Project SCOTTIE: Flight Readiness Review Carnegie Mellon Rocket - - PowerPoint PPT Presentation

Project SCOTTIE: Flight Readiness Review

Carnegie Mellon Rocket Command Mar 7, 2018

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Table of Contents

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1. Vehicle Overview ……………………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………………… 3. Recovery System ……………………………………………………………………………………………… 4. Mission Performance Predictions ……………............................................................... 5. Payload Overview ……………………………………............................................................... 6. Testing …………………………………………………………………………………………………………..… 7. Requirements Compliance Plan ………………............................................................... 8. Logistics …………………………………………………………………………………………………….……..

Table of Contents

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1. Vehicle Overview …………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………………… 3. Recovery System ……………………………………………………………………………………………… 4. Mission Performance Predictions ……………............................................................... 5. Payload Overview ……………………………………............................................................... 6. Testing …………………………………………………………………………………………………………..… 7. Requirements Compliance Plan ………………............................................................... 8. Logistics …………………………………………………………………………………………………….……..

Vehicle Overview

3:1 Ogive Nosecone Ballast Container Nosecone Shoulder UAV Bay UAV Electronics Sub-Compartment Recovery Bay GPS ATS Bay 3 Tapered Fins 75 mm Motor Tube Motor Cap, Base, and Plate UAV Nosecone Airframe Upper Airframe Middle Airframe Lower Airframe Main Chute Drogue Chute =Switchbands 4

Summary of Vehicle Specifications

Vehicle Section Dimensions Mass (lb) Ogive Nosecone 18” Length x 6.17” Base Di. X 4” Shoulder 1.47 Nosecone Airframe 8” L x 6.17” OD 0.99 Upper Airframe 27” L x 6.17” OD 6.38 Middle Airframe 19” L x 6.17” OD 4.53 Lower Airframe 30” L x 6.17” OD 5.23 UAV Bay 14” L x 6” OD 6.94 Recovery Bay 10” L x 6” OD 3.7 ATS Bay 10” L x 6” OD 4.67 Fins [Next Section] 2.64 Motor Retention [Next Section] 4.38 Switchbands (x3) 2” L x 6.17” OD 0.25 Total 6.17” D x 109” L 38.3 (Dry), 48.3 (Wet)

*All airframe/couplers are G12, and bulkheads/fins are G10 fiberglass.

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Nose Cone Design

• 3:1 Tangent Ogive
• Fiberglass reinforced

plastic mold

• 4” shoulder
• 3 PEM nuts to

nosecone airframe

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Fin Design

• 3 Trapezoidal Fins
• 3/16” G10 Fiberglass
• Epoxied to MMT and

filet with epoxy clay

• Fin flutter calcs:

▪ Flutter Velocity- 2909 ft/s ▪ Max rocket velocity- 650 ft/s

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Motor Retention System

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Thrust Plate

• In-house CNC’d from Al 6061
• Screws into aft centering ring

75mm Flanged Retainer

• Purchased from Apogee Components

Table of Contents

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1. Vehicle Overview ……………………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………… 3. Recovery System ……………………………………………………………………………………………… 4. Mission Performance Predictions ……………............................................................... 5. Payload Overview ……………………………………............................................................... 6. Testing …………………………………………………………………………………………………………..… 7. Requirements Compliance Plan ………………............................................................... 8. Logistics …………………………………………………………………………………………………….……..

ATS Overview

• Active prediction and control

system predicts apogee and enacts the appropriate control

• Electronically controlled drag

inducing flaps respond by extending and retracting to control speed

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Flap Deployment System

• Features central hub

controlling flap extension through rotation

• Couples to

electronics bay using threaded rods and servo connection

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Air Brake Flap Performance

• Flap CD evaluated at

key positions to provide prediction model a precise measurement

• f CD at different flap

positions

• Rectangular flap design

produces a predictable, interpolable CD curve

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Electronics Bay

Sensor system

• 4x MPL3115A2

altimeters

• BNO055 IMU

Computational system

• Raspberry Pi 3

Deployment system

• SB2282SG servo

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Flap Deployment System and Electronics Bay Connection

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Apogee Prediction Model Design

Given a state Xt including an altitude ht , vertical velocity st and attitude ht

• 1. While (st > 0)

Set Xt to the prediction of Xt+dt

• 2. Take ht to be the vehicle’s apogee.
• Repeatedly predicting vehicle state one time step into the future using

known launch vehicle physics and flap position based drag model

• Once vertical speed has reached 0, we take the current altitude to be

apogee

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Controller Design

• The controller response Ut corresponds to the distance of extension of the air brakes.
• p and i correspond to the coefficients to the proportional and integral terms of error,

respectively.

