Preliminary Design Review 1 Agenda Mission Success Criteria - - PowerPoint PPT Presentation

49er Rocketry Team University of North Carolina at Charlotte

Preliminary Design Review

1

• Mission Success Criteria
• Vehicle
• Recovery
• Payload - UAV
• Payload - UAV Housing
• Payload - Load Cell
• Safety
• Project Plan

Agenda

2

• The launch vehicle mission will be considered a success when:

○ MSV1 - Delivers a UAV within 250 ft. of our target apogee of 4,200 ft. above ground level. ○ Returns to ground within 90 sec., a 2,500 ft. radius, and under 75 ft-lbf of kinetic energy. ○ MSV2 - All payloads remain secured and protected from all elements of the flight. ○ MSV4 - No safety hazard posed to bystanders

Vehicle Mission Statement and Success Criteria

3

Complete Mission Statement and Success Criteria is located in Section 3.1

Vehicle Dimensions

4

• Total length of ~95.6 in.

Static Stability

5

• Loaded Stability of 2.1 caliber
• Stability at rail exit of 2.2 caliber
• Unloaded Stability of 2.6 caliber

Motor Selection Overview

6

• L800 is the leading design choice for

an overall weight between 41 lbm and 43 lbm

• L1050 is the leading design choice if

weight is between 43 lbm and 44 lbm

• Meets Competition requirements for

velocity off the rail and impulse

• Readily obtainable for purchase

Motor Justification

7

Cesaroni L800 Motor Justification

• Maximum Rail Cant of 10°
• Velocity off the rail of 59.1 ft/sec
• Max acceleration of 145 ft/sec2
• Minimum Apogee of 4039 ft
• Thrust to weight ratio of 5.5:1

Vehicle Material Options

8

Complete Testing Plan is located in Section 6.5

Carbon Fiber PETG Aluminum 6061-T6 Fiberglass

• Payload section airframe will be 4.5” ID 0.06”

wall thickness fiberglass

• LD-Haack nose cone shape
• AM PETG with an aluminum tip

Payload Section and Nose Cone

9

• 4.5 in. ID with 0.06 in. wall thickness carbon fiber tubing will be used for the airframe
• Two piece PETG and aluminum curved boat tail
• Flat plate carbon fiber fins with 5° chamfer on the leading and trailing edges

Booster Section Overview

10

Fin Shape Flat Plate

• Drag coefficient increase of 25%
• Frontal area decrease by 32%
• Overall drag force decreases by 11%

Booster Section Fins

11

Boat Tail Shape

• Aluminum adapter with a composite

shell

• Curved design offered ~15% of drag

reduction shown in comparative CFD simulation

Booster Section - Boat Tail

12

• Lateral deflection prevented by carbon fiber motor tube, centering rings, and fin tabs
• Axial deflection prevented by attaching to load cell and a retaining lip on the boat tail

Motor Retention

13

• LD Haack PETG 3D printed nose cone with

aluminum tip

• Fiberglass payload section airframe
• Carbon fiber booster and recovery airframes

as well as the fins.

Leading Vehicle Design

14

• Flat carbon fiber fin with 5° bevel on leading

and trailing edges

• Aluminum base with composite shell curved

boat tail

Vehicle - Requirements Verification

15

Complete Vehicle Requirement Verification Plan is located in Section 7.1.1

Vehicle - Team Derived Requirements

16

Team Derived Requirements for Vehicle are located in Section 7.1.2

Vehicle - Testing Plan

17

Complete Testing Plan is located in Section 6.5

• Recovery of the launch vehicle will be considered successful if:

○ MSR1 - The booster and payload sections will separate into independent recovery sections at apogee. ○ MSR2 - The drogue parachutes will fully deploy and the main parachutes will partially deploy during initial descent. ○ MSR3 - The main parachutes for the booster and payload sections will fully open at 500 ft. ○ MSR4 - The separate sections will reach the ground within 90 sec. of apogee, within the 2,500

• ft. landing radius, and within 75 ft − lbf of kinetic energy.

Recovery Success Criteria

18

Complete Mission Statement and Success Criteria is located in Section 3.1

1. Initial separation at apogee. 2. 2 sec. after apogee, deployment of drogue parachute with partial deployment of main parachute. 3. Full deployment of main parachute at 500 ft. 4. Touchdown within 90 sec, 2,500 ft. radius, and 75 ft-lbf of kinetic energy. 5. Main parachute is released for UAV deployment.

Recovery - Overview

19

• The parachutes will be released via single deployment of both the drogue and main parachutes.
• Jolly Logic Chute Releases will keep the main parachute closed until 500 ft.

