Preliminary Design Review University of Alabama in Huntsville - - PowerPoint PPT Presentation

NASA USLI Preliminary Design Review

University of Alabama in Huntsville Charger Rocket Works November 7 th, 2018

Agenda

• Introductions and Team Overview
• Mission Objectives
• Flight Overview
• Testing Plan
• Vehicle Fabrication
• Payload Overview
• Safety
• Outreach
• Budget
• Requirements Compliance
• Questions

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Introductions

• Zachary Ruta, Program Manager
• Hope Cash, Safety Officer
• Marcus Shelton, Chief Engineer
• William Hankins, Vehicle Sub-Team Lead
• Colton Connor, Payload Sub-Team Lead
• Tanner Schmitt, Deputy Safety Officer
• Jade Kirkwood, Vehicle Safety Lead
• Connor Gisburne, Payload Safety Lead
• Dr. David Lineberry, Faculty Advisor
• Mr. Jason Winningham, NAR/TRA Team Mentor,

Level III Certification

• Ms. Vivian Braswell, Graduate Student Mentor

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Mission Statement

The objective of the Charger Rocket Works (CRW) team is to construct a safe and successful Level 2 high powered rocket with deployable unmanned air vehicle as a payload through applying engineering judgement and skills. Additionally, CRW will engage with the community in STEM education events and promoting rocketry to diverse groups.

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Mission Objectives

Vehicle: The rocket will deliver the payload to an altitude of approximately 4800 ft., descend safely and within the Mission Performance Requirements set by NASA, and be recovered in a reusable state. Payload: The payload will deploy from the rocket, fly to a target location, and drop a beacon on target zone all while meeting the desired NASA requirements for the USLI competition. Safety: Comprehensive safety methods will be implemented in all aspects of fabrication, testing, and launches of hardware using in-depth analysis and written procedures and checklists. Outreach: The CRW team will meet a minimum of 200 students through hands-on activities as per the request of NASA and will promote STEM and rocketry to diverse groups.

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Team Organization

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Vehicle

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Vehicle Overview

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Summary of Vehicle Characteristics

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Parameter Value Vehicle Length 119 in Body Tube Diameter 6.17 in Motor Selection L1520T-P Major Vehicle Materials Fiberglass, Aluminum, ABS Plastic Center of Gravity Location 69.5 in Center of Pressure Location 82.9 in

Upper Airframe Overview

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• The length of the upper body tube is 52 in
• The major inner diameter is 6 in
• The length of the nose cone is 26 in
• The payload volume is 24 in long
• The main parachute packs at the aft end of the upper

airframe

• The tracker is mounted in the nose cone

Upper Airframe - Nose Cone

• The nose cone is an ogive profile
• The bulkhead was designed to withstand 200 lbf
• The tracker is a custom CRW-built device
• The tracker mounts on the bulkhead inside the nose

cone

• Shear pins attach the nose cone to the upper body tube

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Upper Airframe - Main

• The parachute shock chord will be attached to the eye bolt at the center of

the upper airframe bulkhead

• The upper airframe main bulkhead was designed to withstand a pulling

force on the eye bolt of 500 lbf

• The payload lies between the nosecone and main parachute bay
• The payload is allotted 24 inches of tube volume and 10 lb mass

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24.00in

Avionics Coupler

• Houses primary and redundant altimeters
• Black powder charge Wells for both main and

drogue parachute

• Provides 6 inches of shoulder length per side of the

switch band

• Eye-bolts on each bulkhead for main and drogue

shock cords

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Avionics Coupler

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Black Powder Charge Wells Stainless Steel I-Bolt Primary and Redundant Arming Switches Primary Stratologger CF Altimeter Primary 9V Lithium Battery Redundant 9V Lithium Battery Redundant Stratologger CF Altimeter

Lower Airframe Overview

Requirements:

• Reach an altitude of 4,800 feet
• Maintain a stability margin of 2 calibers throughout ascent
• Houses the motor and recovery subsystems
• Removable fin can assembly

