NASA SLI Critical Design Review UNIVERSITY OF ALABAMA IN - - PowerPoint PPT Presentation
NASA SLI Critical Design Review UNIVERSITY OF ALABAMA IN HUNTSVILLE CHARGER ROCKET WORKS JANUARY 26, 2016 Presentation Summary Project Overview Readiness and Design Summary Vehicle Analysis Mission Performance Recovery
UNIVERSITY OF ALABAMA IN HUNTSVILLE CHARGER ROCKET WORKS JANUARY 26, 2016
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Members
Engineering Majors
Engineering Majors
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successful mission operations
through test and demonstration (ground or flight)
environment
in relevant environment (ground or flight)
experiments as outlined in the component description sheets.
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Vehicle Concept of Operations
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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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Vehicle Dimensions:
**All critical loads used for stress analysis are derived from the main
parachute deployment with shock load of 24 g’s
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Payload Briefing:
updates fin angle to actively control external fins
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CG CP
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storage.
nose via locally machined aluminum ‘L’ bracket.
independent Stratologger SL 100 altimeters, 9V batteries, switches, and locally 3-D printed mounting sled and switch mounts.
while assembled, and eye bolts fore and aft for parachute shock cords during recovery.
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Upper Airframe PDR Changes
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to a max bending stress of 8.4 ksi
Margin of Safety of 1.69% using the known ultimate tensile strength
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Upper Airframe PDR Changes
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Avionics Dual Pull Pin
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Upper Airframe PDR Changes
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Aluminum Bulkhead
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induction and counter roll
decent
Drogue Parachute Storage Payload Section
Bulkhead
Motor Section Fixed Fin Assembly Tail Cone Assembly
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aluminum
bulkhead attached to rocket body
Past motor retention design Updated forward bulkhead retention design
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Lower Airframe Forward Bulkhead
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Polycarbonate due to it’s strength properties and light weight
inch diameter
two 0.25 inch all thread rods
four 8-32 screws
parachute and payload to rocket
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Lower Airframe Bulkhead Analysis
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used, with the load being determined from acceleration analysis
hole
with built in factor of safety of 2
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Computational Fluid Dynamics Analysis:
edge, i.e. the base of the fin bracket.
expected to range from 17 to 18.5 PSI. Finite Element Modeling (FEM) Analysis:
1.61 lbf experienced by base
during ascension
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Tail Cone Assembly Analysis
Compressive force from thrust stage on inner lip has potential to cause failure FEM Analysis:
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Airframe Component Testing
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vacuum sealed container. Charge fire signals were sent at the moment of lowest detected pressure as expected.
made obstacles. Average reception distance was 2.5 miles.
tracking systems. All four altimeters fired as expected, and both trackers transmitted their location to the team’s ground station.
to prevent interference with the altimeter system from the GPS tracker.
compressive loads from thrust phase of flight
during impact
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to meet target apogee.
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Time to apogee, max altitude
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conditions
73.14 fps
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rail): 2.17
2.97
applied to simulation
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more realistic apogee approximation can be determined.
values due to variance applied to inputs
will shrink variance on inputs
Monte Carlo analysis will improve as confidence in variance of inputs shrinks
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Model Assumptions:
period.
component lands.
velocity
deployed
rocket
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Drogue Parachute Deployment:
bulkhead and avionics bay coupler.
Main Parachute Deployment:
bulkhead and avionics bay coupler.
http://fruitychutes.com/ http://SkyAngle_CERT3.llc.homestead.com
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SECTION Section Nose Cone Upper Airframe Lower Airframe Mass (lb) 3.741 10.243 25.51 Velocity (ft/s) 12.81 12.81 12.81 KE (ft-lbf) 9.53 26.09 65.12
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Staged Recovery System Testing
components flown on the subscale that are being utilized on the full- scale rocket.
