[PPT] - UNC Charlotte 2017-2018 NASA Student Launch Competition Critical PowerPoint Presentation

SLIDE 1

NASA Student Launch Competition Critical Design Review

UNC Charlotte 2017-2018

SLIDE 2

System Overview

2

SLIDE 3

Launch Vehicle

3

SLIDE 4

Vehicle Overview

4

Loaded Unloaded Mass (lbs) 50.2 39.9

Rail Buttons: 1515 Delrin

Part Thickness (in.) Bulkhead 0.25 Centering Rings 0.1875 Section ID (in.) OD (in.) Motor Tube 3.9 4.025 Booster 5 5.125 Lower Coupler 4.875 4.98 Transition 5-6.02 5.125-6.16 Upper Coupler 5.875 6 Payload 6.02 6.16

SLIDE 5

Launch Vehicle Design

5

6-32 Stainless Steel Fasteners 4-40 Shear Pins

8 8 4 4 4 2

SLIDE 6

Motor Selection

6

98mm AeroTech L1500T

Total impulse: 5089 N-sec
Max thrust: 1752 N
Motor mass: 10.2 lbm

SLIDE 7

Vehicle Stability

7

Center of Gravity (CG): 56.97 in.
Center of Pressure (CP): 71.35 in.

SLIDE 8

Vehicle Stability

8

Center of Gravity (CG): 49.81 in.
Center of Pressure (CP): 71.35 in.

SLIDE 9

9

Loaded weight: 50.2 lbf
Projected altitude: 5,458 ft.
Thrust-to-weight ratio: 6.71
Rail exit velocity: 66.4 ft/s

Simulation Results

SLIDE 10

10

Mass Statement

Section Mass (lb) Booster (loaded/unloaded) 27.3/17 Recovery 6.12 Payload 16.78 Total (loaded/unloaded) 50.2/39.9

Maximum loaded mass (apogee of 5280 ft.): 52 lbs.
Minimum loaded mass (apogee of 5600 ft.): 49.1 lbs.

SLIDE 11

Removable Fin System

SLIDE 12

Drag Modulation System Overview

Part Material Body ABS Flaps Polycarbonate E-Bay ABS

12

SLIDE 13

DMS Mechanism

13

SLIDE 14

DMS Operation

Components Spec. Sheet

14

22.5°

SLIDE 15

DMS Assembly

15

16 total fasteners

SLIDE 16

DMS Control Scheme

16

SLIDE 17

CFD (DMS closed)

17

Coefficient of drag for the full-scale vehicle was found to be 0.35 Simulations ran at 600 ft/s

SLIDE 18

CFD (DMS open)

18

Deployed DMS increases the full-scale coefficient of drag to 1.06 Simulations ran at 600 ft/s

SLIDE 19

Recovery

19

SLIDE 20

Recovery Overview

20

Event Description Location Redundancy 1 Main vehicle Separation Apogee Apogee + 1 sec 2 Booster Drogue Apogee Apogee + 1 sec 3 Payload Main Deployment Apogee +1 sec Apogee + 2 sec 4 Booster Main 500 ft. 400 ft. 5 Payload Main Opening 500 ft. 400 ft. 6 Section Land Ground level N/A 7 Rover Deployment Ground level N/A

SLIDE 21

Recovery System Hardware

21

Item Booster Payload 8 ft. Main Parachute 1 1 1 ft. Drogue Parachute 1 2400 lbs, 30 ft. Shock Cord 1 1 2400 lbs, 21 ft. Shock Cord 1 1800 lbs, 15 ft. Shock Cord 1 Jolly Logics 2 Reefing Ring 1 1 Eyebolts 3 2 D-Rings 3 2 Altimeters 2+1 2 B.P. Charges 4 2 Tender Descender 1 18” Nomex Blanket 1 1 10” Nomex Blanket 1

SLIDE 22

Kinetic Energy Requirements

22

2.2 Cd 2.4 Cd

Section Weight (lbs) Velocity (ft/s) Kinetic Energy (lbs*ft) Nosecone (1) 1 11.99 2.23 Payload (2) 18 11.71 38.33 Transition (1) 6 13.34 16.58 Booster (2) 17 11.51 34.97 Section Weight (lbs) Velocity (ft/s) Kinetic Energy (lbs*ft) Nosecone (1) 1 11.48 2.05 Payload (2) 18 11.20 35.06 Transition (1) 6 12.77 15.19 Booster (2) 17 10.88 31.25

1 2 1 2

Section Weight (lbs) Velocity (ft/s) Kinetic Energy (lbs*ft) Payload 19.9 116.18 3963.62 Booster 17 129.21 6063.75