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Fins and Fin Can

• Fins:
• Adjust CP for stability
• G10 fiberglass sheet
• Fabricated in-house
• Fixed to fin can with 4 #4-40 bolts (each)
• Fin Can:
• Allows fins to be replaced easily
• ABS Plastic for weight and ease of fabrication
• Fabricated in-house
• Fixed to airframe with 8 #4-40 bolts
• Function as centering rings

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Motor Retention and Boat-Tail

Design:

• Currently an open trade
• 3D printed at UAH
• Reloadable motor casing

Load Path:

• Boost Phase
• Motor case
• Thrust plate
• Body tube
• Coast phase
• Boat-tail retains motor

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Aft Bulkhead

• Functions as recovery retention system
• Eyebolt attached through center hole
• Diameter: 6 in
• Aluminum thickness: 0.25 in
• Fixed to body tube with 4 #4-40 screws

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Vehicle Trade Studies

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Motor Trade Study

Motor Manufacturer # of Grains Velocity off the rail (ft/s) Apogee (ft) Max Velocity (ft/s) Max Acceleration (ft/s2) Time to Apogee (s) Stability off the rail (cal) L820-SK CTI 3 44.1 3311 473 163 15.5 1.80 L645-GR-P CTI 3 41.9 4001 492 120 17.4 1.46 L3200 Vmax CTI 3 103 4335 643 734 15.8 2.45 L1150-P Aerotech 3 68.6 4408 584 230 16.9 1.99 L851-WH CTI 3 48.4 4566 569 163 17.8 1.56 L900DM Aerotech 4 49.5 4640 572 167 17.9 1.42 L995-RL CTI 3 61.8 4659 582 224 17.5 1.87 L800 CTI 3 54.4 4748 561 170 18 1.86 L850W Aerotech 3 56.7 4755 569 204 17.8 1.82 L1040DM-P Aerotech 4 52.5 4771 594 209 17.8 1.58 L1050-BS-P CTI 3 57.9 4846 610 211 17.8 2.05 L1720-WT-P CTI 3 74.5 4919 671 360 17.2 2.28 L1520T-P Aerotech 3 70.9 4951 654 306 17.4 2.23 L1355-SS CTI 4 65.9 5109 645 302 17.9 1.65 L1390G-P Aerotech 3 66.2 5178 662 292 17.9 1.95 L1170FJ-P Aerotech 4 61.2 5343 656 237 18.4 1.65 L1350-CS CTI 3 67.4 5817 722 276 18.8 1.93 L1420R-P Aerotech 4 66.5 6114 750 284 19.2 1.62 L1365M-P Aerotech 4 65.6 6316 749 265 19.6 1.53 L1395-BS CTI 4 68.9 6637 794 303 19.9 1.90 L2375-WT CTI 4 86 6751 867 476 19.4 2.06 L1115 CTI 4 61 6834 747 287 20.5 1.86 L2200G-18 Aerotech 4 89 6918 853 556 19.6 1.89

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Selected Motor

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Hardware RMS-75/3840 Single-Use/Reload/Hybrid Reloadable Total Impulse (lbf*s)/(N*s) 835.37 / 3715.9 Propellant Weight (lbm) 4.09 Loaded Weight (lbm) 8.05 Weight After Burnout (lbm) 3.96 Maximum Thrust (lbf) 396.9 Average Thrust (lbf) 352.5 Burn Time (s) 2.64 Aerotech L1520T

Flight Profile

• Maximum speed: 654 ft/s
• Maximum acceleration: 292 ft/s2
• Apogee: 4973 ft
• Time to apogee: 17.8 s

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Trajectory Verification

• Comparison of OpenRocket Trajectory Results vs.

Self-Derived MATLAB/Simulink package.

• In-house code does not have an accurate value of

drag coefficient for the rocket; testing will aid in calculating this value.

• Performs Monte Carlo Analysis

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Stability Margin

• Static margin of 2.23 off the rail
• Calculated using average weather and launch day

conditions.

• Average wind speeds of 5-6 MPH
• 5o minimum rail angle
• Effective rail length
• Values will change as the rocket mass estimates

become better.

