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

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NASA SL Preliminary Design Review University of Alabama in Huntsville University of Alabama in Huntsville 11/3/2017 1 USLI PDR Mission Summary ry Design, fabricate, test and fly a rocket and payload to 1 mile in altitude Deploy a

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SLIDE 1

University of Alabama in Huntsville

NASA SL Preliminary Design Review

11/3/2017 University of Alabama in Huntsville USLI PDR 1

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SLIDE 2
  • Design, fabricate, test and fly a rocket and

payload to 1 mile in altitude

  • Deploy a rover upon landing to autonomously

travel and unfold solar panels

  • Conduct STEM outreach with students

*Throughout the presentation, all dimensions are in inches

Mission Summary ry

11/3/2017 University of Alabama in Huntsville USLI PDR 2

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SLIDE 3

VEHICLE DESIGN

University of Alabama in Huntsville USLI PDR 3 11/3/2017

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SLIDE 4
  • Launch Vehicle Dimensions

– Fairing Diameter: 6 in. – Body Tube Diameter: 4 in. – Mass at lift off: 39.7 lbm. – Length: 96 in.

  • Concept

– L-Class Solid Commercial Motor – Rover Delivery – Electronic Dual Deployment – Fiberglass Airframe

Vehicle Summary ry

11/3/2017 University of Alabama in Huntsville USLI PDR 4

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SLIDE 5

Vehicle System Locations

11/3/2017 University of Alabama in Huntsville USLI PDR 5

Rover Piston Main Parachute Drogue Parachute Coupler 12 in. Tracking/Rover Deployment Avionics Fins (x4) Recovery Avionics Forward Airframe 24 in. Aft Airframe 41 in. Payload Fairing 36 in. CG 51 in. CP 63 in.

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SLIDE 6

Vehicle CONOPS

11/3/2017 University of Alabama in Huntsville USLI PDR 6

Powered Ascent: 0 – 3.2 seconds 0 – 1,050 ft. Deploy Drogue: 19 seconds 5,282 ft. Deploy Main: 50 seconds 600 ft. Landing: 100 seconds 0 ft. Deploy Rover: Team Command

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SLIDE 7
  • OpenRocket Sim:

– A 1-D in house Monte Carlo simulation will be used to verify results – Results will also be compared to flight tests for verification

Fli light Sim imulation

11/3/2017 University of Alabama in Huntsville USLI PDR 7

Attribute Value Apogee (ft.) 5282 Length (in.) 96

  • Max. Mach Number

0.56 Rail Exit Velocity (ft./s) 55.7 Static Stability (cal.) 2.0 Motor Designation AT L1520T - P Thrust-to-Weight Ratio 8.7 CG 51 in. CP 63 in.

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SLIDE 8
  • Apogee of approximately 5282 ft. at 19 sec.
  • Motor burnout at approximately 1050 ft. at 3.2 sec.

Simulation Results

11/3/2017 University of Alabama in Huntsville USLI PDR 8 50 sec. Main deploy (600 ft.) Apogee of 5282 ft. (19 sec.) Burnout at 3.2 sec.

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SLIDE 9
  • Stability of 2.06 cal. at rail exit

– Calculated with no wind conditions

  • Stability of 2.74 cal. at motor burnout

Stability Analysis

11/3/2017 University of Alabama in Huntsville USLI PDR 9 Takeoff Stability: 2.06 Maximum Stability: 2.74

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SLIDE 10

UPPER AIR IRFRAME

University of Alabama in Huntsville USLI PDR 10 11/3/2017 Nose Cone Payload Fairing Transition Forward Body Tube

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SLIDE 11

Obje jectives

  • Protect and deploy the payload
  • House assembly for tracking vehicle location
  • Transition upper airframe to payload fairing

Forward System Overview

11/3/2017 University of Alabama in Huntsville USLI PDR 11

Payload Piston Avionics Bay

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SLIDE 12
  • 3D printed High Strength ABS
  • Ejected with rover deployment
  • Room to store ballast for stability
  • No electronics housed inside
  • Shear pin interface
  • Bulkhead at base
  • 6 in. ellipsoid shape
  • 2 in. shoulder

Nose Cone and Fairing

11/3/2017 University of Alabama in Huntsville USLI PDR 12

6.0 in. 2.0 in.

  • Responsible for housing the rover and rover

deployment system​

  • Filament wound fiberglass

6.0 in. 24.0 in.

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SLIDE 13
  • Used to deploy rover from fairing
  • Spring driven spike punctures cartridge
  • Spring released by hotwire upon

command; redundant arming

Pis iston Overview

11/3/2017 University of Alabama in Huntsville USLI PDR 13

Plunger Ø 6.0 in. Cylinder Ø 6.0 in.