• The function e(t) is the current difference between predicted apogee and desired

apogee.

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ATS Testing Procedures

Component Test Success Criteria Software Speed testing to ensure apogee prediction cycle can occur within receipt of new sensor data Prediction of apogee can be made in less than 0.51 seconds Sensor Integration Data transmission testing to ensure that prediction and control system receives timely and accurate information ATS code on Raspberry Pi 3 successfully receives accurate data from each sensor Electrical Speed testing to ensure that flaps can extend and retract within receipt of new sensor data Full extension and Retraction of flaps can

• ccur within 0.51 seconds

Mechanical Stress testing to ensure that flaps can withstand maximum expected load during flight Flaps can extend and retract while under a load of 29 lbs. Total System Full performance test of ATS during test launch of SCOTTIE Apogee Targeting System allows SCOTTIE to reach an altitude of 5100 +- 17 feet

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Table of Contents

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1. Vehicle Overview ……………………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………………… 3. Recovery System …………………………………………………………………………………… 4. Mission Performance Predictions ……………............................................................... 5. Payload Overview ……………………………………............................................................... 6. Testing …………………………………………………………………………………………………………..… 7. Requirements Compliance Plan ………………............................................................... 8. Logistics …………………………………………………………………………………………………….……..

Recovery Subsystem

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Flight Profile

• 1. Launch
• 2. Motor Burnout

& ATS Activation

• 3. Unpowered flight

ATS Active ~12 sec

• 3. Apogee at 5100 ft

& ATS Deactivation

• 4. Drogue Deploy

0-1 sec after apogee

• 5. Main Deploy at

500 ft AGL

• 6. Landing

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Recovery Bay

• Dimensions
• Length: 10”
• Mass: 2.3 lb
• Key Features
• 2 Stratologger CF altimeters
• 3D printed 9V battery case and cover
• Shurter rotary switch standoffs
• Acrylic circular sled for mounting hardware
• Terminal blocks, black powder canisters,

and E-matches for ejection charges

• Coupler coated in aluminum tape for RF

shielding

• Closed forged steel eye bolts, ¼-20

threaded rods with lock nuts to secure bay

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Electronics Wiring

• Two redundant systems
• Each have own battery
• Each have own switch
• Drogue charges
• Primary: Apogee
• Backup: Apogee + 1s
• Main charges
• Primary: 500 ft
• Backup: 500 ft + 1s

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Parachute Overview

Parameter Main Parachute Drogue Parachute Name Iris Ultra Standard 120” SkyAngle Classic II 32” Shape Toroidal Extended Panel Cd 2.2 1.14 Descent Rate 13 ft/s 75 ft/s Diameter 120 in 32 in Weight 36 oz 7.7 Packed Length (6” airframe ~ 10 in ~ 7 in Shroud Line Strength 400 lbf x 12 lines 950 lbf x 3 lines Cost $402.00 $41.25

Main Drogue

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Attachment Hardware

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• Location
• Fixed to middle airframe, below the

recovery bay

• Provide easy access to turn on while
• n launch pad
• Press fit seal protects GPS from

ejection charge

• Components
• 3D printed custom housing module
• Eggfinder Tracking System, Openlog
• 7.4V LiPo battery pack
• Shurter rotary switch

GPS

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Table of Contents

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1. Vehicle Overview ……………………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………………… 3. Recovery System ……………………………………………………………………………………………… 4. Mission Performance Predictions ……………...................................................... 5. Payload Overview ……………………………………............................................................... 6. Testing ………………………………………………………………………………………………..………….. 7. Requirements Compliance Plan ………………............................................................... 8. Logistics …………………………………………………………………………………………………….……..