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Kinetic Energy Calculations

Body Section Mass (lbm) Kinetic Energy at Touch Down (ft-lbf) Upper Airframe 21.14 54.29 Coupler 2.3 5.91 Lower Airframe 10.22 26.25

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• Heaviest component under main parachute is upper airframe
• All sections descend at 12.86 ft/s (slower than the necessary 15.12 ft/s)
• Set speeds will be reassessed as mass estimates are refined

Drift Analysis

• Made using following assumptions:
• Apogee is over launch rail
• Horizontal wind speed is constant and uni-

directional from apogee to touch down

• Parachutes are immediately opened
• Max drift with 20 MPH wind is 2493 feet

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Recovery

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Recovery System

• Drogue:
• Deploys at apogee
• FruityChutes CFC-18 (CD = 1.5)
• Shock Cords: 50 ft in tubular nylon (½ in)
• Connected between aft bulkhead and avionics

coupler

• Descent velocity: 103.8 ft/s
• Main:
• Deploys at 600 feet AGL
• FruityChutes IFC-120 (CD = 2.2)
• Shock Cords: 50 ft in tubular nylon (½ in)
• Connected between upper bulkhead and avionics

coupler

• Descent velocity: 12.86 ft/s

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Avionics

• Two Stratologger CF altimeters
• One primary and one redundant
• Independent 9V Battery for each
• Arming key switch on coupler switch band
• Black powder terminals for both Drogue and Main

deployment

• Redundant charges will be sized larger than primary

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GPS Tracking

• Xbee-Pro S3B radio transmitter and Antenova GPS
• Transmits between 902 to 928 MHz
• Transmits to distances up to six miles away
• Powered by single CR123 3V Lithium Ion Battery

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Vehicle Fabrication

• Manufacturing will be done in Johnson Research Center

and UAH Machine Shop

• Body tubes fabricated on X-Winder 4 axis filament

winder

• Bulkheads and fin can will be CNC machined
• Avionics fixtures and boattail will be 3D printed
• Fins will be cut from fiberglass sheet

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Vehicle Testing Plan

• Black powder charge testing
• Material strength/ stress testing
• Radio frequency interference testing
• Subscale vehicle launch
• Full scale vehicle demonstration launch
• Full scale payload demonstration launch

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Payload

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Payload Overview

. Overall UAV Design:

• Quadcopter
• Mechanically folding arms
• FPV imaging

Deployment:

• Sheath design
• Unfolding UAV deployment casing

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UAV Mechanical Details

Beacon release system

• Solenoid driven
• One movement release – direct descent
• Actively retained in all direction
• Offset weight of camera assembly

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Deployment

• Unfolded deployment sheath
• Piston ejects by use of black powder
• Bulkheads and internal vehicle body tube create axial

and longitudinal retention

• Unfolding physics of deployment sheath is naturally

self-orientating

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UAV within Deployment

• Folding arms to conserve space
• Retention system:
• Casing restricts vertical

movement

• Pegs restrict horizontal movement

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Airframe Dimensions

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Mass Budget

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Trade Study

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UAV Electronics Trade Selection

Description Quantity Model/Specification Flight computer 1 mRo PixRacer R15 32 bit flight computer FPV camera 1 Caddx Turtle 1080p 60fps Mini HD FPV Camera w/ DVR GPS 1 mRo GPS u-Blox Neo-M8N Power module 1 AUAV Power Module (ACSP5) 10S-LIPO Electronic Speed Controller 4 Airbot Wraith32 V2 BLHeli32 35A ESC Motor 4 EMAX RS2306 2400KV Brushless Motor 4 Pieces Battery 2 ZOP Power 11.1V 4000MAH 3S 30C Lipo Battery XT60 Plug Video transmitter 1 Airy Mini 5848 5.8Ghz VTX Control/telemetry transceiver 1 HKPilot Transceiver Telemetry Radio Set V2

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UAV Block Diagram

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Ground Station Video Receiver 2 X Battery (LiPo 3s) Electric Speed Controllers (ESC) Motor + Propeller Flight Computer Camera GPS + Compass Power Module Video Transmitter Telemetry/Controller Transceiver Transceiver 11.1V Solenoid 5V Power line Data line Legend

