Preliminary Design Review Bearcat Ballistics 2018-2019 1 NASA U - - PowerPoint PPT Presentation

Preliminary Design Review

Bearcat Ballistics 2018-2019

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NASA University Student Launch Initiative (USLI)

• Annual Competition hosted at the Marshall Space Flight Center
• Gives an opportunity for engineering students to collaborate on a project

involving building a full scale model rocket

○ Helps students gain valuable experience in a professional setting while simultaneously completing hands-on tasks

• Our Mission: Rover Deployment with Soil Recovery and Rocket Launch

at Altitude

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Meet the Team

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Team Launch Vehicle Requirements

• Conor is Launch Vehicle Team Lead
• Subsystems of the Launch Vehicle:

○ Motor ○ Fins ○ Recovery ○ Telemetry and Electronics ○ Computing

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2.4.3 Recovery system must bring the rocket to the ground within 90 seconds of reaching apogee. Testing The team shall test the recovery system’s ability to reach the ground from apogee within the predetermined time.

Team Payload Requirements

• Andy is Payload Team Lead
• Subsystems of the Payload:

○ Rover Power ○ Deploy Power ○ Rover Structures ○ Deploy Structures ○ Computing ○ Excavation

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3.1.4 The payload shall be capable of withstanding sustained acceleration of up to 10 Gs. Analysis Simulations shall be conducted and flight data shall be analyzed to measure the acceleration force the payload will withstand.

Team Safety Requirements

• Adam is Safety Team Lead
• Subsystems of Safety:

○ Training ○ Housekeeping

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4.2.1 Every team member shall return all supplies they use while in the Rocket Lab to the correct place prior to leaving for the day, both as a safety precaution and good housekeeping process. Demonstration Team members shall demonstrate good habits of putting supplies in their proper location for the safety of those using the lab.

Team Finance Requirements

• Alex is Finance Team Lead
• Subsystems of the Finances:

○ Budget ○ Sponsorship Revenue ○ Travel Expenses ○ Reserve

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5.1.1 The budget shall be closely monitored and analyzed by the team treasurer throughout the design and build process to ensure that the budget is not exceeded. Inspection The team treasurer shall inspect the team expenses and budgeting process during the length of the project.

Launch Vehicle Design

Mission Criteria and Design Driving Factors Design Overview Simulation Trade Studies Flight Events

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Mission Success Criteria and Design Driving Factors

1) The launch vehicle shall reach an apogee of +/- 100 ft of 5,000 ft AGL. 2) The launch vehicle shall touch down from apogee in under 90 seconds. 3) The launch vehicle shall deploy a soil sample rover payload. 4) The launch vehicle shall deploy recovery devices in order to achieve a landing energy of less than 75

• ft. lbf.

5) The launch vehicle shall be constructed in a manner such that it is reusable. Primary Design Driving Factors

• rocket motor
• payload dimensions and mass
• fins
• recovery system

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Current Design Overview

• Weight on Launch Pad (Lbs): 31.9
• Descent Weight (Lbs): 28.0
• Length (in): 122
• Motor: AMW L900RR
• Thrust-to-Weight Ratio: 6.40
• Stability Margin (at launch): 2.24
• Rail Exit Velocity: 58.57
• Landing Energy (ft-Lbf): 70.0
• Avg. Max Altitude (ft): 5556

Center of Gravity 72.6” from Nose Center of Pressure 89.8” from Nose

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Launch Vehicle Design Evolution

From v1 to v2

• 8.5” length increase
• 5.8 Lb launch weight reduction
• 2” span reduction
• 0.71 Lb propellant mass reduction
• 659 ft simulated altitude gain

Version Motor Length (in) Outer diameter (in) Launch Mass (Lbs) Descent Mass (Lbs) Stability Margin at Launch Simulated Altitude Achieved (ft) v1 CTI L850W 113.5 7.75 37.7 33.1 2.08 4897 v2 AMW L900RR 122 7.67 / 6.26 31.9 28.0 2.24 5556

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Simulation

Motor Max Accel. (ft/s2) Launch Angle (deg) Wind Speed (mph) Temp. (F) Altitude Achieved AMW L900RR 272.2 5 5-10 65 5556 AMW L900RR 274.0 10 5-10 65 5321 AT L1150 262.14 5 5-10 65 5768 AT L1150 261.87 5 5-10 40 5695

All simulations so far have been conducted using RockSim 9. The program provides useful data estimating a wide variety of performance data in diverse environments

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Motor Trade Study

Size (mm) Model

• Max. Altitude

(ft)

• Max. Vel.