Apogee Targeting Procedure

Target Apogee: 5100 ft Methodology

• Select motor that achieves apogee 5300 ft – 6000 ft
• Apply ballast so that apogee is reduced to 5200 ft
• Use ATS to apply drag and fine tune altitude to 5100 ft

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Motor Selection

Parameter Value Name AeroTech L1420 Propellant APCP Peak Thrust (lbf) 408 Average Thrust (lbf) 319 Total Impulse (lbf-s) 1035 Duration (s) 3.2 Apogee Range (ft) 5200-5600

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Flight Profile for AeroTech L1420

Parameter Value Apogee (ft) 5133 Thrust to Weight Ratio 6.6 Rail Exit Velocity (ft/s) 70.01 Maximum Velocity (ft/s) 604 Drogue Terminal Velocity (ft/s) 75 Main Terminal Velocity (ft/s) 13 Descent Time (s) 93 Wind Speed (mph) Ballast (oz) 29

Altitude Predictions

Due to an increase in mass, the launch vehicle is likely to undershoot the desired apogee

30 Wind Speed Upwind Apogee (ft) Crosswind Apogee (ft) Downwind Apogee (ft) 5133 5133 5133 5 5169 5119 5069 10 5175 5079 4985 15 5159 5020 4887 20 5125 4947 4781

Drift Calculations

Wind Speed Calculated Drift Open Rocket Drift 1140 5 682 1367 10 1364 1577 15 2046 1874 20 2728 2186

𝐷𝑏𝑚𝑑𝑣𝑚𝑏𝑢𝑓𝑒 𝐸𝑠𝑗𝑔𝑢 = 𝑢𝐸𝑤 𝑢𝐸 = 89.4 𝑡 𝑤 = 𝑥𝑗𝑜𝑒 𝑡𝑞𝑓𝑓𝑒

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At 20mph the calculated drift slightly exceeds the radius of 2500 ft. Open Rocket Simulations suggest this is an

• verestimate

Kinetic Energy

Section Mass (oz) Kinetic Energy (lbf-ft) Upper Section 261 54.51 Middle Section 136 28.40 Lower Section 288 60.15

𝐿𝐹 = 1 2 𝑛𝑊2 𝑊 = 2𝑛𝑕 ρ𝐵𝐷𝐸

Middle Section Upper Section Lower Section 32

Static Stability

Case CG Location (in from tip) CP Location (in from tip) Stability Margin (cal) 0 oz (minimum) 66.98 84.27 2.80 16 oz (maximum) 66.70 80.96 2.85

Min Ballast Max Ballast

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Dynamic Stability

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Table of Contents

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1. Vehicle Overview ……………………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………………… 3. Recovery System …………………………………………………………………………………………….. 4. Mission Performance Predictions ……………............................................................... 5. Payload Overview ……………………………………..................................................... 6. Testing …………………………………………………………………………………………………………..… 7. Requirements Compliance Plan ………………............................................................... 8. Logistics …………………………………………………………………………………………………….……..

UAV Design

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UAV Design Overview

• Off the Shelf Frame (from EMAX)
• Compact Caged Structure
• No Moving Parts on Cage
• Manufacturing
• 3D Printed Cage Rings
• Retrofit Cage onto Motor

Mounts

• Mount Beacon

Deployment System to Bottom of Electronic Stack

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UAV Beacon Deployment

• Micro Linear Servos provide actuation
• Extremely light servo (1.5g) increases

range

• “Hook” locks beacon into place
• Beacon remains locked in place even

without power

• Beacon provides counterweight for

drone in cage

• No Major Changes to Beacon

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Payload Deployment System Overview

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Manufactured Payload Deployment System

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Table of Contents

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1. Vehicle Overview ……………………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………………… 3. Recovery System …………………………………………………………………………………………….. 4. Mission Performance Predictions ……………............................................................... 5. Payload Overview ……………………………………............................................................... 6. Testing …………………………………………………………………………………………………… 7. Requirements Compliance Plan ………………............................................................... 8. Logistics …………………………………………………………………………………………………….……..