UAV Power Budget

Component Voltage (V) Current (A) Power (W) Duty Cycle Supply Efficiency Power Draw (W) Flight computer 5.0 0.045 0.23 100% 90% 0.25 Camera 7.0 0.38 2.66 100% 90% 2.96 GPS 5.0 0.033 0.17 100% 90% 0.18 Transceiver 5.0 0.1 0.50 100% 90% 0.56 Video transmitter 7.0 0.56 3.94 100% 90% 4.37 Solenoid 11.1 0.25 2.78 1% 100% 0.03 Motors 11.1 50.9 564.99 100% 100% 564.99 Total weighted power draw (W) 573.34 Total battery capacity (WHr) 88.8 Run time (min) 9.29

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\

UAV Link Budget (Telemetry/Command Deployment)

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Dipole Antenna Dipole Antenna

RX sensitivity (dB) Transmit power (dBm) RX Antenna Gain (dB) TX Antenna Gain (dB) Link Margin (dB) RX Antenna Loss (dB) TX Antenna Loss (dB) Maximum free space loss (dB) Frequency (GHz) Range (km)

• 117

20 2.15 2.15 12 2 2 125.3 0.915 48

48 km

UAV Link Budget (Video Link)

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RX sensitivity (dB) Transmit power (dBm) RX Antenna Gain (dB) TX Antenna Gain (dB) Link Margin (dB) RX Antenna Loss (dB) TX Antenna Loss (dB) Maximum free space loss (dB) Frequency (GHz) Range (km)

• 95

20 9.5 2.15 12 2 2 108.5 5.8 1.4

1.4 km

Biquad Antenna Dipole Antenna

Deployment Electrical System

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Microcontroller 6V power supply (batteries) 3.3V power supply (buck regulator) XBee radio Latch actuator (solenoid) Dual E-match firing circuits Arming indicator Ground station Controller Transceiver Power line Data line Legend 12V power supply (boost convertor)

Payload Propulsion Sub-System

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Parameter Value Maximum thrust (lbf) 7.49 Weight (lbf) 3.53 Thrust-to-weight ratio 2.1 Nominal throttle point (lbf) 4.19 Airspeed (mph) 30.1 Range (mi) in 20 mph headwind 1.44 Flight time (min) 9.29

Deployment Sub-System

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Deployment Controller Retention Latch Deployment Signal Receiver

• Black powder deploys payload
• Latch secures payload until

deployment

• No transmission from radio

Deployment Piston

• Redundant black powder charges
• Piston deploys complex assembly
• Payload
• Orientation sheath
• Nosecone

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Payload Testing Plan

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Drop Test Ejection Test Video Range Test Control/Telemetry Range Test Purpose To test the durability

• f the UAV structure

To test the ejection of the payload from the vehicle To test the range of the video receiver To test the range of the controls Procedure Drop the UAV from a predetermined height Load the deployment system in a body tube and eject using black powder Increase the distance between the UAV and ground station until connection is lost Increase the distance between the UAV and ground station until connection is lost Desired Result No damage to the structure of the UAV Full ejection with no damage to the deployment or payload system Range of the video exceeds half a mile Range of the controls exceeds half a mile

Payload Testing Plan

Flight Endurance Test Flight Range Test Flight Test Retention Test Purpose To test the time limit

• f flight for the UAV

(find deviation from presumed limit) To test the overall flight range of the UAV To test the overall stability of flight To test the retention system of the deployment system Procedure Continuously hover the UAV until power is lost Continuously fly in a precise circle to calculate the overall flight distance Ascend the UAV, travel a predetermined distance, drop the beacon, and descend Lock the deployment into place, then apply loads to test retention Desired Result Flight time is roughly nine minutes Flight distance covers at least half a mile Complete overall flight control with working systems Have complete retention of the deployment system without failure

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Key Safety Personnel

• Hope Cash, Safety Officer
• Tanner Schmitt, Deputy Safety Officer
• Jade Kirkwood, Vehicle Team Safety Lead
• Connor Gisburne, Payload Team Safety Lead

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Hope Cash

Safety Officer

Tanner Schmitt

Deputy Safety Officer

Jade K.

Vehicle Team Safety Lead

Connor G.