(ft/s) Rail Exit Vel. (ft/s) 75 AMW L900RR 5556 636.34 58.57 75 CTI L3200 5645 730.88 124.88 75 AMW L1060GG 5897 676.46 61.84 75 AMW L1111ST 5749 668.85 65.42 75 AT L1150 5805 673.19 76.06 Takeaway: AMW L900RR flies the closest to our target altitude and has high availability

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Launch Vehicle Airframe Trade Study

Tube Material Manufacturers Dimensions (in) Material Description Strength Rating Weight (oz) Phenolic Public Missiles Dia: 6.01 L: 48 Resin-Impregnated, Heat cured High 36.9 Phenolic Public Missiles Dia: 7.5 L: 48 Resin-Impregnated, Heat cured High 48.1 Cardboard LOC Apogee Dia: 7.5 L: 48 Brown Kraft Paper Medium 60.91 Fiberglass Filament Tube Apogee Dia: 6.01 L: 48 G12 Filament Wound Tube Very High 97.56 Blue Tube Apogee Dia: 5.97 L: 48 High Density, High Strength Paper Very High 41.94 Takeaway: Phenolic Tubing offers high strength with competitively low weight

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Launch Vehicle Fins Trade Study

Shape Result Elliptical “Ideal” shape but is not effective at high speeds Trapezoidal Offers balanced static margin easily modified with root and tip

• length. Less damage upon impact

Rectangular Raises static margin beyond desired limit, not aerodynamic Swept Lowers stability margin below desired limit. High probability of damage upon impact Material Properties Balsa

• Weak. High probability of

damage upon impact G10 High strength. Industry

• standard. Difficult to cut

Aircraft Plywood Medium strength. Can be wrapped to strengthen

Drogue Parachute Study

Objective: Identify drogue parachute options Takeaway: 30 in. Public Missile is the current leading choice, given the CD and exerted force during main parachute deployment

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Main Parachute Study

Objective: Identify Main parachute options Takeaway: 130 in. Custom Fruity Chute is the current leading choice, given the CD and Kinetic Energy during launch vehicle landing

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Launch Vehicle Electronics and Recovery Subsystem

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Altimeter Circuit

Telemetry Circuit

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Launch: Vehicle leaves the launch pad Landing: Launch vehicle returns to ground with less than 75 ft.-Ibf. Kinetic energy 510 ft. AGL: Main parachute deployed by StratologgerCF Altimeter Apogee: Launch Vehicle reaches target altitude of 5000 ft. and drogue parachute deploys

Flight Events

Payload Design

Payload Design Overview Payload Electronics Overview Weight Breakdown Ground Station Payload Trade Studies

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Payload Mission Objectives

• Deploy safely and travel 10 feet from the launch vehicle
• Collect a soil sample

○ Sample must be at least 10 mL ○ Sample must be stored in an on-board container

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Primary Payload/Rover Design Overview

The payload consists of the rover and the rover deployment system

• Rover

○ Uses two 6” diameter wheels to propel itself ○ Collects soil with an on-board auger system ○ Resists rotation with a small set of deployable wheels ○ Measures distance travelled with an IMU and motor encoders ○ Uses an active control system to maintain heading

• Deployment system

○ Uses an 18” stroke linear actuator ○ Provides 150 lbs of force to push rover out of the rocket ○ Actuates a switch that causes the rover to power on

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Rover Design Overview--Counter Torque Arm

• Rover will use a deployable arm to

counteract the motor torque

○ Stops the motors from rotating the chassis instead of the wheels

• Arm connects to the chassis by means of

a hinge

○ Hinge is spring loaded ○ A servo at the mounting point will pull a pin that deploys the arm ○ The arm will lock in place in its new position

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Payload Design Overview--Auger

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• The auger is driven by a hollow shaft

motor

• The motor is mounted to the top of

the chassis via extension springs

• A linear actuator pulls a cable/line to

lower the auger ○ Force redirected by pulley ○ Configuration reduces required height of auger system ○ Springs allow auger to retract when actuator extends

Payload Launch Vehicle Interface

Rover mounts to the actuator by means of an aluminum/HIPS disk with a 0.5” lip around the circumference. Rover mounts to nose cone with an identical disk. The rover is not fixed to these mounting points, but instead rests on them, allowing it to free itself upon deployment. The linear actuator is bolted to a bulkhead about 23” aft of the back end of the rover.