Recovery - Overview

20

• Tender Descender will release payload main parachute line.

Recovery - Deployment

21

Booster just after apogee separation Nomex Blanket Drogue Parachute Main Parachute (closed) Booster Section Booster Recovery Section Kevlar Tether Line

Recovery - Deployment

22

Kevlar Tether Line Drogue Parachute Main Parachute (open) Nomex Blanket Booster Recovery Section Booster Section

Recovery - Parachutes

23

Booster Section Payload Section Main Parachute

Iris Ultra Light Iris Ultra Light Diameter 72 in. 96 in. Cd 2.2 2.2 Packing Volume 30.3 in3 50.2 in3

Drogue Parachute

Classic Elliptical Classic Elliptical Diameter 12 in. 12 in. Cd 1.5 1.5 Packing Volume 7.4 in3 7.4 in3

Iris Ultra Light Classic Elliptical

Recovery - Altimeter Bay

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1. Perfectflite Stratologger CF 2. Black Powder Charge Blocks 3. 9V Batteries 4. Eyebolt for Tether Connection 5. Altimeter Sled 6. Carbon Fiber Bulkhead *Carbon fiber outer shell, arming switches, pressure relief holes not shown.

Recovery - Booster Section

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• One altimeter used for initial

separation (primary or secondary)

• Two altimeters used for booster

separation (primary and secondary)

• Three independent 9V batteries
• Dual e-match wiring
• Dual Jolly Logic Chute Release

Recovery - Payload Section

26

• Same procedure as previously

listed for booster recovery section

• MCU, IMU, LiPo for main

parachute release located in payload section

Recovery - Performance

27

Recovery - Requirement Verification

28

Complete Recovery Requirement Verification Plan is located in Section 7.1.1

Recovery - Team Derived Requirements

29

Team Derived Requirements for Recovery are located in Section 7.1.2

Recovery - Testing Plan

30

Complete Testing Plan is located in Section 6.5

• Payload mission will be considered successful if:

○ MPS3 - The nose cone and airframe successfully separate. ○ MPS5 - The UAV is successfully lifted above the airframe prior to take off. ○ MPS10 - Camera vision successfully locates and positions UAV above the FEA for beacon deployment. ○ MPS11 - UAV successfully avoids encounters with objects via object detection system. ○ MPS12 - UAV successfully delivers navigational beacon. ○ MPS13 - Load cell successfully logs motor thrust data.

Payload Success Criteria

31

Complete Mission Statement and Success Criteria is located in Section 5.1

Payload Overview

32

Property Payload Section Nose Cone Length 25 in. 22.5 in. Overall Weight 21 lbs. (including payload recovery) UAV Weight 1.75 lbs.

UAV - System Overview

33

Objective: To autonomously control the UAV flight characteristics during operation.

• Raspberry Pi Zero W

○ Open source Linux-based Operating System ○ Can be programmed with Python and C

• 3DR Pixhawk PX4 2.4.8 Flight Controller

○ Open source flight stack ○ Supports extra peripherals via I2C ○ Supports autonomous flying and Mission Planner

UAV - Flight Control System

34

Objective: To use machine vision technologies to locate the FEA and initiate beacon delivery behavior.

• Will detect an FEA and interrupt the FCS then direct UAV movement

towards the center of the FEA, and trigger beacon drop

• Jevois A33 Camera

○ features built-in CPU and GPU ○ Communicates with Flight Control system via serial

UAV - FEA Detection System

35

Objective: To retain the navigational beacon

• n-board the UAV until signaled to release.
• Beacon assembly will be secured to airframe with

a PETG mount. Servo horn will hold beacon in place

• HS-40 Nano Servo Motor

○ 8.4 oz/in at 4.8V; 10.5 oz/in at 6V ○ Weighs 0.17 ounces

UAV - Beacon Retention and Deployment

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Objective: To locate and respond appropriately to any obstructions encountered during operation.

UAV - Object Detection and Avoidance

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• MaxBotix MB1240

○ 10 Hz sample rate ○ Range of 8 to 300 inches ○ 0.4 inch resolution

• MakerFocus Lidar Range Finder

○ 100 Hz sample rate ○ Range of 12 to 472 inches ○ 0.4 inch resolution

• DJI 8331 folding propellers

○ 8.3 inch diameter ○ 3.1 inch pitch

• Edge R2304 High Performance F3P 3D Foamy Motor

○ 1480 KV (RPM/Volt) ○ 125W Maximum Continuous Power ○ Approximately 24.5 ounces of thrust

• Four EMAX 20A electronic speed controllers (ESC)

○ Max continuous current draw: 20A ○ Max peak current draw: 30A ○ Input voltage: 7.4V - 14.8V ○ Weighs only 0.12 ounces

UAV - Drive System

38

Objective: To privilege the designated UAV operator with the ability to abort autonomous flight in the event of an error.

