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University of
Alabama in
Huntsville
NASA SL
Preliminary
Design Review
11/3/2017University of Alabama in Huntsville
USLI PDR1
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR2
VEHICLE DESIGN
University of Alabama in Huntsville
USLI PDR311/3/2017
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR4
Vehicle System Locations
11/3/2017University of Alabama in Huntsville
USLI PDR5
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.
Vehicle CONOPS
11/3/2017University of Alabama in Huntsville
USLI PDR6
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
• 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
Flight Simulation
11/3/2017University of Alabama in Huntsville
USLI PDR7
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.
• Apogee of approximately 5282 ft. at 19 sec.
• Motor burnout at approximately 1050 ft. at 3.2 sec.
Simulation Results
11/3/2017University of Alabama in Huntsville
USLI PDR8
50 sec. Main deploy (600 ft.)
Apogee of 5282 ft. (19 sec.)
Burnout at 3.2 sec.
• Stability of 2.06 cal. at rail exit– Calculated with no wind conditions
• Stability of 2.74 cal. at motor burnout
Stability Analysis
11/3/2017University of Alabama in Huntsville
USLI PDR9
Takeoff Stability: 2.06
Maximum Stability: 2.74
UPPER AIRFRAME
University of Alabama in Huntsville
USLI PDR1011/3/2017
Nose Cone Payload Fairing TransitionForward Body Tube
Objectives• Protect and deploy the payload
• House assembly for tracking vehicle location
• Transition upper airframe to payload fairing
Forward System Overview
11/3/2017University of Alabama in Huntsville
USLI PDR11
Payload Piston Avionics Bay
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR12
6.0 in. 2.0 in.
• Responsible for housing the rover and rover deployment system
• Filament wound fiberglass
6.0 in.
24.0 in.
• Used to deploy rover from fairing • Spring driven spike punctures cartridge • Spring released by hotwire upon
command; redundant arming
Piston Overview
11/3/2017University of Alabama in Huntsville
USLI PDR13
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
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR14
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR15
CENTRALSUBSYSTEM
University of Alabama in Huntsville
USLI PDR1611/3/2017
• Central Subsystem responsibilities:
– Primary coupler between airframes
– Flight Avionics
– Ejection System
– Tracking and Ground Station
– Recovery System
Central Subsystem Overview
11/3/2017University of Alabama in Huntsville
USLI PDR17
Coupler
11/3/2017University of Alabama in Huntsville
USLI PDR18
U Bolt(2 Places)
Black Powder Housing (4 Places)
Stratologger CFAltimeter (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.
Recovery Avionics 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 redundancy in avionics and ignition
Avionics
11/3/2017University of Alabama in Huntsville
USLI PDR19
Recovery Deployment Avionics
11/3/2017University of Alabama in Huntsville
USLI PDR20
• 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
GPS Tracking Subsystem
11/3/2017University of Alabama in Huntsville
USLI PDR21
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 operation success
Structure Integration
• 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
• 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 System
11/3/2017University of Alabama in Huntsville
USLI PDR22
• Open Rocket Simulation between 0 and 20 mph winds showed a maximum drift at 15 mph of about 1,700 ft.
• 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
• 𝐾𝐸 =1
2𝑚𝑣2
– 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
• 𝐷 =8𝑚𝑔
𝜋𝜌𝐶𝐷𝑣2
– D = diameter of parachute, ft.
– m = mass of vehicle, lbm
– g = force of gravity, ft/s2
– 𝝆 = density of the air, lbm/ft3
– CD = Coefficient of Drag
– v = previously calculated velocity, ft/s
• Minimum Diameter must be 93.3 inches
Recovery System Calculations
11/3/2017University of Alabama in Huntsville
USLI PDR23
• 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 (Drogue and Main)
11/3/2017University of Alabama in Huntsville
USLI PDR24
1
2
3
4
AFT SUBSYSTEM
University of Alabama in Huntsville
USLI PDR2511/3/2017
• 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 SystemObjectives
11/3/2017University of Alabama in Huntsville
USLI PDR26
• 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 System Components
11/3/2017University of Alabama in Huntsville
USLI PDR27
Fin Can/Centering Ring
Motor/Motor CasingThrust Ring
Trapezoidal Fin(s) (4)
Forward/Recovery Retention Bulkhead
Secondary Centering Ring
Motor Selection
11/3/2017University of Alabama in Huntsville
USLI PDR28
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
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 PDR2911/3/2017
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR 30
Fin Can
Fin Can Dimensions
11/3/2017University of Alabama in Huntsville
USLI PDR31
• Purpose: align motor as it is inserted into the rocket• Bolted to the aft body tube using 4-40 bolts• Material: Polycarbonate
Secondary Centering Ring
11/3/2017University of Alabama in Huntsville
USLI PDR32
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR33
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR34
• Flexural Modulus:
– Crosswise: 2400 ksi
– Lengthwise: 2700 ksi
• Compressive Strength: 65 ksi
• Its density is 0.065 lbm/in^3.
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 PDR3511/3/2017
• Approximately half-scale – 4 in. body → 2.125 in. body– 6 in. fairing → 3 in. fairing– Mach 0.56 → 0.49
Subscale Rocket
11/3/2017University of Alabama in Huntsville
USLI PDR36
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
PAYLOAD DESIGN
University of Alabama in Huntsville
USLI PDR3711/3/2017
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR38
Rover Assembly
11/3/2017University of Alabama in Huntsville
USLI PDR39
• 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.