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CAD Photos of Payload Interface

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Actuator Mounting to Bulkhead

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Stowed vs Deployed

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Design: Structure and Housing

• The structure of the payload

will be made as a 3.2x4.2x12 inch rectangular prism.

• The internal payload volume

will be 144 cubic inch.

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Design: Materials

• The plate used to interface the actuator to the rover will consist of aluminum
• r 3D printed High Impact Polystyrene (HIPS)
• The rover chassis will be made of 0.25” thick ABS

○ Easy to manufacture ○ Relatively strong ○ Can make complicated mounting points w/ additive manufacturing technology

• Auger bit will be made of steel

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Alternative Payload/Rover Design

Forward Deployment

• Uses four 3.25” diameter wheels
• Rover sits inside of a rotating cylinder
• Cylinder settles in a favorable position upon

landing

• Rover deploys by driving itself out of the landed

rocket body

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Payload Electronics Overview

12V DC motor control

• Arduino Mega

○ Control Center

• L298N Driver

○ Regulates volts with pulse width modulation ○ Controls wheels with H-bridge

• IMU

○ Will sense acceleration, attitude and heading to create a “drive straight” system

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Payload Electronics Overview

Auger Control

• Auger will have a dedicated power

supply

• IMU and motor encoders for odometry

○ Will trigger auger to begin excavation

• nce rover has traveled 10 feet

○ Control system will use IMU to maintain heading

• Rover controlled by Arduino Mega

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Payload Electronics Overview Cont.

• Payload team will install encoders on the drive motors

○ Allows microcontroller to utilize motor speed information

• Current design requires at least 6 analog input pins

○ Two for I2C connection from IMU (x2) ○ One for each drive motor encoder (x2) ○ One for auger motor encoder (x1) ○ One for the auger deployment actuator feedback (x1) ○ OPTIONAL: One for battery voltage monitor ○ OPTIONAL: One for a temperature sensor on high-current components ○ OPTIONAL: One for a photoresistor to confirm the rover has left the payload bay

• Analog pin scarcity is the main factor pushing the team towards using a Mega

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Payload Electronics: Battery

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Name V5 Robot Battery Li-Ion Venom DRIVE LiPo Battery Venom DRIVE LiPo Battery RobotShop LiPo Battery Voltage (V) 12.8V 11.1V 11.1V 11.1V Capacity (mAh) 1100 5400 1300 3500 Discharge Rate (A) 20 108 45.5 105 Weight (lb) 0.77 0.8625 0.23125 0.50995 Price ($) 49.99 69.99 33.99 39.99 Length (in) 6.31 5.5 3.5 4.7 Volume (in^3) 13.55 11.22 2.94 6.11

Venom DRIVE LiPo Battery

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Payload Electronics: Deployment Actuator

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Name PA-14P-18-150 LACT12P-12V-20 FA-PO-150-12-12 FA-HF-100-12-15 Stroke (in) 18 12 12 15 Force (lbs) 150 110 100 150 Input Voltage (V) 12 12 12 12 Feedback? Yes Yes Yes No Weight (lbs) 3.3 3.2 3.85 6.5 Price ($) 138.99 129.95 139.99 149.99

PA-14P-18-150 Actuator

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Payload Electronics: Drive Motor

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Name Robot DC Gearhead Motor Cytron 12V 17RPM 194.4oz-in Spur Gearmotor 227:1 Metal Gearmotor No Load RPM 212 16.7 33 No Load Current (mA) 400 90 200 Stall Current (A) 6 1.8 2.1 Stall Torque (oz-in) 41.66 778 320 Weight (lbs) Unknown 0.353 Unknown Price ($) 20 15 35

Cytron 12V 17RPM 194.4oz-in Spur Gearmotor

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Payload Electronics: Rover Controller

