIVERSITY OF ALABAMA IN HUNTSVILLE

16 Test Number Rocket / Section Volume (gram) Results 1 First launch/Upper 4

Separation but main parachute did not eject from rocket

2 First launch/Upper 5

Separation and main parachute ejected

3 First launch/Upper 5

Separation and main parachute ejected

4 First launch/Lower 3

Separation and drogue parachute ejected

5 First launch/Lower 3

Separation and drogue parachute ejected

1 Second launch/Lower 3

Separation and drogue parachute ejected

2 Second launch/Upper 5

Separation and main parachute ejected

3 Second launch/Upper 5

Separation and main parachute ejected

Main Drogue Primary Charge 5g at 600ft 3g at apogee Secondary Charge 5.5g at 550ft 3.5g one second after apogee

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Monte Carlo Analysis

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  • Distribution of projected altitudes
  • Normalized by random variable

distributions

  • Done to obtain more realistic range of

altitude values

  • Standard deviation of 117 feet
  • 2𝜏 of 234 feet
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Flight 1 Overview

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Objectives:

  • Ensure structural reliability of vehicle

components for launch, flight and recovery.

  • Payload RIC not powered – neutral position.
  • Verify prediction methods.
  • Test dual deploy recovery system.
  • Match stability margin of final vehicle.
  • Not fully ballasted.

Launch Conditions

Date February 4th 2017 Location Childersburg, AL Wind 5 mph Temperature 56°F Motor Aerotech L2200 Parachute SkyAngle XL Launch Rod Angle 4°

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Flight 1 Analysis

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Apogee (ft) Apogee % Error Prediction Simulation 5489 2.66% Flight Data 5639

  • Post-Flight Simulation

5613 0.46% Key Flight Components Wet Mass (pounds) 50.40 Stability Margin (caliber) 2.18 Thrust to Weight 9.80 Cd (coast phase) 0.45

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Flight 1 Recovery

  • Drogue Parachute : Fruity Chute CFC-18
  • Terminal Velocity: 80.7 ft/s
  • Main Parachute: SkyAngle CERT-3 XL
  • Terminal Velocity: 17.2 ft/s

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Section Nose Cone Upper Airframe Lower Airframe Mass (lb) 5.03 10.78 23.93 Velocity (ft/s) 17.2 17.2 17.2 KE (ft-lbf) 23.11 49.52 109.93

Landing Kinetic Energies

Wind Speed Drift Distance (ft) 5 mph 2079

Drift Landing Distance

SkyAngle CERT-3 XL

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Flight 2 Overview

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Objectives:

  • Payload RIC powered
  • Demonstrate ability to control

roll

  • Verify launch detect system
  • Verify altitude, kinetic energy & drift

prediction methods

  • Test dual deploy recovery system

Launch Conditions

Date February 18th 2017 Location Murfreesboro, TN Wind 4 mph Temperature 54°F Motor Aerotech L1420 Parachute SkyAngle XL Launch Rod Angle 7°

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Flight 2 Analysis

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Apogee (ft) Apogee % Error Prediction Simulation 4337 1.50% Flight Data 4273

  • Post-Flight Simulation

4296 0.46% Key Flight Components Wet Mass (pounds) 52.72 Stability Margin (caliber) 2.09 Thrust to Weight 6.02 Cd (coast phase) 0.485

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Flight 2 Recovery

  • Drogue Parachute : Fruity Chute CFC-18
  • Terminal Velocity: 86.2 ft/s
  • Main Parachute: SkyAngle CERT-3 XXL
  • Terminal Velocity: 18.9 ft/s

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Section Nose Cone Upper Airframe Lower Airframe Mass (lb) 4.77 11.2 24.61 Velocity (ft/s) 18.9 18.9 18.9 KE (ft-lbf) 26.46 62.12 136.51

Landing Kinetic Energies

Wind Speed Drift Distance (ft) 4 mph 2177

Drift Landing Distance

SkyAngle CERT-3 XXL

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Payload Final Design

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Changes Made Since CDR

  • Housing modified to include holes and stand-offs for

components that ease the assembly process.

  • Went from one voltage regulator for three servos to
  • ne regulator for each servo, total of three.

Final Dimensions

  • Length: 9.05”
  • Diameter: 5.82”
  • Weight: 4.7 lbs

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Payload Vehicle Integration

UNIVERSITY OF ALABAMA IN HUNTSVILLE

  • Forward of motor case and aft of drogue recovery system.
  • Attaches to body tube via two aluminum bulkheads.
  • All thread holds bulkheads and payload as one piece.

Installation

  • Payload and bulkhead assembly is inserted into lower body tube.
  • Bulkheads anchored to body tube with fasteners.
  • Control rods attached to servos with fasteners.
  • Fins attached to control rods with fasteners.

