Mechanical Engineers:Brian FrostKevin SabodaMichael SaittaEthan Willistein

Electrical Engineers:Daniel UerzAmberly Prill

P07110P07110 –– Test StandTest StandFinal PresentationFinal Presentation

SponsorsSponsors::

Team MembersTeam Members:: Faculty AdvisorsFaculty Advisors::Dr. Kozak (ME)Dr. Patru (EE)

18 May 200718 May 2007

About Project About Project METEORMETEOR

Project Meteor is a university-based project

• short-term goal is to launch and place small payloads in low earth orbit

• long-term goal is to place such payloads on near earth asteroids and lunar surfaces

It is a hands-on, multi-phase, multi-disciplinary, teaching and research program for investigation and developing micro-systems engineering, science, and technologies for the exploration of outer space.

http://meteor.rit.edu/

BackgroundBackground

The Vertical Test Stand Team has been given the task to:

• Improve upon the horizontal test stand designed and built by last year’s Sr. Design Team, P06006

- working with P07105 - Steel Rocket Team

• Design, develop, and build a Vertical Test Stand - working with P07106 – Guidance & P07109 – Flying Rocket

Teams

• Design and build a “Plug & Go” Data Acquisition System that will be interchangeable between the two stands

Horizontal Test Stand ModificationsHorizontal Test Stand Modifications

• Replaced rusted rail system with new stainless steel “railroad tie”system that allows for storage away from the harsh elements in the bunker.

• Created a new mount for the load cell that is independent of the rail system.

• Replaced calibration wire with a lower gage that is more flexible and has a protective coating.

• Replaced original damaged linear bearings on rocket pillowblocks with new linear bearings.

• Constructed new frames for the large diameter rocket.

• Vertical Thrust Reading

• Lateral Force

• Plume Removal

• Option for Roll

• Acceleration Readings on Rocket

• Rocket must be restrained safely

• Pressure & Temperature Readings

• Simple Set Up

• Need Amplifier for Sensors

• “Plug & Go” Data Acquisition System

Requirements for Vertical Requirements for Vertical

OrientationOrientation

Final DesignFinal Design

Final DesignFinal Design

Data Acquisition SystemData Acquisition System

Load Cell AmplifierLoad Cell Amplifier

High Risk AssessmentHigh Risk Assessment

• Largest risk is restraining the rocket safely but still allowing the force measurements

• Conducted analysis of high stress areas to determine the factors of safety

• Lowest factor of safety on the working components is 19.

• Bunker containment for additional safety

Load Case Factor of Safety

Failure of Yoke in Tension or Compression 125

Failure of U-Joint Bolt in Shear 147

Failure of Bearing on Bolt (Hand Calculations) 600Failure of U-Joint Bearing (Hand Calculations) 100

Failure of U-Joint Bearing Compression (FEA) 117

Failure of U-Joint Bearing Tension (FEA) 238

Torsional U-Joint FailureTorque Unknown

22,000inlbf allowable

Torsional Bolt FailureTorque Unknown

75,000inlbf allowable

Support Bolt Tension Compression 95

Support Bolt Shear Failure of the Bolt Threads when one Thread

takes entire load 19

Support Bolt Shear Failure of Bolt Threads when Threads Share

Load380

Axial Tension of Bearing Shaft 23

Axial Compression of Bearing Shaft 25Bearing Binding and Torque on Bearing Shaft 19

Design Factor of Safety Table

Mitigations for NonMitigations for Non--CompliancesCompliances

Nose cone coupling has been tentatively designed and materials have been purchased, but construction is on hold until final construction of the flying rocket is complete

Final Phase of DevelopmentFinal Phase of Development

• Redesigned horizontal test stand has been used for multiple steel rocket testing, including the new larger diameter rocket

• Vertical test stand has been built and assembled at the bunker

• Data acquisition system has been built and successfully tested

Customer Needs AssessmentCustomer Needs Assessment

Still using the software that came

with the A/D ConvertersMetDetermine what software to use to integrate the systems1.6

Needs improvement, but will work

much better than the previous set-upMetBuild the Data Acquisition “box”1.5

Current amplifier will amplify

signal between 9 and 10VMetBuild a more effective amplifier for the Load Cell1.4

Process was completed during SD2,

producing readings for the Flying

Rocket team

MetImprove Thermal Measurements/Calculations for full length

of rocket1.3

New calibration rope and pulley

spacingMet

Calibration System/Method needs to be improved for better

accuracy1.2

Rails replaced with SS rails, new

test stand configurationMetRail & Bearing System needs improvement1.1

DetailsNeed StatusCustomer NeedNeed

Number

Horizontal Test Stand Customer Needs

Customer Needs AssessmentCustomer Needs Assessment

System designed to accommodate

multiple load cells and other data

acquisition equipment

Met

The Data Acquisition System for the horizontal stand will be

interchangeable with the vertical stand and will incorporate any

necessary modifications the flying rocket requires

2.9

One bolt attachment, simple, can

store parts out of the elementsMetSimplified Setup Procedure2.8

Reinforced present concrete, as well

as enclosed rocket within barrelMetSafety Issues with Bunker Stability2.7

Flying rocket never completedNot MetPressure & Temperature Readings; work with flying rocket

group2.6

Deal with vibrations using

accelerometersMetVibrations2.5

Rocket restrained with large factor of

safetyMetRocket Restraint2.4

Adjusted the original deflector plate

to accommodate the vertical standMetPlume Removal/Deflection2.3

Single axis accelerometers spec'd outMetAcceleration Readings2.2

Vertical, lateral and torsional force

readings capableMetForce Readings2.1

DetailsNeed StatusCustomer NeedNeed

Number

Vertical Test Stand Customer Needs

Engineering Specs AssessmentEngineering Specs Assessment

Still need info from other teamsNTBD3Establish, from other teams, what the required readings need to be