  • Machined from aluminum​
  • Powered by 8 or 12 gram CO2 cartridge​
  • Plunger tethered to base​
  • Standard Operating Procedure in development
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SLIDE 14
  • Aerodynamic transition between upper airframe and fairing,

load path supplemented with aluminum insert

  • 3-D printed with ABS plastic, single piece design
  • Threaded rod in tension connecting to aft bulkhead to built in

forward coupler

Fairing Transition

11/3/2017 University of Alabama in Huntsville USLI PDR 14

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SLIDE 15
  • Problems with ABS single piece design

– Mass: 4.7 lbm – Complicated FEA – Structurally weak without aluminum insert – Aluminum insert could pose manufacturing difficulties

  • Other options considered:

– Aluminum brace with direct bulkhead connection, purely aerodynamic cover

Fairing Transition

11/3/2017 University of Alabama in Huntsville USLI PDR 15

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SLIDE 16

CENTRAL SUBSYSTEM

University of Alabama in Huntsville USLI PDR 16 11/3/2017

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SLIDE 17
  • Central Subsystem responsibilities:

– Primary coupler between airframes – Flight Avionics – Ejection System – Tracking and Ground Station – Recovery System

Central Subsystem Overview

11/3/2017 University of Alabama in Huntsville USLI PDR 17

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SLIDE 18

Coupler

11/3/2017 University of Alabama in Huntsville USLI PDR 18

U Bolt (2 Places) Black Powder Housing (4 Places) Stratologger CF Altimeter (2 Places) 9V Battery (2 Places) Switch/Pressure Equalization holes (2 Places) All-Thread (2 Places) 1 in. Switchband Aluminum Bulkheads 3D Printed Avionics Sled

9 in. 12.5 in. 1 in.

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SLIDE 19

Recovery Avio ionics Subsystem

  • 2 PerfectFlite StratoLoggerCF altimeters; each

with a 9V battery and SPDT momentary activation switch

  • 4 Safe Touch terminals, E-matches, and black

powder charges

  • Full

ll re redundancy in in avionics and ig igniti tion

Avionics

11/3/2017 University of Alabama in Huntsville USLI PDR 19

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SLIDE 20

Recovery ry Deployment Avio ionics

11/3/2017 University of Alabama in Huntsville USLI PDR 20

  • Normally Closed SPDT Pull Pin

Microswitch – Prevents detonation during assembly – Helps preserve battery life

  • Primary Drogue charge fired at apogee

– Secondary fired one second after

  • Primary Main fired at 600 ft.

– Secondary fired at 550 ft.

  • Primary charges are roughly 4 g of

black powder

  • Secondary charges are 2 g larger

than primary

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SLIDE 21

GPS Tracking Subsystem

11/3/2017 University of Alabama in Huntsville USLI PDR 21

System

  • CRW will reuse a previously designed PCB that contains an Xbee Pro-

PRO 900HP RF module, and an Antenova GPS Chip – PCB will includes traces for all relevant connections including battery sources.

  • Xbee transmits GPS coordinates to a receiver connected to the

ground station laptop.

  • Tests will be performed prior to the full scale launch to verify
  • peration success

Stru Structure Integr gratio ion

  • 3D printed mount to secure tracker and its essentials within the

transition section of the rocket.

  • Three axis security and battery retention to ensure components are

kept in tact

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SLIDE 22
  • Drogue Parachute Deployment:

– Deployment at apogee – Fruity Chute CFC-18 (CD = 1.5) – Shock Cords: 1 inch Nylon (50 ft.) – Connected between forward motor retention bulkhead in lower airframe and avionics bay housing. – Descent speed under drogue: 62.2 ft/s

  • Main Parachute Deployment:

– Deployment at 700 ft. above ground level – Fruity Chute 60 in. Iris Ultra (CD = 2.2) – Shock Cords: 1 inch Nylon (50 ft.) – Connected between fairing bulkhead and avionics bay housing. – Descent speed under main: 15.23 ft/s

Recovery ry System

11/3/2017 University of Alabama in Huntsville USLI PDR 22

  • Open Rocket Simulation between 0 and 20 mph winds showed a

maximum drift at 15 mph of about 1,700 ft.

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SLIDE 23
  • Required that each individual

section will have a maximum kinetic energy of 75 ft-lbf

  • For initial calculations, a

conservative estimate of 75 ft- lbf was used for the heaviest section

  • 𝐿𝐹 = 1

2 𝑛𝑤2

– m = mass of the section, lbm – v = velocity, ft/s

  • The largest independent section

is 15 lbm, so the safe descent speed was determined to be 17.9 ft/s

  • 𝐸 =

8𝑛𝑕 𝜌𝜍𝐷𝐸𝑤2

– D = diameter of parachute, ft. – m = mass of vehicle, lbm – g = force of gravity, ft/s2 – 𝝇 = density of the air, lbm/ft3 – CD = Coefficient of Drag – v = previously calculated velocity, ft/s

  • Minimum Diameter must be

93.3 inches

Recovery ry System Calc lculations

11/3/2017 University of Alabama in Huntsville USLI PDR 23

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SLIDE 24
  • The load in 1, 2, and 3 are

causing tension under Drogue and Main. Shock cord applies load to eyebolt in the coupler bulkhead.