• Transmitter: FrSky 2.4GHz ACCST Taranis X9D Plus

○ 100mW transmitting power ○ Configurable switches

• Receiver: FrSky G-RX6 2.4G Receiver

○ Low power consumption ○ Lightweight (0.1 oz.) ○ > 1.25 mile range ○ 5 PWM ports

• Readytosky M8N GPS

○ 10 Hz GNSS sample rate ○ Pixhawk compatible ○ Low power

UAV - Wireless Comms. and GPS

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Objective: To provide adequate power to all electrical components on the UAV

UAV - Battery Requirements

40

• Tattu 11.1V Lipo Battery Pack

○ 2700mAh ○ 3 cell (3.7V per cell) ○ Discharge Rate: 25C ○ Max Burst Discharge Rate: 50C

• Turnigy HV SBEC 5A Switch Regulator

○ 5V or 6V user selectable output voltage ○ 8V-42V (2-10S Lipo) input voltage ○ 4A continuous current draw A limit switch making contact with the deployment mechanism will be located under the UAV and will latch a silicon control rectifier on, powering the UAV.

UAV - Power Distribution

41

• Plate Construction
• Folding Arms
• AM Brackets for securing

components

UAV - Frame

42

UAV - Frame

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1. Receiver 2. Servo Motor 3. Beacon 4. Beacon Retention 5. Battery 6. Lidar Sensor 7. JeVois Camera 8. Ultrasonic Sensor 9. Mounting Bracket 10. Raspberry Pi Zero 11. GPS Module 12. Pixhawk

UAV - Frame

44

1. Propellers 2. Motor 3. ESC

UAV Arms with Dimensions

45

UAV - Dimensions

46

UAV - Dimensions

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UAV Housing Subsystems:

• Retention
• Separation
• Orientation
• Stabilization
• Lifting

UAV Housing - Overview

48

UAV - Separation Process

49

1 2 3 4 5

UAV Housing - Dimensions

50

Nose Cone Coupler Payload Section

UAV Housing - UAV Retention

51

• Two Retention Mechanisms

1. Lateral Retention Pins 2. Vertical Retention U Brackets

• Separation leadscrew goes through sled and connects to two fixed bulkheads
• Prevents rotation during flight

UAV Housing - Sled Retention

52

Separation Leadscrew Fixed Bulkheads

• Leadscrew driven
• Minimum travel of 16.5 in. to clear UAV compartment
• 114 oz-in of torque minimum, to apply 190 lbf.
• Required force based on a typical 12 psi separation charge

UAV Housing - Separation

53

Main Separation Leadscrew

• Servo and worm screw are mounted to the nose cone
• Worm wheel is mounted directly to the orientation sled
• Three ball bearings will be mounted evenly spaced

around the bulkhead, to reduce contact area and friction in orientation

• Accelerometer on MCU is in a feedback loop driving

the orientation

UAV Housing - Orientation

54

• Legs used to prevent airframe rolling
• Fine-pitch leadscrew is used to drive legs, and retain them during the vehicle's flight

UAV Housing - Stabilization

55

• Table is driven vertically by a single

leadscrew, and scissor linkage

• Lifts the UAV up to 6” vertical off of the sled
• Bottom of UAV will be be a minimum of 2”

above airframe.

UAV Housing - Table Lift

56

Objective: To log motor thrust data.

• Digi XBee-PRO 900HP

○ Long range 900 MHz OEM RF module ○ Range of up to 9 miles ○ 250 mW transmitting power

• Micropython Pyboard PYBv1.1

○ Open source ○ Embedded 3-axis accelerometer (MMA7660) ○ 29 programmable GPIO ○ On-board 3.3V voltage regulator

UAV Housing - Electrical Design

57

UAV Housing - Deployment Servos

58

• Team Tenergy 7.4V LiPo Battery Pack

○ 2200mAh ○ 2 cell (3.7V per cell) ○ Discharge Rate: 30C

• Pololu 6V Regulator (D24V150F6)

○ 15A maximum output current ○ 7.2V - 40V input voltage

UAV Housing - Electronics Components

59

• The Load cell is a PT Global 500-kg S-type

○ Aluminum ○ Work Rated FOS of 5 ○ 3.3” long ○ 0.88 lbm

• Located directly fore of the motor

○ Used to transmit thrust to the vehicle ○ Load cell bay will be pinned and glued to the airframe ○ Used to verify manufacture specific thrust ○ More accurate thrust curve giving better flight performance predictions