Altimeters
Black Powder Charges
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Vehicle 1 Vehicle 2 Forward Fins None Included Stability Margin 2.18 2.18 Mass (wet) 7.47 lb. 7.62 lb. Thrust to Weight 10.57 10.36 Both Vehicles Half scale geometry Mach: 0.46 Aerotech I284 Flight Data received by Stratologger CF
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Vehicle 1 Vehicle 2 Main Parachute did not deploy Successful launch and recovery Time of flight: 70.35 seconds Time of flight 84.7 seconds Max Vertical Velocity: 454.40 fps Max Vertical Velocity: 463. 41 fps
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𝐷𝑒 = −2𝑛 𝑏 + 𝐵𝜍𝑊2 Sources of Error:
Method 𝑫𝒆 of Vehicle 1 (No Fins) 𝑫𝒆 of Vehicle 2 (With Fins) Open Rocket 0.532 0.517 RockSim 0.534 0.5295 Analytical (Measured Data) 0.64 0.5335
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Payload
Recovery
Flight
Sub-Scale Flight Test Matrix Type of Test Test Goals Results Sub-Scale Flights Verify the vehicle stability margin and flight characteristics Successful (12/10/16) Recovery System Hardware Test hardware that will allow for a single separation dual deploy setup Successful (12/10/16) Acceleration flight test Ensure that avionics will survive launch forces Successful (12/10/16)
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Changes Made Since PDR
incorporating a voltage regulator for servos
piece to two pieces holding forward and aft bulkheads
manufacturing Final Dimensions
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Payload Fin 1 Servo Connector Rod 2 Fin Bolts 3 Servo Extension 4 Servo 5
1 2 3 4 5
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housing
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0.25” Aluminum Bulkhead 1 Payload Housing 2 All thread 3 myRIO 4 LiPo 5 IMU 6
1 2 3 4 5 6
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Li-Po Battery myRIO Voltage Regulator IMU Servo Wings Rotational Data Power Input/Signal Motion
Remove Before Flight Pin 44
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Realistic mAmps Hours Battery Drain myRIO (pre-flight) 945.95 1 945.95 myRIO (flight/postflight) 945.95 1 945.95 Servo (during roll) 1300 2.00E-03 2.6 Gyro (pre-flight/post-flight) 8.00E-06 2 1.60E-05 Gyro (flight) 3.2 5.00E-03 1.60E-02 accel (pre-flight/post-flight) 8.40E-06 2 1.68E-05 accel (active) 4.50E-04 5.00E-03 2.25E-06 mAh 2105.21 Left over charge
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alluded time
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𝑏𝑑𝑝𝑛𝑞 = 𝑏0 1 − 𝑁∞
2 +
𝑏0 𝜌𝑓1𝐵𝑆
2
+ 𝑏0/(𝜌𝐵𝑆)
𝑏0 − 𝑀𝑗𝑔𝑢 𝐷𝑣𝑠𝑤𝑓 𝑇𝑚𝑝𝑞𝑓 𝑁∞ − 𝑁𝑏𝑑𝑖 𝑂𝑣𝑛𝑐𝑓𝑠 𝐵𝑆 − 𝐵𝑡𝑞𝑓𝑑𝑢 𝑆𝑏𝑢𝑗𝑝 𝑓1 − Span Efficiency Factor
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velocity constant
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fundamentals for a successful safety program
informed and educated on safety topics relevant to upcoming activities
Operating Procedures used to instill good work practices and ensure all mitigation options are verified
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Identification
proactive and vigilant
Risk Assessment
and severity
Mitigation and Verification
severity and/or likelihood are implemented
for verification
Table 1: RAC Probability Severity 1 Catastrophic 2 Critical 3 Marginal 4 Negligible A - Frequent 1A 2A 3A 4A B – Probable 1B 2B 3B 4B C – Occasional 1C 2C 3C 4C D - Remote 1D 2D 3D 4D E - Improbable 1E 2E 3E 4E Table 2 Level of Risk and Level of Management Approval Level of Risk Level of Management Approval/Approving Authority High Risk Highly Undesirable. Documented approval from the MSFC EMC or an equivalent level independent management committee. Moderate Risk
Department/Laboratory/Office Manager or designee(s) or an equivalent level management committee. Low Risk
for operating the facility or performing the operation. Minimal Risk
the supervisor directly responsible for operating the facility or performing the operation is highly recommended. Use of a generic JHA posted on the SHE Webpage is recommended.