  • The load in 4 is transferred

through the all thread and down to the motor casing then back up the tube. represents force due to drag represents the force due to mass

Load Path (D (Drogue and Main in)

11/3/2017 University of Alabama in Huntsville USLI PDR 24

1 2 3 4

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SLIDE 25

AFT SUBSYSTEM

University of Alabama in Huntsville USLI PDR 25 11/3/2017

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SLIDE 26
  • Objectives/Responsibilities

– Fin Design ▪ Optimize dimensions and materials for flight stability – Centering Ring/Thrust Plate ▪ Carry load path from the vehicle ▪ Centering and fin integration ability – Forward/Recovery Retention ▪ Provide method for recovery attachment ▪ Carry thrust through the vehicle via forward retention

Aft ft System Objectives

11/3/2017 University of Alabama in Huntsville USLI PDR 26

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SLIDE 27
  • Design Overview

– Through the wall design/slotted body tube ▪ Slots allow for fin mounting integration – G10 Fiberglass fins attached with seven 4-40 bolts per fin ▪ Fins will be mounted to centering ring – 3-D printed centering ring/fin mounting bracket ▪ Can be removed from body tube for repair/inspection – Aluminum Forward/Recovery retention bulkhead ▪ Uses U bolt for recovery system ▪ Motor case tapped to allow for forward retention

Aft ft System Components

11/3/2017 University of Alabama in Huntsville USLI PDR 27

Fin Can/Centering Ring Motor/Motor Casing Thrust Ring Trapezoidal Fin(s) (4) Forward/Recovery Retention Bulkhead Secondary Centering Ring

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SLIDE 28

Motor Selection

11/3/2017 University of Alabama in Huntsville USLI PDR 28

Aerotech L1520R-P Specifications Motor Designation L1520T-P Apogee 5,282 ft. Stability 2.0 cal. Ballast 51 in. Diameter 75 mm. (3 in.) Length 25.7 in. Propellant Mass 8.0 lbm Total Impulse 835 lbf.-s Max Acceleration 289 ft./s2 Velocity off the Rail 55.7 ft./s Burn Time 2.5 sec

  • Other motors considered:

– L1150 ▪ Too little total impulse – L850 ▪ Too slow off the rail – L1390 ▪ Too much total impulse

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SLIDE 29

Motor Retention

  • Forward Retention

Bulkhead

– Screwed onto top of motor – Recovery retention is fixed on U-bolt – 3.9 in. diameter – 0.5 in. thick Aluminum – Fixed to body tube with four ¼-20 screws

University of Alabama in Huntsville USLI PDR 29 11/3/2017

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SLIDE 30
  • Requirements fulfilled by part: motor centering, fin

mounting, thrust takeout from motor

  • Material: 3D printed high strength ABS plastic
  • Location: inserted in the bottom of the aft body

tube

Fin Can

11/3/2017 University of Alabama in Huntsville USLI PDR 30

Fin Can

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SLIDE 31

Fin Can Dimensions

11/3/2017 University of Alabama in Huntsville USLI PDR 31

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SLIDE 32
  • Purpose: align motor as it is inserted into the rocket
  • Bolted to the aft body tube using 4-40 bolts
  • Material: Polycarbonate

Secondary ry Centering Rin ing

11/3/2017 University of Alabama in Huntsville USLI PDR 32

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SLIDE 33
  • Trapezoidal Fin Design

– Allows more freedom in fin design – Adjust fin shape to shift CP

  • Fin Dimensions

– 8 in base – 3.5 in height with extended base for body tube insertion – Seven holes allow integrated mounting to centering ring located inside body tube – Rounded leading edge

  • Fin Material

– G10 Fiberglass – Will be fabricated/designed in house

  • Fin Mounting

– Fins mounted through the body tube to centering ring – Replaceable upon breakage/damage

  • Flutter speed

– Calculated to be 1444.76 mph (Mach 1.88)

Fin Design

11/3/2017 University of Alabama in Huntsville USLI PDR 33

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SLIDE 34
  • Fins made out of G-10

fiberglass

  • This material was

chosen for its high strength to weight ratio

  • Tensile Strength:

– Crosswise: 38 ksi – Lengthwise: 45 ksi

  • Flexural Strength:

– Crosswise: 65 ksi – Lengthwise: 75 ksi

Fin Material

11/3/2017 University of Alabama in Huntsville USLI PDR 34

  • Flexural Modulus:

– Crosswise: 2400 ksi – Lengthwise: 2700 ksi

  • Compressive Strength: 65 ksi
  • Its density is 0.065 lbm/in^3.
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SLIDE 35

Fin Retention

  • Each fin mounted with

seven 4-40 bolts; normal to fin face

  • Four sets of ten 4-40

bolts normal to body tube surface used to maintain body tube shape under motor thrust