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Control Algorithm

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The coding logic is broken into six states and ground tested extensively. The is flow can be summarized as follows:

  • State 0 – Sitting on the launch pad, awaits launch detect
  • State 1 – Launch detect flag triggered, awaits motor burnout
  • State 2 – Determine roll direction and rotate control fins eight degrees so as

to oppose initial rolling direction and hold for three seconds

  • State 3 – Return fins to a zero degree rotation (neutral) for one second
  • State 4 – Rotate control fins the opposite way of State 2’s direction and hold

for three seconds

  • State 5 – Return fins to a zero degree rotation (neutral) and hold for

remainder of flight

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Flight Test

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The control algorithm was tested and verified in a full scale flight

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Flight Comparison

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Validation that changing the fin angle of attack effects the roll rate

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Uncertainty & Calibration

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  • The roll rate is proportional to the oncoming air velocity squared.
  • Measurements for velocity accumulate error quickly due to integration
  • Alignment & Calibration of the IMU and servos has been difficult but is

improving with each flight

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Verification and Testing

UNIVERSITY OF ALABAMA IN HUNTSVILLE

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Requirements Verification for Launch Vehicle

UNIVERSITY OF ALABAMA IN HUNTSVILLE

For a full list of Requirements & Verifications, see FRR Document, Appendix H: Vehicle Verification Requirements

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Legend: V = Vehicle, P = Payload, R = Recovery, S = System, H = Hazard, T = Test Example: Key items were included in the vehicle verification plan with traceability through the test plan

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Tests Conducted

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**In addition to full scale and sub scale test flights

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Launch Day Procedures

UNIVERSITY OF ALABAMA IN HUNTSVILLE

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Launch and Assembly Procedures

UNIVERSITY OF ALABAMA IN HUNTSVILLE

Standardization

  • Allows for seamless modular changes to well

developed documents

Development

  • Optimized operating procedures through test

flights

Review and Hazard Assessment

  • Significant changes to existing procedures,

particularly safety-critical items, have been subjected to peer review and hazard assessment

Simulation and Training

  • A red team runs approved procedures in a

controlled environment to verify accuracy

Implementation

  • Finalized procedures are carried out under the

supervision of the safety monitor and team mentor

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SLIDE 36

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Launch and Assembly Procedures

  • Step-by-step process starting with packing

and prep that begins the day before launch

  • Safety precautions and PPE requirements

highlighted in RED

  • Verification signatures required for each sub-

team’s respective section

  • Ejection charge and motor installation

performed by team mentor

  • Launch pad and rocket retrieval conducted by

designated Red Team members

  • Safety monitor delegates and oversees all

launch and assembly procedures

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SLIDE 37

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Launch and Assembly Procedures

Pre-travel Preparation Pre-launch Assembly Motor Installation Final Checkout Prep Ejection Charges Pack Supplies

Upper Airframe Payload Drogue Ejection Charges Main Lower Airframe

Verify Thrust to Weight Verify Stability Margin Flight Card

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Program Management

UNIVERSITY OF ALABAMA IN HUNTSVILLE

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SLIDE 39

Program Schedule – Spring 2017

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Educational Engagement

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Event Date Type of Engagement Number of Individuals Impacted

UAH Discovery Days 10/29/2016 Outreach: Direct Interaction 100 Girl's Science & Engineering Day 11/5/2016 Education: Direct Interaction 160 Girl Scouts STEM Fest 11/12/2016 Education: Direct Interaction 80 UAH Discovery Days 11/19/2016 Outreach: Direct Interaction 500 Society of Women Engineers: FIRST LEGO League Qualifier 1/14/2017 Education: Direct Interaction 400 UAH Engineering Organization Presentations 2/22/2017 Outreach: Indirect Interaction 300 Science Olympiad 3/4/2017 Education: Direct Interaction 50 FIRST LEGO League: Alabama Championship 3/4/2017 Outreach: Direct Interaction 100 8th Annual Gala for Sacred Hearts 3/4/2017 Outreach: Indirect Interaction 25 UAH Discovery Days Apr-17 Outreach: Direct Interaction 500 James Clemens High School Presentation Apr-17 Outreach: Direct Interaction 100

2315 Total Impacted

UNIVERSITY OF ALABAMA IN HUNTSVILLE

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Program Total Budget Summary

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Program Budget Breakdown

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Subscale (One) Full-Scale (One)

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Program Budget Progression

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Questions?

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Appendix

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Drift Analysis

Model Assumptions:

  • Apogee occurs directly above

launch rail.

  • The parachute opens over a set

time period.

  • The drift distance stops when the

first component lands.

  • Horizontal acceleration is based on

relative velocity

  • Drogue drag neglected once main

is fully deployed

  • Validated against flight data from

similar rocket

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Information on Website

For the convenience of all team members, the following items will be located

  • n the CRW team website:
  • Material Safety Data Sheets
  • Operators Manuals
  • CRW Safety Regulations
  • Safety Briefing slides
  • Standard Operating Procedures

The Safety Officer will work to keep this information relevant and up to date

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Full-Scale Thrust Curves

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100 200 300 400 500 600 700 800 0.5 1 1.5 2 2.5 3 3.5

Thrust (lbf)

Time (s)

L1420 L2200

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Flysheet

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Flysheet cont.

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Flysheet cont.

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Flysheet cont.

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