Vehicle Demonstration Test

• On March 3, CMRC traveled to South Charleston Ohio to launch with TRA Mid-Ohio
• Low cloud ceiling ~ 3500 ft
• Prepared SCOTTIE to launch if opportunity arose during the day
• Unable to launch due to continual cloud cover
• Backup launch on March 4 in Grove City PA with NAR Pittsburgh Space Command
• Snow storm incoming
• Cancelled due to weather
• Test launch was unable to occur

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Ejection Charge Testing

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Drogue:

• 4g (Primary)
• 5g (Backup)

Main:

• 4g (Primary)
• 5g (Backup)

Recovery Testing plan

• Other recovery bay testing plans were postponed due to the cancellation of the

launch

• During the next launch, the fully configured recovery bay will be tested prior to

flight on the day of launch

• Pressure seal: Ensure bay has been properly sealed
• Ematch continuity: Ensure ematches have been properly connected in order
• Battery test: Ensure batteries are fully charged

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ATS Testing plan

• Deployment/retraction of flaps test
• Verify proper actuation while under flight loads - Completed
• Flap extension accuracy test
• Verify proper actuation for a given input - Completed
• Sensor Integration testing
• Verify that all sensors send data to the ATS control architecture - Completed
• Code speed and stability testing
• Verify that code is robust and runs sufficiently fast - Completed
• Standby readiness battery life test
• Ensure sufficient battery life – Complete
• In-flight test - Incomplete

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Payload Testing plan

• Flight duration test
• Ensure sufficient flight time - Complete
• IMU accuracy test
• Ensure accuracy and precision of IMU to allow for UAV reorientation - Complete
• UAV rotation test
• Verify UAV reorientation capability - Complete
• Deployment test
• Verify proper UAV deployment - Incomplete
• Deployment signal range test
• Ensure sufficient deployment signal range - Incomplete

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Table of Contents

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1. Vehicle Overview ……………………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………………… 3. Recovery System ……………………………………………………………………………………………… 4. Mission Performance Predictions ……………............................................................... 5. Payload Overview ……………………………………............................................................... 6. Testing …………………………………………………………………………………………………………..… 7. Requirements Compliance Plan ………………...................................................... 8. Logistics …………………………………………………………………………………………………….……..

NASA Derived Requirements

Requirements Section Met In Progress Comments General 13/13 0/13 Complete with final STEM events Vehicle 22/24 2/24 Incomplete Vehicle Demonstration and Payload Demonstration Flights Recovery 11/12 1/12 GPS requires repairs before next flight Payload 12/14 2/14 Verification pending launch day activities Safety 5/5 0/5 Met through procedures

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Requirements Section Met In Progress Comments Vehicle 4/5 1/5 Pending full-scale flight and testing Recovery 2/2 0/2 Complete Payload 3/3 0/3 Complete

Team Derived Requirements

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Table of Contents

1. Vehicle Overview ……………………………………………………………………………………………… 2. Apogee Targeting System ………………………………………………………………………………… 3. Recovery System ……………………………………………………………………………………………… 4. Mission Performance Predictions ……………............................................................... 5. Payload Overview ……………………………………............................................................... 6. Testing …………………………………………………………………………………………………………..… 7. Requirements Compliance Plan ……………….............................................................. 8. Logistics ………………………………………………………………………………………….……..

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Budget

Category Amount Percent Total Travel $3,890.00 34.7 Launch Vehicles $3,323.78 29.7 Payload $2,065.00 18.4 Avionics $1,053.92 9.4 Recovery $475.23 4.2 Reserve $400.00 3.6 Total $11,207.93 100.0 $3,890 $3,324 $2,065 $1,054 $476 $400 Travel Launch Vehicles Payload Avionics Recovery Reserve 51

Funding

Category Amount Percent Total Allocated Budget $5,837 37.7 Crowdfunding $3,933 25.4 Sponsorships $1,500 9.7 CMU College of Engineering $1,200 7.8 CMU Mech. Eng. $1,000 6.5 Drone Club $750 4.8 Member Dues $750 4.8 CMU Physics $500 3.2 Total $15,470 100.0 $5,837 $3,933 $1,500 $1,200 $1,000 $750 $750 $500 Allocated Budget Crowdfunding Sponsorships CMU College of Engineering CMU Mech. Eng. Drone Club Member Dues CMU Physics 52

Educational Engagement

15 75 60 45 25 200

YMCA Burrel/Huston School Environmental Charter School CMU Children's School CMU Homecoming Moon District School

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YMCA Fluid Mechanics CMRC Open House CMU Children's School CMU Homecoming Everyday Engineering

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Mechanical Team Timeline

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Avionics Team Timeline

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Payload Team Timeline

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Thank you,

Questions?

Special thanks to John Haught, Prof. Satbir Singh, and Prof. Mark Bedillion! 57