University of Alabama in Huntsville USLI PDR 35 11/3/2017

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SLIDE 36
  • Approximately half-scale

– 4 in. body → 2.125 in. body – 6 in. fairing → 3 in. fairing – Mach 0.56 → 0.49

Subscale Rocket

11/3/2017 University of Alabama in Huntsville USLI PDR 36

Subscale Rocket Full-Scale Rocket

– 3 in. motor → 1.5 in. motor – 96 in. length→ 49 in. length – 9.0 G → 15.2 G

3.0 in 6.0 in

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SLIDE 37

PAYLOAD DESIGN

University of Alabama in Huntsville USLI PDR 37 11/3/2017

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SLIDE 38
  • Objective: Design an autonomous rover that will deploy from

the interior of the rocket, move a minimum of 5 ft. away from the rocket, and deploy solar panels

  • The rover’s design consists of a rectangular chassis, two

expandable wheels, and a stabilizing arm

  • The rover measures temperature, pressure, location, and

transmits this data with images to a ground station

Payload Summary ry

11/3/2017 University of Alabama in Huntsville USLI PDR 38

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SLIDE 39

Rover Assembly

11/3/2017 University of Alabama in Huntsville USLI PDR 39

  • The tail will be wrapped around the chassis while inside the fairing.
  • Rover will be kept collapsed passively by the fairing.
  • The collapsed diameter is 5.7 in with 0.15 in of clearance.
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SLIDE 40

Rover Assembly

11/3/2017 University of Alabama in Huntsville USLI PDR 40

  • Rover wheels will expand to

14.24 in. diameter when deployed

  • Wheels rotate
  • independently. Allows for

steering via differential

  • Lid will slide open via linear

gear driven by a DC motor

  • Solar panel will increase its

effective area from 0 to 100%

  • Solar panel will charge

battery for distance extension

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SLIDE 41
  • Aluminum Unibody selected

– Highest strength to weight design – Resistant to drastic changes in temperature – Least deflection under load protects motors and electronics

  • 3D Printed ABS Unibody is secondary selection

– Will be used if aluminum unibody is too difficult to manufacture

Rover Chassis Trade Study

11/3/2017 University of Alabama in Huntsville USLI PDR 41

Aluminum Unibody 3D Printed ABS Unibody Aluminum Base/3D Printed ABS Walls Ease of Manufacturing 2 5 4 Strength to Weight 5 2 3 Environmental Protection 5 2 1 Total Score 12 9 8

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SLIDE 42
  • The chassis will be milled out of a single block of 6061-T6 aluminum
  • The chassis will house all electronics
  • The drive motors will be mounted directly to the sidewalls
  • The tail will be mounted to the bottom of the chassis

Rover Chassis Design

11/3/2017 University of Alabama in Huntsville USLI PDR 42

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SLIDE 43
  • The chassis can sustain a 30G (210 lbf) load to the sidewall, simulating a load from

the wheel during adverse deployment conditions (left)

  • The chassis can sustain a 30G (210 lbf) load to the base, simulating loading from

inside the rocket upon landing (right)

Rover Chassis Stress Analysis

11/3/2017 University of Alabama in Huntsville USLI PDR 43

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SLIDE 44
  • Measuring Tape selected

– Ease of manufacturing – Results in a longer tail and moment arm

  • Sideways Hinged Aluminum is secondary selection

– Will be used if measuring tape fails integration and deployment tests

Rover Tail Trade Study

11/3/2017 University of Alabama in Huntsville USLI PDR 44

18 inch Measuri uring ng Tape (Wrapped ed around) d) 11 inch Sideways ys Hinged Hinged Aluminum Aluminum Tail ail Ease of Manufacturing 5 2 Strength 3 5 Tail Length th 5 3 Total Score 13 10

Wheel Rotation

Counter moment from tail

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SLIDE 45
  • Main Goals for design: Expanding wheels

– 6 in. diameter constraint while inside rocket – > 6 in. diameter desired for handing terrain

  • Chosen Design: Umbrella wheel

– Desired for handling terrain – All designs similarly decent in other categories

Trade Study: : Wheel Desig ign

11/3/2017 University of Alabama in Huntsville USLI PDR 45

Telescoping Wheels Foam Umbrella wheel Cost 3 4 3 Design Complexity 2 4 3 Low Risk of Damage 4 5 4 Terrain Effectiveness 4 1 5 Total 13 14 15

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SLIDE 46
  • Main Considerations:

– Pushing wheels out of rocket without taking damage – Ease of manufacturing wheel shapes

  • Chosen Material: Aluminum

– Highest strength while maintaining low weight – Easiest to manufacture wheels

Trade Study: : Wheel Material

11/3/2017 University of Alabama in Huntsville USLI PDR 46

Aluminum ABS Polycarbonate Cost 4 3 3 Design Complexity 5 4 4 Weight 3 5 4 Strength of Material 5 3 4 Total 17 15 15