Drogue/Reefed

SLIDE 23

Opening Force Calculations

Opening Forces (Altitude) Change in Altitude (ft) Payload (lbs) Booster (lbs) 25 1192.57 1482.59 35 857.13 1064.9 45 670.83 832.92 55 552.61 685.71 65 470.46 583.42 75 410.24 508.43 85 364.19 451.09 95 327.85 405.83 105 298.51 369.31 115 274.2 339.03 125 253.77 313.6 135 236.38 291.94 Opening Forces (Time) T Deployment (s) Payload (lbs) Booster (lbs) 0.1 1270.78 1765.73 0.2 654.29 906.24 0.3 448.79 619.74 0.4 346.04 476.5 0.5 284.4 390.55 0.6 243.3 333.25 0.7 213.94 292.32 0.8 191.92 261.63 0.9 174.8 237.75 1 161.1 218.65

SLIDE 24

Recovery System Safety Factors

24

Section Max Force S.F. Realistic Force S.F. Booster 1.01 4.87 Payload 1.42 6.03 Max Force from 0.1 sec opening Realistic Force from 100 ft. opening

SLIDE 25

Reefing System

Used in both Booster and Payload

main parachutes

25

Used only in Payload recovery

1 3 2

SLIDE 26

Drift Estimates

2.2 Cd 2.4 Cd

26

Wind Speed (mph) Payload Drift Distance (ft) Booster Drift Distance (ft) 5 607.5 546.2 10 1214.9 1092.5 15 1822.4 1844.8 20 2429.8 2184.8 Wind Speed (mph) Payload Drift Distance (ft) Booster Drift Distance (ft) 5 621.1 558.5 10 1242.1 1116.9 15 1863.2 1675.3 20 2484.2 2233.7

SLIDE 27

Separation Methods

27

Section Payload Main Vehicle Separation Booster Main Calculated B.P. Charge (grams) 1.3 1.2 2.3 # of 4/40 Shear Pins 2 4 4 Planned B.P. Charge (grams) 1.5/2 1.5/2 2.5/3

SLIDE 28

Sub-Scale Launches

28

SLIDE 29

Sub-scale Vehicle Overview

Vehicle Property Full-Scale Sub-scale Percent Error from Exact 3/5 Scale (%) Vehicle Length (in.) 96.5 63.75 10.1 Vehicle Outer Diameter (in.) 6.16 3.85 4.17 Length-to-Diameter Ratio 15.67 16.56 5.74 Center of Pressure (% length from nose) 74.77 71.98 3.73 Center of Mass (% length from nose) 58.14 56.05 3.59 Loaded Static Stability Margin (cal) 2.67 2.64 1.12 Stability Margin at Rail Exit (cal) 2.71 2.67 1.48 Loaded Mass (lbs.) 50.5 10.1/10.9 64.03

29

SLIDE 30

Sub-scale Control Flight 1

30

Ballasted Configuration

Reefed to 300 ft.
Apogee: 2807 ft.
Max Velocity: 427 ft/s

SLIDE 31

Sub-scale Test Flight 2

31

Payload Configuration

Reefed to 500 ft.
Apogee: 2629 ft.
Max Velocity: 421 ft/s

SLIDE 32

Sub-scale Test Flight 2

Recovery failure due to opening forces and reefing design
Sub-scale housing test successful despite non-ideal landing

32

SLIDE 33

Sub-scale Test Flight 3

33

Payload Configuration

Reefed to 500 ft.
Apogee: 2539 ft.
Max Velocity: 405 ft/s

SLIDE 34

Subscale Flight Results

34

Averaged Value Simulated Value with Cd = 0.3 Percent Error (%) Simulated Value with Cd = 0.29 Percent Error (%) Apogee (ft.) 2584 2577 0.27 2583 0.04 Maximum Velocity (ft/s) 413 393 4.84 393 4.48 No. Simulated Maximum Altitude (ft.) Actual Maximum Altitude (ft.) Percent Error (%) Simulated Maximum Velocity (ft/s) Actual Maximum Velocity (ft/s) Percent Error (%) 1 2725 2807 3 426 427 0.2 2 2450 2629 7.3 389 421 8.2 3 2432 2539 4.4 388 405 4.4

SLIDE 35

Subscale Thrust Curve

35

SLIDE 36

Coefficient of Drag Estimation

36

Open Rocket simulations predicted a Cd = 0.29

SLIDE 37

Coefficient of Drag Estimation

37

SLIDE 38

Payload

38

SLIDE 39

Payload System Overview

39

Rover Mass (lbm) Housing Mass (lbm) Payload Mass - No AV Bay (lbm) Payload Mass - w/ AV Bay (lbm) Rover Max Height (in.) Rover Max Length (in.) Rover Max Width (in.) 4.56 5.07 9.63 11.02 4.07 8.83 4.8