43 Name Arduino Uno Arduino Mega Raspberry Pi Model B Price 30 39 35 Size 7.6 x 1.9 x 6.4 cm 10.16 x 5.35 x 1.24 cm 8.6x 5.4 x 1.7 cm Memory .002 MB .008MB 512 MB Clock Speed 16 Mhz 16 Mhz 700 Mhz On Board Network none none 10/10 wired RJ45 Multi Tasking No no Yes Input voltage 7 to 12 V 7/12 5 V Flash 32KB 256KB SD 2 - 16 *may be Larger USB One Input One input Two, Peripherals OK OS None None Linux Integrated Development Environment Arduino Arduino Any linux supported Digital I/O 14 54 Analog I/O (Can be used for digital) 6 16

Arduino Mega

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Payload Weight Breakdown

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Payload Ground Station

• Because the rocket trajectory can be reasonably estimated (wind conditions,

launchpad location), a directional antenna will be used

• Planning to use two Yagi-Uda antennas, 440 MHz @ 250mW

○ Will act as a receivers during the flight phase ○ Will reconfigure after rocket landing to initiate deployment phase

• Interface with hamshield+arduino
• Telemetry data will be displayed on a laptop via the arduino USB adapter
• Deployment command will be passed by loading the deployment sketch onto

the arduino

○ May include an abort mode if the actuator has feedback, will allow deployment to “retry”

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Payload Ground Station Cont.

• Two Yagis will be used to improve reception
• One Yagi will be level with the horizon, the other will be elevated 45 degrees

○ Subject to change based on testing ○ Will allow telemetry from the rocket to be obtained for more of the flight

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• Each yagi will be able to receive data from separate lobes
• Change configuration when launch vehicle lands

○ Both antennas pointing at horizon, towards landing site ○ One Yagi will be assigned the receiver role ○ One Yagi will be assigned the transmitter role

Safety Overview

Personnel Hazard Analysis Failure Modes and Effects Analysis (FMEA) Hazard Analysis Project Risks

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Hazard Analysis Matrix

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Pre-Mitigation Breakdown: Pre-Mitigation 5 Red 20 Yellow 5 Green

Personnel Hazard Analysis

• Compiled a list of Personnel Hazards that could affect the team throughout

the course of the preliminary design and construction process

• Strategies were also thought of to help mitigate these hazards and failure

modes as much as possible

• All team members will complete the required UC online safety training models

prior to any construction

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Personnel Hazard Analysis

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Personnel Hazard Analysis

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Failure Modes and Effects Analysis

• Compiled list of hazards and failure modes that could potentially affect the

preliminary design phase.

• Hazards and failure modes were organized by design category and ran

through the Hazard Analysis Matrix to receive a Value-Risk Level.

• Strategies were also thought of to help mitigate these hazards and failure

modes as much as possible

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Rocket Failure Modes and Effects Analysis

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Rocket Failure Modes and Effects Analysis

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Payload Failure Modes and Effects Analysis

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Payload Failure Modes and Effects Analysis

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Team Finances

Financial Overview Budget Timeline Revenues Expenses Sponsorship Tiers

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Financial Overview

• $24,000

Overall Funding Goal

• $7,000

Funding Procured as of November 2, 2018

• $12,000

Funding Committed to Project

• $5,000

Funding Expected

• $20,090

Current Projected Expenses

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This number is subject to change

• $610.11

Incurred Expenses as of November 2, 2018

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Revenues

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Procured Revenues Source Amount Procurement Date UC AIC $6,000 October 23, 2018 Sponsorship $1,000 August 25, 2018 Total $7,000 Expected/Committed Revenues Source Amount OSGC Grant $5,000 UC AEEM Department $3,000 CEAS Department of Undergraduate Affairs $3,000 Corporate Sponsorship $6,000 Total $17,000

Expenses

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Incurred Expenses Expense Type Amount NAR Certification Materials $610.11 Total: $610.11 Projected Expenses Expense Type Amount Travel $5,600 Rocket $5,400 Electronics $1,150 Payload $2,400 Educational Outreach $250 Additional Certification Materials $990 Overhead $1,280 Management Reserve $3,020 Total: $20,090

Sponsorship Tiers

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Gold Silver Bronze $1000 $500 $250 Social Media Thank You Post ✔ ✔ ✔ Team T-Shirts Company Logo (Large) ✔ Company Logo (Medium) ✔ Company Logo (Small) ✔ Event Publicity Company Logo on Team Banner ✔ ✔ Company Logo on Rocket ✔

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