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SLIDE 47
  • Current Chosen Design: Umbrella

Wheel – 0.703 lbm

– 5.7 in. diameter wheel expands to 14 in. diameter wheel – Linear extension spring for compression and expansion – Keeps compressed while in rocket, expands naturally once out – Spring located on the exterior, pulls in to bring spoke vertical – Rod used for assembly of main wheel to spokes

Wheel Design

11/3/2017 University of Alabama in Huntsville USLI PDR 47

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SLIDE 48
  • Made of Aluminum 6061 – T6
  • Eight notches for eight spokes, holes for attaching spokes with rod

Wheel Desig ign Main in Wheel

11/3/2017 University of Alabama in Huntsville USLI PDR 48

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SLIDE 49
  • 6061 – T6 Aluminum
  • 0.75 in. extrusion for grip with expanded wheel
  • Circular piece for attaching to wheel base

Wheel Desig ign Spoke

11/3/2017 University of Alabama in Huntsville USLI PDR 49

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SLIDE 50
  • 6061 – T6 Aluminum
  • Attaches to wheel base

Wheel Desig ign Motor Mount

11/3/2017 University of Alabama in Huntsville USLI PDR 50

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SLIDE 51
  • Can withstand 120 lbf before yielding
  • Load: Pushed out by piston, no more than few pounds
  • Will likely be more distributed to entire wheel base

Main Wheel

11/3/2017 University of Alabama in Huntsville USLI PDR 51

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SLIDE 52
  • Can withstand 35 lbf before yielding to 40 ksi
  • Max Stress – 15 ksi

– Full weight of rover and motor torque

Spoke

11/3/2017 University of Alabama in Huntsville USLI PDR 52

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SLIDE 53
  • Can withstand 900 lbf before yielding
  • Load: Pushed out by piston, absorbed by other parts
  • Max load by piston no more than a few pounds

Motor Mount

11/3/2017 University of Alabama in Huntsville USLI PDR 53

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SLIDE 54
  • Sliding solar panel lid utilizing

remote servo gear

  • Solar panels will remain static
  • Solar panels recharge battery

Solar Deployment

11/3/2017 University of Alabama in Huntsville USLI PDR 54

Gear System Hinge Simplicity 3 4 Functionality 5 3 Weight 2 2 Cost 1 1 Total Score 11 10

  • Two different designs considered for solar

panel deployment mechanism​ ̶ Gear system lid​ ̶ Hinged lid​

  • Lid with gear system was selected

– Hinge mechanism would be harder to close once opened – Gear system would be easier to bring the cover back over the solar panels

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SLIDE 55

Rover Mass Budget

  • The mass of all components totaled 6.4 lbm.
  • A 10% Margin was added to the total weight to

account for fasteners, adhesives, and design changes

University of Alabama in Huntsville USLI PDR 55 11/3/2017

Component Mass (lbm) Chassis 2.5 Wheel Assembly 1.4 Lid/Solar Deployment 1.0 Tail 0.1 Electronics 1.4 10% Margin 0.6 Total 7.0

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SLIDE 56

Li-Ion 18650 CR123A Surefire Energizer Recharge Power Plus Power 4 3 4 Capacity 5 4 4 Weight 4 3 2 Safety 3 5 5 Reusability 5 5 5 Power Density 5 3 2 Total 26 23 22

Battery ry Trade Study

11/3/2017 University of Alabama in Huntsville USLI PDR 56

  • Three different batteries considered

– 3x Li-Ion 18650 in series – 4x CR123a Surefire in series – 8x Energizer Recharge Power in series

  • Trade studies conducted by rating each battery’s benefits on a scale of 1 – 5
  • Li-Ion 18650 was selected based on criteria
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SLIDE 57

MCU Trade Study

11/3/2017 University of Alabama in Huntsville USLI PDR 57

Arduino Mega Arduino Uno PCB with ATMega 2560 Beaglebone Raspberry Pi 3 Clock Speed 3 3 3 5 5 I/O Pins 5 3 5 3 4 Operating Voltage 4 3 4 2 4 Power Draw 4 4 4 3 1 Complexity 4 4 2 5 2 Volume 3 4 3 4 3 Mass 4 5 4 4 3 Cost 4 4 2 2 4 Total 31 30 28 28 28

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SLIDE 58

Component Selection

11/3/2017 University of Alabama in Huntsville USLI PDR 58

Component Sel Selection Fea eatures MCU Arduino Mega

  • (7 – 12) Vin
  • I2C, SPI, UART, GPIO
  • 16 MHz

IMU Adafruit LSM9DS0

  • Accelerometer
  • Gyroscope
  • Magnetometer
  • 3 Axis
  • I2C, SPI

Temperature and Pressure Sensor Adafruit BMP280

  • Press range: (300 – 1100) hPa
  • Temp range: (-40 – 85) °C
  • SPI, I2C
  • 0.8" x 0.7" x 0.1"

Motor Cytron DC Geared Motor SPG30-300K

  • 12 V
  • At load 410 mA
  • Stall torque 1.18 Nm
  • Mass: 160 g
  • Brushed
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SLIDE 59

Selection cont.