SLIDE 40

Payload Mission Overview

40

SLIDE 41

Payload Mission Overview

41

SLIDE 42

Rover Payload

42

SLIDE 43

Rover Overview

43

Servo Assembly Magnetic Encoder Collar Pillow Block Leadnut Bracket Sprocket and Axle Assembly Limit Switch

SLIDE 44

Rover Overview

44

Shroud Micro Servo Solar Panels Camera

44

Tracks Ultrasonics PCB

SLIDE 45

Rover Dimensions

45

SLIDE 46

Rover Dimensions

46

SLIDE 47

Rover Dimensions

47

SLIDE 48

Rover Control Scheme

48

SLIDE 49

Camera Vision Algorithm - Option 1

49

SLIDE 50

Option 1 Testing Results

50

SLIDE 51

Camera Vision Algorithm - Option 2

51

SLIDE 52

Option 2 Results

52

SLIDE 53

Distance Estimation Algorithm

53

SLIDE 54

Rover Components

54

Raspberry Pi Zero v1.3

○ 1GHz single-core CPU ○ 512MB RAM

Teensy 3.5

○ 120MHz ARM Cortex-M4 ○ 512K Flash, 192K RAM

SLIDE 55

Rover Components

55

Raspberry Pi Camera Module v2

○ 3280 x 2464 static images

○

53 degree horizontal FOV

MB1220 LV-MaxSonar-EZ

○ Resolution of 1 in.

○

20Hz sample rate

3-Space Embedded 9 DOF IMU

○ Shock survivability of 5000g ○ Pre-filtered outputs

SLIDE 56

Rover Components

56

HSR-2645CRH

○ Continuous rotation

○

Stall Torque @ 7.4V = 166.64 oz-in

TowerPro-SG92R

○ 23 x 12.2 x 27mm ○ Stall Torque @ 4.8V = 34.72 oz-in

Pololu 12 CPR Magnetic Encoder

○ 10.6 x 11.6mm

SLIDE 57

Housing Payload

57

SLIDE 58

Payload Housing Overview

58

The payload housing

includes the rover bay, electronics bay, retention and deployment system, and rotational coupler

The coupler will interface

with the altimeter bay, and the end of the rover housing will be coupled to the vehicle

SLIDE 59

Retention and Deployment System

59

The leadscrew system

will be used to retain and deploy the rover

The leadscrew will

interface with the leadscrew nut mounted

n the bottom of the

rover chassis

The retention bulkhead

will be fastened to the electronics sled, which will be fastened to the rotation bulkhead

Leadscrew High Load Bearing Retention Bulkhead Collar Coupler DC Motor Electronics Sled

SLIDE 60

Housing Rotation System

60

The rotation system will
rient the rover upon

receiving the signal from the ground team after landing

During rover

deployment, if the rover housing shifts, the leadscrew deployment will stop and the housing will reorient

Rover Housing Bushings Rover Bulkhead Electronics Servo and Servo Dog Clutch Altimeter Bay Rotation Bulkhead

SLIDE 61

Payload Housing Dimensions

61

SLIDE 62

Housing Internal Dimensions

62

SLIDE 63

Housing Vehicle Integration

The servo and coupler system allows the

housing to flex while rotating to prevent binding

The coupler is the interface between the

payload and altimeter bay

63

SLIDE 64

Housing Vehicle Integration

The raised shoulder of the housing sits flush

with the bushing, which will be epoxied to the airframe

This acts to retain the housing through flight

64

SLIDE 65

Payload Housing Component Placement

65

SLIDE 66

Payload Housing Electrical Design

66

SLIDE 67

Orientation Algorithm

67

SLIDE 68

Payload Performance Predictions

Leadscrew Thrust Calculations:

68

For a safety factor of 10, and assuming the selected motor will be operating at half of no-load speed, the required motor torque is approximately 275 oz-in.

SLIDE 69

Payload Performance Predictions

Rotational Torque Calculations:

Substituting in a total mass of the housing and internal components (including the 3.8 lb rover) of 10 lbm with a diameter of 5.645 and a desired rotational acceleration the total torque necessary is approximately 3 oz-in.

69

SLIDE 70

Payload Performance Predictions

Rover Torque Calculations:

70

To achieve the appropriate safety factor, the rated output torque of each motor should be on the order of 125 oz-in

SLIDE 71

Testing Plan

71

SLIDE 72

Testing Plan - Rover

72

Test Test ID Test Description Maneuverability Testing RT1 The rover will be tested on controlled and uncontrolled surfaces to assess maneuverability in adverse conditions and driving failure modes Sensor Fidelity Testing RT2 The full rover software will be run during platform tests to assess sensor noise and data acquisition rates Dead Reckoning Testing RT3 The NDTS software will be tested and compared to actual rover performance to assess system reliability in determining the rover's position. Object Detection Testing RT4 The ODAS software will be tested and to assess object detection capabilities and limitations Test Test ID Test Description Autonomy Testing RT5 The full rover software will be tested in controlled and uncontrolled environments to verify autonomy and assess system performance Integration and Deployment Testing RT6 Integration of the rover and the leadscrew system will be tested to ensure rover retention and deployment Flight Testing RT7 The rover will be flown during the full-scale test flight to ensure the system can survive launch and landing forces