Load Cell - Overview

60

• AST-500 S-type Load Cell

○ Work Capacity of 1100 lbs

• SparkFun Load Cell HX711 Amplifier

○ 24-bit ADC ○ 80 samples/second ○ Serial Output

• Teensy 3.6 Microcontroller

○ Embedded µSD Slot ○ Compatible with Arduino IDE

• Sparkfun 1Ah Lithium Ion Battery

○ Total power usage is expected to be 300 mAh per hour

Load Cell - Electrical Design

61

Payload - Requirement Verification

62

Complete Payload Requirement Verification Plan is located in Section 7.1.1

Payload - Team Derived Requirements

63

Team Derived Requirements for Payload are located in Section 7.1.2

Payload - Testing Plan

64

Complete Testing Plan is located in Section 6.5

• Safety Officer: Alexander DeChant

○ Alternate Safety Officer: Robert Cook

• Hazard Recognition and Avoidance

○ Hazard Communication Briefing ■ OSHA’s “Right to Know”, 29 CFR 1910.1200 ■ Safety Manual ○ Dual Verification ■ Launch Checklists ■ Initials, record settings ○ Hazard and Risk Analyses ■ FMEA

Safety

65

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 Risk Definitions Table is located in Section 4.2.1

Launch Checklists

66

• Caution Statement Identification

○ **WARNING**: Injury to personnel ○ *CAUTION*: Damage to equipment ○ NOTE: Highlights important procedure

• Safety Icons

Procedure is susceptible to electrostatic discharge Pinch point hazard Gloves required Safety glasses required Personnel must ground themselves

Personnel Hazards

67

Hazard Cause Effect Pre-Rac Mitigation Verification Post-Rac Team member injured by motor detonation (CATO, installation, etc.) Withdrawal distances not

• bserved during

launch Loss of life, limb, eyesight 1C Safe withdrawal limits will be

• bserved at all times.

Safety Handbook Section 3, NAR High Powered Rocket Safety Code para. 3 “Motors” and para. 6 “Launch Safety” 1E Team member injured by motor detonation Igniter installed prematurely Loss of life, limb, eyesight 1C Igniter will not be installed into motor until rocket is on launch rail. Safety Handbook Section 3, NAR High Powered Rocket Safety Code para. 4 “Ignition System” 1E Team member injured by motor detonation Improper assembly

• f solid rocket motor

Loss of life, limb, eyesight 1C Motors will only be purchased from reputable dealers or assembled by qualified/ certified personnel. Safety Handbook Section 3, NAR High Powered Rocket Safety Code para. 1 “Certification” and para. 3 “Motors” 1E

Complete Personnel Hazards Table is located in Section 4.2.1

FMEA - Recovery

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Subsystem/ Component Hazard Cause Effect Pre-Rac Mitigation Verification Post-Rac Booster Recovery E-match disconnection from altimeters Assembly of altimeter bay removes e-match leads from altimeter Catastrophic mission failure; Primary parachute fails to deploy 1B Ensure e-match leads are fully inserted into applicable altimeter terminal and terminal screws are sufficiently tightened Assembly Procedures checklist: Launch Vehicle Assembly 1E Booster Recovery Failed ejection charge Defective altimeter Catastrophic mission failure; Parachute fails to deploy 1B Test altimeters for proper operation/ setting prior to securing altimeters to respective mounting points Altimeters will be secured in a test bay and placed under a vacuum to simulate

• descent. Altimeters

will detonate an e-match as indication

• f proper operation

1E

Complete Recovery FMEA Table is located in Section 4.2.2

FMEA - Vehicle

69

Subsystem/ Component Hazard Cause Effect Pre-Rac Mitigation Verification Post-Rac Motor CATO Fracture of motor casing Catastrophic loss of vehicle at take-off 1A Select a certified motor for use in launches. Ensure licensed vendor is utilized for purchasing of certified motors Assembly Procedures checklist: Launch Vehicle Assembly and Booster section procedures 1E Motor CATO Improper grain packing Catastrophic loss of vehicle at take-off 1A Motor assembly will be performed by NAR-certified team members under the supervision of the team's NAR-certified mentor Assembly Procedures checklist: Motor