11/3/2017 University of Alabama in Huntsville USLI PDR 59

Component Sel Selection Fea eatures Solar Cell OSEPP Monocrystalline Solar Cell

  • 100mA
  • 5 V
  • 4” x 3” x 0.2”

GPS Adafruit MTK3339

  • 5V
  • 20 mA
  • 10 Hz updates
  • 165 dBm sensitivity

Radio X-Bee PRO

  • 28 mile range (with high gain antenna)
  • 900 MHz
  • Data rate 200 kbps
  • UART, SPI

Lid Motor NMB Technologies PPN7PA12C1

  • 5V DC
  • Brushed
  • 0.022 lbm

DC/DC converter LM3671 Buck Converter

  • 3.3 V output
  • 600mA draw
  • 0.6" x 0.4" x 0.1"

Camera ArduCam CMOS OV7670

  • 640×480 VGA
  • 3.3V supply needed
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SLIDE 60

Component nent Current nt (mA) Voltag tage (V) Time me (hr hr) Duty Cycle (%) Efficie iency ncy (%) Necessary ary Capacity ity (mAhr)

Arduino Mega 50.0 5.00 1.00 100 100 22.5 Pressure/ Temp 1.12 5.00 0.25 100 100 0.13 IMU 6.10 5.00 1.00 100 100 2.75 Wheel Motors 820 11.1 0.17 100 100 136 Lid Motors 96.0 5.00 0.01 100 100 0.43 Radio 210 3.30 1.00 100 80.0 78.0 Camera 20.0 3.30 0.25 100 80.0 1.86 GPS 20.0 5.00 0.25 100 100 2.25 Voltage Regulator 600 5.00 1.00 100 100 270

Power Budget

11/3/2017 University of Alabama in Huntsville USLI PDR 60

Required battery capacity =

𝐽 𝑛𝐵 ∗𝑊 𝑊 ∗𝐸𝐷 ∗𝑈𝑗𝑛𝑓 ℎ𝑠 𝐹𝑔𝑔𝑗𝑑𝑗𝑓𝑜𝑑𝑧 ∗11.1 𝑊

Required uired Capacity ity (mAhr) Available lable Capacity ity (mAhr) Safety ty Facto tor

514 2600 5.06

slide-61
SLIDE 61

11/3/2017 University of Alabama in Huntsville USLI PDR 61

Component Block Diagram

slide-62
SLIDE 62

Payload Soft ftware Flo low Dia iagram

11/3/2017 University of Alabama in Huntsville USLI PDR 62

Remove RBF; Payload detects launch via acceleration Takes acceleration data throughout flight, calculates changes Once acceleration is zero for several iterations, waits for deployment signal from ground station Rover transmits acknowledgement, waits for confirmation signal Receives confirmation signal; Delays 30 seconds Supplies power to motor, begins taking temperature, pressure, and IMU data Get position data via GPS and accelerometer; Sample 2 times per second Transmit data back to ground station, save on board to eeprom If position change by a certain margin, back up, turn motor, begin moving again Once distance traveled, deploy solar panels, end data collection Measure battery voltage Transmit data back to ground station, save on board to eeprom

slide-63
SLIDE 63

REQUIREMENTS COMPLIANCE

University of Alabama in Huntsville USLI PDR 63 11/3/2017

slide-64
SLIDE 64

Requirements Compliance Pla lan

University of Alabama in Huntsville USLI PDR 64 11/3/2017

  • Demonstration

– System verification through repeatable exhibition of the design feature – Pre-determined pass/fail criteria – Parachute deployment, repeat flight tests, capability to launch within an hour

  • Testing

– Demonstration of system with known input and output values – Numerical data feedback as well as demonstrative verification – Static motor fire, flight test with altimeters, recovery location tracking

  • Inspection

– Nondestructive/passive examination of the system – No numerical data collected – Design components present, use of checklists, follow safety guidelines

  • Analysis

– Calculation of performance prior to any physical testing – Completely theoretical based on expected performance – Simulation software, FEA, hand calculations, CAD

  • All requirements, both USLI and derived, will be complied

with, and verified using the following methods

  • The requirements may be found in the PDR Document
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SLIDE 65
  • Test launches will only occur at

NAR or TRA sponsored launch events.