SLIDE 73

Testing Plan - Housing

73

Test Test ID Test Description Re-orientation Testing HT1 The housing orientation software will be tested on the subscale and full-scale housing to assess orientation accuracy Signal Acquisition Testing HT2 The XBee transmitter used to initiate the deployment protocol will be tested on the subscale and full-scale flights to verify functionality and assess limitations Sub-Scale Flight Test HT3 A subscale housing will be manufactured, installed, and flown in the subscale to ensure the system can survive launch and landing forces Full-Scale Flight Test HT4 The housing will be flown on all full-scale flights to ensure the system can survive launch and landing forces

SLIDE 74

Testing Plan - DMS

74

Test Test ID Test Description Sensor Fidelity Testing DT1 The DMS software will be tested and flown

n all full-scale launches to assess sensor

noise, data acquisition rates, and state update rates HIL Testing DT2 Hardware-in-loop testing will be done to verify algorithm functionality and robustness to adverse conditions Braking Power Testing DT3 Two full-scale flights will be used to determine the altitude attenuation capabilities of the DMS and the factor by which the DMS increases the vehicle's coefficient of drag Flight Testing DT4 A fully functioning DMS will be flown and actuated to assess braking algorithm accuracy in reaching 5,280 ft.

SLIDE 75

Testing Plan - Vehicle

75

Test Test ID Test Description Sub-Scale Vehicle Separation Testing VT1 Ground separation testing will be performed with the calculated black powder charge sizes to ensure separation and verify calculations Sub-Scale Vehicle Control Flight 1 VT2 The subscale vehicle will be flown with a ballasted configuration to verify vehicle stability and safety through flight Sub-Scale Vehicle Test Flight 2 VT3 The subscale vehicle will be flown with the subscale housing in place to verify simulation accuracy and to acquire data that will be used to estimate the full-scale vehicle coefficient of drag Sub-Scale Vehicle Test Flight 3 VT4 The subscale vehicle will be flown with the subscale housing in place to verify simulation accuracy and to acquire data that will be used to estimate the full-scale vehicle coefficient of drag Test Test ID Test Description Bulkhead Assembly Failure Testing VT5 All bulkhead assembly configurations will be pulled to failure on an Instron to assess failure modes and safety factors

f recovery connection points to the

vehicle Recovery Drop Testing VT6 The sub-scale and full-scale parachute reefing systems will be drop tested to assess opening speeds and forces and to verify system functionality and safety Full-Scale Vehicle Separation Testing VT7 Ground separation testing will be performed with the calculated black powder charge sizes to ensure separation and verify calculations Full-Scale Vehicle Control Flight 1 VT8 The full-scale vehicle will be flown in a ballasted configuration to verify flight stability and safety before flying the fully integrated configuration

SLIDE 76

Testing Plan - Vehicle Cont.

76

Test Test ID Test Description Full-Scale Vehicle Braking Test Flight 2 VT9 The full-scale vehicle will be flown in a fully integrated configuration to verify simulation accuracy and test the stability of the vehicle Full-Scale Vehicle Test Flight 3 VT10 The full-scale vehicle will be flown in a fully integrated configuration to verify simulation accuracy and test the stability of the vehicle Vehicle Telemetry and Tracking Testing VT11 The GPS telemetry system and RF tracker will be flown on all full-scale launch vehicles to ensure system functionality and vehicle recovery

SLIDE 77

Safety

77

SLIDE 78

Safety - Personnel Hazards

78

Complete Table located in Sec. 4.3.2

SLIDE 79

Safety - Environmental

79

Complete Table located in Sec. 4.3.4

SLIDE 80

Safety - Environmental

80

Complete Table located in Sec. 4.3.4

SLIDE 81

Safety - FMEA

81

Complete Table located in Sec. 4.3.3

SLIDE 82

Safety - FMEA

82

Complete Table located in Sec. 4.3.3

SLIDE 83

Safety - FMEA

83

Complete Table located in Sec. 4.3.3

SLIDE 84

Safety - FMEA

84

Complete Table located in Sec. 4.3.3

SLIDE 85

Safety - FMEA

85

Complete Table located in Sec. 4.3.3

SLIDE 86

Safety - Final Assembly Procedures

86

SLIDE 87

Safety - Subscale Checklists

87

Subscale Launch 2 Subscale Launch 3

SLIDE 88

Project Plan

88

SLIDE 89