Payload Team Safety Lead

Training

• 17 members of the 20 person team have been Red Cross CPR/AED/First Aid certified
• Multiple safety briefings carried out through the year to ensure safety is always a priority
• Each Team member has signed Safety Pledge

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Safety Training Schedule Training Topic Date CPR/AED/First Aid 10/4/18 – 10/19/18 Basic Emergency Procedures 10/18/18 Black Powder Testing and Motor Safety 10/30/18 Outreach Safety 11/1/18

Launch Checklists and SOPs

• Safety Operating Procedures are written, planned procedures intended to guide testing and ensure safe
• peration throughout the course of the test
• All SOP’s must be reviewed by the Safety Officer, Red Team, and Propulsion Research Center Staff
• Launch Checklists are also made for every launch
• The Launch Checklists make sure that every step in the launch is carried out in the safest manner
• Launch Checklists must also be reviewed by the Safety Officer, Red Team, and Propulsion Research Center

Staff

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Hazard and Risk Assessment

• The Safety Team analyzed the various risks, hazards, and failure modes present in the Student Launch

project

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RAC Probability Level Severity Level 1 Catastrophic 2 Critical 3 Marginal 4 Negligible A – Highly Probable 1A 2A 3A 4A B – Likely 1B 2B 3B 4B C – Moderate 1C 2C 3C 4C D – Unlikely 1D 2D 3D 4D E – Improbable 1E 2E 3E 4E Severity Level Description Criteria 1 – Catastrophic Loss of life or permanent injury, irreparable major damage to facilities

• r hardware, complete project failure.

2 – Critical Severe personal injury, significant damage to hardware or facilities, significant impact on overall schedule. 3 – Marginal Minor personal injury, reparable damage to facilities or hardware, significant impact on immediate schedule. 4 – Negligible Minor personal injury, little to no damage to hardware, little impact on immediate schedule.

Next Steps

• Scheduled Black Powder Test – Thursday, November 8th
• Scheduled Sub-Scale Launch – Saturday, November 10th
• Fabrication of Payload – Coming Weeks

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Outreach

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Past Events

• Oct. 12 – Outreach at St. Francis Borgia Regional

High School

• CRW Team member: Connor Gisburne
• Rocketry Basics Presentation
• Activity: Estes Rockets built and launched.
• Survey Results:
• Informative: 4.54/5
• Fun:4.69/5

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Upcoming Events

• Nov. 3 – Girls Science and Engineering Day
• Partnership with Propulsion Research Center Student Association & UAH Society of Women Engineers
• Activities: Stomp Rockets & CD Hovercrafts
• Anticipated number of individuals: ≈200
• Nov. 10 – UAH Society of Women Engineers
• Partnership with UAH Society of Women Engineers
• Activities: Rocketry Basics Presentation
• Anticipated number of individuals: ≈100

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Future Events

• December 2018: High school outreach
• CRW team members
• Activity: Estes Rockets & Rocketry Basics Presentation Presentation
• Spring 2019: Science Olympiad
• CRW team members
• Activity: Rocketry Basics Presentation
• TBA: Davis Hill Elementary School
• Activity: Propulsion and Vehicle Design
• TBA: Challenger Middle School
• Projectile Motion and Forces

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Budget

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Budget Summary Totals Sub-Scale Rocket $667.92 Full-Scale Rocket $2,574.45 UAV Payload $1,328.88 STEM Outreach $400.00 15% Margin $745.69 Grand Total $5,716.93 Total Expenditures as

• f PDR

$667.92

Requirements Compliance Plan

• Vehicle requirements will be verified primarily through testing of vehicle subsystems and the full launch

vehicle

• Payload requirements will be verified by testing of the UAV systems during and after full construction and

integration

• Safety requirements will be verified via Safety Briefings and the creation of Standard Operating Procedures,

Launch Procedures, and Launch Checklists for all testing and launches

• Laws and Regulations are available in the CRW Safety Manual, and the CRW Safety Pledge covers the

compliance of all regulations by the CRW team.

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Questions

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Appendix

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Theoretical Recovery Drag

 Parachute Recovery Systems Design Manual by Theo Knacke  Drag Coefficients do not exceed 1.0  Values specified by manufacturers are incorrectly derived  Subscale and Full Scale testing will assess the accuracy of these studies with respect to the project

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Funding Sources

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