  • Only the mentor is allowed to

handle rocket motors

  • The rocket will use an L motors

and will not exceed the impulse limit set by NASA

NAR and FAA Compliance

11/3/2017 University of Alabama in Huntsville USLI PDR 65

slide-66
SLIDE 66

Launch Vehicle Verification

11/3/2017 University of Alabama in Huntsville USLI PDR 66

Recovery Ejec Ejection Cou Couple ler Str Strength Motor

  • r Thrust/ Loa

Load Path th Si Simulation/ Aer erodynamics Ov Overall System Perf erformance Will the parachutes eject properly with the planned explosives? Will the rocket buckle at the coupler under max. thrust? Is the load path sufficiently strong/how does the motor behave when fired? Is the simulation accurate/is the rocket stable? Does the rocket reach the expected altitude/does every component work properly? Multiple ground ejections of each component Apply calculated moment to coupler Static fire of the motor, measuring thrust through the high-risk loadpath components Launch a subscale version

  • f the rocket

multiple times Launch the full-scale (final) rocket multiple times

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SLIDE 67

General Requirements Compliance

  • Most of the General Requirements are fulfilled through

inspection of the schedule and design documents

  • The TRA Mentor’s (Jason Winningham) credentials have

been confirmed

  • Outreach will be demonstrated through the Outreach

Reports

  • The team will demonstrate the ability to teleconference

during the review

  • Rocket rail launch capability, reusability, and readiness will

be demonstrated at the test flight

University of Alabama in Huntsville USLI PDR 67 11/3/2017

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SLIDE 68

SAFETY

University of Alabama in Huntsville USLI PDR 68 11/3/2017

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SLIDE 69
  • Training and Communications are key

– Weekly Safety Briefings on relevant current activities – Create Hazard analysis and Standard operating procedures

  • Team work and proper supervision are how risks and hazards

can be minimized

– No team member shall work alone when manufacturing and testing the rocket and its components. – CRW members double and triple check each other’s work to ensure that all steps of manuals and standard procedures are followed – Supervision from experienced mentors and staff ensures all procedures are done correctly.

CRW Safety Commitment

11/3/2017 University of Alabama in Huntsville USLI PDR 69

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SLIDE 70
  • Rocket motors, e-match, igniters are purchased

by the mentor or appropriate PRC staff with the proper license to ensure legality and compliance.

  • Motors will be stored in Type 2 Magazine and

transported in Type 3 magazines.

ATF, , DOT, , and NPFA Compliance

11/3/2017 University of Alabama in Huntsville USLI PDR 70

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SLIDE 71
  • Hold weekly Safety Briefings with the entire CRW team
  • Each sub-team will designate a Safety Representative to work with the
  • Safety Officer

– Aid in Hazard and failure mode analysis for their respective sub-section of the rocket

  • A Component Description Sheet will be created for each component used in the

rocket – Analyze failure modes – Track evolution of the component to aid in verification process

  • CRW has identified the required success criteria and a method of verification for

each (as outlined in the PDR report)

  • A Test Plan has been created based on the verification of all identified success

criteria (as outlined in the PDR report)

Safety Plan

11/3/2017 University of Alabama in Huntsville USLI PDR 71

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SLIDE 72

Safety Representatives

11/3/2017 University of Alabama in Huntsville USLI PDR 72

Bao H. Safety Officer Davis H. Launch Vehicle Lead Andrew W. Payload Lead

  • The Safety Officer will be responsible for the overall safety outlined by the

SLI Handbook

  • The Launch Vehicle lead and the Payload lead will be responsible for the

reliability and risk assessment of their systems.

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SLIDE 73

Safety Bri riefings and Trainings

Train ainin ing Activ tivity ty Date Red Cross Fir irst Aid CPR/ R/AED/FA 10/13/2017 Bas asic ic Eme Emergency y Proc

  • cedures

10/17/2017 Proc

  • cess Haz

Hazard d Analy alysis is 10/18/2017 Saf afe Testi ting Proc

  • cedures

10/24/2017 Roo

  • ot-Cause Analy

alysis is 10/24/2017 Outr utreach Saf afety y Proc

  • cedures

11/7/2017 Sub ub-scale le Lau Launch Saf afety y Proc

  • cedures

11/14/2017 Haz Hazardous Materia ial Han Handlin ling/Dis isposal 11/21/2017 Fir ire Ext Extin inguis isher trai ainin ing 11/21/2017 TBD TBD

  • The Red Team have completed training for First Aid

and CPR/AED

  • Additional training content will be added based on

relevance to the stages in the development cycle.

University of Alabama in Huntsville USLI PDR 73 11/3/2017

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SLIDE 74

Launch and Assembly Procedures

  • The Test Plan and Verification Processes will be used

to optimize the final design, assembly, and launch procedures

  • Final rocket assembly procedures have been

developed to fit the design concept

  • Any changes to the design that require updating the

assembly or launch procedures will be coordinated through the team safety officer

  • Simulated runs of all procedures will take place at

least one week prior to any launch

University of Alabama in Huntsville USLI PDR 74 11/3/2017

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SLIDE 75
  • For the convenience of all team members, the

following items will be located on 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

Published In Information

11/3/2017 University of Alabama in Huntsville USLI PDR 75

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SLIDE 76

PROGRAM MANAGEMENT

University of Alabama in Huntsville USLI PDR 76 11/3/2017

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SLIDE 77

CRW

Man anagement

  • Website Updates
  • Outreach Coordination
  • Schedule and budget tracking
  • Requirements Verification
  • Interface management