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Strategies
Risk Assessment
Mitigation and Verification
likelihood are implemented
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Effects of rocket on environment
Effects of environment on rocket
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Launch and Assembly Procedures
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Standardization
used for the subscale will be used to optimize full-scale flight procedures
Development
perform at the launch site or in preparation
Review and Hazard Assessment
and hazard assessment
Simulation and Training
controlled environment to verify accuracy
Implementation
the supervision of the safety monitor and team mentor
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CRW Team Training
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Test # Test Plan Status T01 Test tracker in various environments to confirm range Complete T02 Ground testing of the charge size required to successfully shear the Nylon pins and eject the parachutes. Completed successfully for subscale Full-scale testing planned for mid Jan 2017 T03 System Test for timing mechanics Not yet complete T04 Rotate payload about roll axis and look for fin actuation Awaiting parts – Testing planned for the end of Jan 2017 T05 Remove power source to one of the servos,
Awaiting parts – Testing planned for the end of Jan 2017 T06 Place IMU on a flat table and calibrate each axis
Place the IMU on a spinning table that is rotating at a fixed rate to calibrate the gyros. Calibration will be completed by the end of January T07 Subscale launch successfully completed on December 10, 2016 Successfully Completed T08 The CRW team has identified dates to launch before FRR. Primary date is currently February 4, 2017 and secondary date of March 4, 2017 Not yet completed -- Primary date is currently February 4, 2017 and secondary date of March 4, 2017 T09 Ground test to verify payload response to vehicle rotation Awaiting parts – Planned for end of Jan 2017 T10 In-house compression test Awaiting parts – Planned for end of Jan 2017 T11 Ensure GPS Tracker does not induce a charge on ematches Test planned for last week of January
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For the convenience of all team members, the following items will be located on the CRW team website:
The Safety Officer will work to keep this information relevant and up to date
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University of Alabama in Huntsville
Educational Engagement Schedule
Event Date Type of Engagemnt Anticipated Number of Individuals Impacted UAH Discovery Days October 29th Outreach: Direct Interaction 100 Girl's Science & Engineering Day November 5th Education: Direct Interaction 160 Girl Scouts STEM Fest November 12th Education: Direct Interaction 80 UAH Discovery Days November 19th Outreach: Direct Interaction 500 Society of Women Engineers: First LEGO League Qualifier January 14th Education: Direct Interaction 400 James Clemens High School Mar-17 Outreach: Direct Interaction 1250 Bob Jones High School Mar-17 Outreach: Direct Interaction 1250 Science Olympiad Mar-17 Education: Direct Interaction 50 Boys & Girls Club Mar-17 Education: Direct Interaction 25 UAH Engineering Organization Presentations Varies Outreach: Direct Interaction 100 Additive Manufacturing Program Varies Education: Direct Interaction 25 Total Impacted 3940
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Educational Engagement Activities:
University of Alabama in Huntsville
Past Outreach Event Photos: UAH Society of Women Engineers FIRST Lego League Qualifier
complete a number of tasks to advance to the state level.
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Status of Requirements Verification
Number Source Requirement Statement Verification Method Status V01 SLI The vehicle shall deliver a payload to an apogee altitude of 5,280 feet above ground level (AGL), but will not exceed 5,600 feet Open Rocket simulations have verified the design will obtain the desired altitude Complete Full Scale Launch T08 V02 SLI The vehicle will carry a commercially available, barometric altimeter to be used for official scoring Selection of Stratologger SL 100 Altimeters Complete R01 SLI All recovery electronics shall be powered by commercially available batteries Selection of commercially available CR123 batteries battery powered electronics Complete S01 SLI Vehicle must be recoverable and same day reusable without repairs or modifications. Selection of durable materials in PDR, and adequate recovery system based on max landing velocity of 13.76
ft sComplete V03 SLI The vehicle will have no more than four sections during descent. The vehicle design has three sections during descent Complete V04 SLI Must be propelled by a single stage, commercially available solid motor. The vehicle design is single stage utilizing an Aerotech L2200 motor. Complete
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For a full list of Requirements & Verifications, see CDR Document, Appendix D: Vehicle Verification Requirements
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Project Schedule – Spring 2017
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Black Powder Housing (4 Places) Eye Bolt (2 Places) Black Powder Terminal (4 Places) All Thread (2 Places) 9 V Battery (2 Places) Switch/Port Hole (4 Places) Stratologger SL100 Altimeter (2 Places) 2” 14”
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Stratologger SL100 (Primary)
9V
Stratologger SL100 (Secondary)
9V
Primary BP
Charge
Secondary BP Charge
Switch Switch
Primary BP Charge Secondary BP Charge
Drogue Parachute Bay
Charge Fired at apogee (5,280 ft)
Avionics Bay Main Parachute Bay
Charge Fired at 600 ft
Line of Redundancy
Bulkheads Rocket Nose
*Secondary 130% of primary
Charge Fired 1 sec after apogee
Charge Fired at 550 ft
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Aerotech L2200 Thrust Curve
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Project Schedule – Fall 2016
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