• Preparation. Motors will be

assembled IAW assembly instructions supplied with Motor Kit 1E

Complete Environmental Hazards to Vehicle Table is located in Section 4.2.2

FMEA - Payload

70

Subsystem/ Component Hazard Cause Effect Pre-Rac Mitigation Verification Post-Rac UAV Deployment signal fails to power on UAV Receiver being blocked by non-RF transmission material Payload does not deploy; Mission failure 1A Payload section made of fiberglass Test Plan UDT5. UAV and housing will be ground and flight tested for integration and survivability and

• perability before and

after flight 1E UAV Improper transmission

• f data

Grounded simulation due to moisture Improper signals received resulting in improper deployment; damage to drone and deployment setup; Mission failure 1A Insulating all electrical connections from water Test Plan UT6. UAV electronics will be tested before integrating with UAV 1E

Complete Team Payload FMEA Table is located in Section 4.2.2

Environmental Hazards

71

Hazard Cause Effect Pre-Rac Mitigation Verification Post-Rac Rocket impacts bystanders or vehicles Excessive winds Injury to bystanders; death; damage to vehicles and surrounding equipment 1C Monitor wind speeds throughout the day; Launch will not be performed if wind speeds exceed 20mph Safety Handbook Section 3: IAW NAR High Powered Rocket Safety Code para. 9 “Safety Code” 1E Inadvertent ignition of black powder charges or motor grains Premature insertion of igniter wire into rocket motor Damage to launch field; fire; severe burns; Damage to property 1C Igniter will only be inserted into rocket motor when vehicle is

• n the launch rail and

after all electronics have been powered ON. Assembly Procedures checklist: Igniter Installation second warning 1E

Complete Environmental Hazards to Vehicle Table is located in Section 4.2.3

Risks to Project Completion

72

Risk Impact Chance Mitigation Quantification Loss of full- or subscale vehicle High Medium All components are tested for proper

• peration/ assembly prior to use on

sub- or full-scale vehicle Loss of sub- or full-scale vehicle will double our budget due to having to rebuild and will result in a several week setback in construction and testing Long lead time for parts High Medium Parts with long lead times will be

• rdered early to alleviate a potential

schedule compression A long lead time will cause a schedule setback equal to the lead time and delay construction Damage to electronics High Medium Electronics secured when not in use and only used when absolutely necessary Damaged electronics will result in budget increases stemming from their replacement Loss/ Lack of funding High Medium Crowdfunding efforts, additional fundraisers planeed Loss or lack of funding can result in inability to

• btain necessary parts for project, resulting in

delays of construction and project completion

Complete Risks to Project Completion Table is located in Section 4.2.4

Safety Requirement Verification

73

Complete Safety Requirement Verifications are located in Section 7.1.1

Project Plan - Timeline

74

Task Start Date Completion Date Payload Design Finalization 10/5/2018 11/16/2018 UAV Manual Flight Testing 10/26/2018 11/9/2018 Subscale Vehicle Assembly 10/28/2018 11/2/2018 Subscale Vehicle Launch 11/3/2018 11/4/2018 Full-Scale Vehicle Design Finalization 11/5/2018 11/30/2018 PDR Teleconference 11/7/2018 11/7/2018 UAV Autonomous Flight Integration Testing 11/9/2018 12/7/2018 Payload Manufacturing and Assembly 11/19/2018 1/4/2019 Full-scale Vehicle Manufacturing and Assembly 12/1/2018 1/11/2019 UAV Autonomous Flight Testing 12/7/2018 1/4/2019 Full Project Timeline is located in Appendix B

Project Plan - Budget

Complete Budget is located in Section 7.2.1 and 7.2.2

Category Cost Travel $ 8,900.00 Launch Vehicle $ 7,386.47 Payload $ 3,468.69 Testing $ 1,150.00 Outreach $ 700.00 Total: $21,605.16

75

• Current Anticipated Budget: $21,605.16

Sustainability:

• Recruit underclassmen and members from UNCC

Rocketry Club

• Improve team workspace resources for future

teams

• Leave excess of $2,500 in funds carried forward

for next year’s team

Project Plan - Funding & Sustainability

Complete Funding Plan is located in Section 7.2.4

Funding Source Amount NC Space Grant $5,000 Sponsorships/Fundraisers $2,000 UNCC Senior Design $2,000 Crowdfunding $12,000 Department Donations $2,000 Bridge Tournament $1,000 Ideal Total $24,000

Current Funding Plan

76

Recent Events

• Charlotte Kids’ Fest
• YouthQuest Foundation/SC

Presentation

• Engage ME! Program

Upcoming Events

• UNCC Intro to Engineering

Seminar

• JMR Middle School
• Science Olympiad at North

Gaston High School

Educational Outreach

77

General Requirements Verification

78

Complete Requirements Verification Plan are located in Section 7.1.1

Questions?

79