Sa Safety

  • Risk Identification and Analysis
  • Mitigation Strategy Development
  • Safety Briefing
  • Manufacturing and Testing supervision

Lau Launch Veh ehicle

  • Aft
  • Motor Selection
  • Fins
  • Lower Body Tube
  • Simulation
  • Central
  • Avionics
  • Recovery
  • Forward
  • Upper Body Tube
  • Nosecone
  • Payload Fairing

Payload

  • Mechanical Structure
  • Wheel Design
  • Chassis Design
  • Vehicle fabrication
  • Electrical Design
  • Component Selection
  • Schematic Development
  • Software
  • Rover software
  • Ground Station

Work rk Breakdown Structure

11/3/2017 University of Alabama in Huntsville USLI PDR 77

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SLIDE 78
  • Schedule Philosophy

– Work around finals and Winter Break – Internal deadlines 2 weeks ahead of NASA deadline for all documents – Identify backup dates for critical test launches

  • Upcoming Events

– Launch Opportunities: Nov 18, Dec 16, Jan 20, Feb 17 – CDR Internal due date: Dec 22

Schedule

11/3/2017 University of Alabama in Huntsville USLI PDR 78

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SLIDE 79

Budget/Funding Summary ry

  • Launch vehicle- two

subscales (6 flights) and two full scales (6 flights) - $5,760

  • Payload- two fully operation

rovers -$1,010

  • $750 margin for

shipping/unexpected expenses

  • Proposed to ASGC and UAH

Propulsion Research Center for funding and

Rover Frame 4% Rover Electronics 11% Airframe 13% Motors 50% Recovery 22% Rover Frame Rover Electronics Airframe Motors Recovery

79 11/3/2017 University of Alabama in Huntsville USLI PDR

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SLIDE 80
  • Girls Science and Engineering Day

– Before project started, but good practice – 80 middle school girls participated

  • FIRST Robotics
  • Boy Scout STEM Winter Camp

– Invited to teach space, robotics, and maker culture

  • Science Olympiad at UAH, February

2018

Outreach

11/3/2017 University of Alabama in Huntsville USLI PDR 80

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SLIDE 81

Web Presence

  • Website updated and

reformatted to highlight current content while preserving 2017 team documents

  • Facebook and Instagram kept

current

  • Press release posted
  • www.chargerrocketworks.com

University of Alabama in Huntsville USLI PDR 81 11/3/2017

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SLIDE 82

Questions

11/3/2017 University of Alabama in Huntsville USLI PDR 82

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SLIDE 83

11/3/2017 University of Alabama in Huntsville USLI PDR 83

  • NASA USLI
  • https://www.nasa.gov/audience/forstudents/studentlaunch/handbook/index.html
  • Wikipedia
  • https://upload.wikimedia.org/wikipedia/commons/d/dc/PIA16239_High-Resolution_Self-

Portrait_by_Curiosity_Rover_Arm_Camera.jpg

  • NASA
  • https://www.nasa.gov/sites/default/files/images/640942main_orion_chute_full.jpg
  • Thrustcurve.org
  • http://www.thrustcurve.org/simfilesearch.jsp?id=1898
  • Wonderfulengineering.com
  • http://cdn.wonderfulengineering.com/wp-content/uploads/2015/03/NASA-Tests-Mars-Rocket-Booster-6.jpg
  • Professionalgrantwriter.org
  • https://www.professionalgrantwriter.org/wp-content/uploads/2016/03/shutterstock_127266677.jpg
  • National Association of Rocketry
  • http://www.nar.org/wp-content/uploads/2014/05/Logo.gif
  • Youtube
  • https://i.ytimg.com/vi/i3T9Hps3iqs/maxresdefault.jpg
  • Emotionalhealth.net
  • http://emotionalhealth.net.au/wp-content/uploads/2013/05/question-marks.jpg

Picture Credits

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SLIDE 84

Compo ponent Mass s (g) g) Numbe mber r per r rove ver Total al Mass s (g) g) Total al Mass s (lb lbm) Arduino Mega 37.0 1 37.0 0.08 BMP280 1.30 1 1.30 0.00 SPG30 geared motor 160 2 320 0.71 Motor Shield 30.0 1 30.0 0.07 LSM9DS0 2.30 1 2.30 0.01 Solar cell 8.50 3 25.5 0.06 Camera 10.0 1 22.5 0.05 900 MHz Xbee 8.50 1 6.50 0.01 Brushed DC motor 9.98 2 20.0 0.04 Battery 150 1 150 0.33 GPS 8.50 1 8.50 0.02 Voltage regulator 0.90 1 0.90 0.00 Total mass

  • 625

1.38

Appendix A: Ele lectronics Mass Budget

11/3/2017 University of Alabama in Huntsville USLI PDR 84