Rover Assembly
11/3/2017University of Alabama in Huntsville
USLI PDR40
• 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
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR41
Aluminum Unibody3D Printed ABS
Unibody
Aluminum Base/3D
Printed ABS Walls
Ease of Manufacturing 2 5 4
Strength to Weight 5 2 3
Environmental
Protection5 2 1
Total Score 12 9 8
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR42
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR43
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR44
18 inch
Measuring
Tape (Wrapped
around)
11 inch
Sideways
Hinged
Aluminum Tail
Ease of
Manufacturing5 2
Strength 3 5
Tail Length 5 3
Total Score 13 10
Wheel Rotation
Counter moment from tail
• 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 Design
11/3/2017University of Alabama in Huntsville
USLI PDR45
Telescoping
WheelsFoam 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
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR46
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
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR47
• Made of Aluminum 6061 – T6
• Eight notches for eight spokes, holes for attaching spokes with rod
Wheel DesignMain Wheel
11/3/2017University of Alabama in Huntsville
USLI PDR48
• 6061 – T6 Aluminum
• 0.75 in. extrusion for grip with expanded wheel
• Circular piece for attaching to wheel base
Wheel DesignSpoke
11/3/2017University of Alabama in Huntsville
USLI PDR49
• 6061 – T6 Aluminum
• Attaches to wheel base
Wheel DesignMotor Mount
11/3/2017University of Alabama in Huntsville
USLI PDR50
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR51
• Can withstand 35 lbf before yielding to 40 ksi
• Max Stress – 15 ksi– Full weight of rover and motor torque
Spoke
11/3/2017University of Alabama in Huntsville
USLI PDR52
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR53
• Sliding solar panel lid utilizing remote servo gear
• Solar panels will remain static
• Solar panels recharge battery
Solar Deployment
11/3/2017University of Alabama in Huntsville
USLI PDR54
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
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 PDR5511/3/2017
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
Li-Ion 18650 CR123A SurefireEnergizer 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 Trade Study
11/3/2017University of Alabama in Huntsville
USLI PDR56
• 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
MCU Trade Study
11/3/2017University of Alabama in Huntsville
USLI PDR57
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
Component Selection
11/3/2017University of Alabama in Huntsville
USLI PDR58
Component Selection Features
MCU Arduino Mega• (7 – 12) Vin
• I2C, SPI, UART, GPIO• 16 MHz
IMUAdafruit 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"
MotorCytron DC Geared Motor
SPG30-300K
• 12 V • At load 410 mA
• Stall torque 1.18 Nm • Mass: 160 g • Brushed
Selection cont.
11/3/2017University of Alabama in Huntsville
USLI PDR59
Component Selection Features
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
ComponentCurrent
(mA)
Voltage
(V) Time (hr)
Duty
Cycle (%)
Efficiency
(%)
Necessary Capacity
(mAhr)
Arduino Mega 50.0 5.00 1.00 100 100 22.5
Pressure/
Temp1.12 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
Regulator600 5.00 1.00 100 100 270
Power Budget
11/3/2017University of Alabama in Huntsville
USLI PDR60
Required battery capacity = 𝐼 𝑚𝐴 ∗𝑉 𝑉 ∗𝐷𝐶 ∗𝑇𝑖𝑚𝑒 ℎ𝑟
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 ∗11.1 𝑉
Required Capacity
(mAhr)
Available Capacity
(mAhr)Safety Factor
514 2600 5.06
11/3/2017University of Alabama in Huntsville
USLI PDR61
Component Block Diagram
Payload Software Flow Diagram
11/3/2017University of Alabama in Huntsville
USLI PDR62
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
REQUIREMENTS COMPLIANCE
University of Alabama in Huntsville
USLI PDR6311/3/2017
Requirements Compliance Plan
University of Alabama in Huntsville
USLI PDR6411/3/2017
• 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
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR65
Launch Vehicle Verification
11/3/2017University of Alabama in Huntsville
USLI PDR66
Recovery Ejection
Coupler Strength
Motor Thrust/ Load Path
Simulation/ Aerodynamics
Overall System Performance
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?
Multipleground
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
of the rocket multiple times
Launch the full-scale (final) rocket multiple
times
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 PDR6711/3/2017
SAFETY
University of Alabama in Huntsville
USLI PDR6811/3/2017
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR69
• 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
11/3/2017University of Alabama in Huntsville
USLI PDR70
• 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
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Safety Representatives
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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.
Safety Briefings and Trainings
Training Activity Date
Red Cross First Aid CPR/AED/FA 10/13/2017
Basic Emergency Procedures 10/17/2017
Process Hazard Analysis 10/18/2017
Safe Testing Procedures 10/24/2017
Root-Cause Analysis 10/24/2017
Outreach Safety Procedures 11/7/2017
Sub-scale Launch Safety Procedures
11/14/2017
Hazardous Material Handling/Disposal
11/21/2017
Fire Extinguisher training 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.
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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
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• 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 Information
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PROGRAM MANAGEMENT
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CRW
Management
• Website Updates
• Outreach Coordination
• Schedule and budget tracking
• Requirements Verification
• Interface management
Safety
• Risk Identification and Analysis
• Mitigation Strategy Development
• Safety Briefing
• Manufacturing and Testing supervision
Launch Vehicle
• 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 Breakdown Structure
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• 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
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Budget/Funding Summary
• 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 Frame4% Rover
Electronics11%
Airframe13%
Motors50%
Recovery22%
Rover Frame Rover Electronics Airframe Motors Recovery
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• 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
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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
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Questions
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• 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
Component Mass (g) Number per rover Total Mass (g) Total Mass (lbm)
Arduino Mega 37.0 1 37.0 0.08
BMP280 1.30 1 1.30 0.00
SPG30 geared
motor160 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:Electronics Mass Budget
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