2.1, 2.2, 2.6, 2.9

22

One bolt attachment, can remove from elements

YEasy SetupEasy SetupN/A1Modularize components of set-up2.821

Lowest factor of safety is 19Y105FOS5Maintain a factor of safety on test stand

2.3, 2.4, 2.7

20

Y>200<200lbf5Construct vertical stand to withstand 200lb thrust

2.1, 2.219

To test week 11, materials ordered, method developed

N>1300<1300C3Obtain an accurate thermal reading inside rocket

1.3, 2.618

Replaced pulley systemYeasy,

accurate calibration

easy, accurate calibration

N/A2Minimize error in line and pulleys1.217

Analysis done to verify test stand supports

Y>200<200lbf2Force analysis on horizontal rail system

1.1, 1.216

Rails in alignment and bearings slide smoothly

Ysquare and free to slide

squareN/A4Proper rail alignment1.115

SS rails, new bearings, slides smoothly

Yfree to slide

free to slide

N/A4Minimize friction on rails and bearings

1.114

Still going with the software that came with the A/D Converters

Y--EA4Determine what software to use to integrate the systems

1.613

Using current set of cables,others can be readily made

Y100~100LF2Lengths of cables1.510

Using RS232s already on handY32 to 3EA4RS2321.59

Using converters already on handY32 to 3EA3A/D Converters1.58

Using 18V Lithium Battery packsY~109V3Powering Load Cell1.57

Using 3V AA & 18V Lithium Battery packs

Y±18±16V3Powering the Op.Amp1.56

Using 18V Lithium Battery packsY1812 to 24V3Powering the Temperature Sensors

1.55

Using 18V Lithium Battery packsY189 to 30V3Powering the Pressure Sensors1.54

All sensors can now be plugged directly into the DAQ box

Y>88EA4Sensor Plugs1.53

All electrical/power components should fit in the current box

Y16.5x16x4.2

5in.3Size of Data Acquisition Box1.52

Current amplifier will amplify signal between 9 and 10V

Y90-10V5Amplify load cell output signal1.41

Details Met?Ideal Values

Marginal Values

UnitsImportanceDesign SpecificationCustomer Need #

Spec. #

Still need info from other teamsNTBD3Establish, from other teams, what the required readings need to be

2.1, 2.2, 2.6, 2.9

22

One bolt attachment, can remove from elements

YEasy SetupEasy SetupN/A1Modularize components of set-up2.821

Lowest factor of safety is 19Y105FOS5Maintain a factor of safety on test stand

2.3, 2.4, 2.7

20

Y>200<200lbf5Construct vertical stand to withstand 200lb thrust

2.1, 2.219

To test week 11, materials ordered, method developed

N>1300<1300C3Obtain an accurate thermal reading inside rocket

1.3, 2.618

Replaced pulley systemYeasy,

accurate calibration

easy, accurate calibration

N/A2Minimize error in line and pulleys1.217

Analysis done to verify test stand supports

Y>200<200lbf2Force analysis on horizontal rail system

1.1, 1.216

Rails in alignment and bearings slide smoothly

Ysquare and free to slide

squareN/A4Proper rail alignment1.115

SS rails, new bearings, slides smoothly

Yfree to slide

free to slide

N/A4Minimize friction on rails and bearings

1.114

Still going with the software that came with the A/D Converters

Y--EA4Determine what software to use to integrate the systems

1.613

Using current set of cables,others can be readily made

Y100~100LF2Lengths of cables1.510

Using RS232s already on handY32 to 3EA4RS2321.59

Using converters already on handY32 to 3EA3A/D Converters1.58

Using 18V Lithium Battery packsY~109V3Powering Load Cell1.57

Using 3V AA & 18V Lithium Battery packs

Y±18±16V3Powering the Op.Amp1.56

Using 18V Lithium Battery packsY1812 to 24V3Powering the Temperature Sensors

1.55

Using 18V Lithium Battery packsY189 to 30V3Powering the Pressure Sensors1.54

All sensors can now be plugged directly into the DAQ box

Y>88EA4Sensor Plugs1.53

All electrical/power components should fit in the current box

Y16.5x16x4.2

5in.3Size of Data Acquisition Box1.52

Current amplifier will amplify signal between 9 and 10V

Y90-10V5Amplify load cell output signal1.41

Details Met?Ideal Values

Marginal Values

UnitsImportanceDesign SpecificationCustomer Need #

Spec. #

Final Budget Final Budget –– Vertical StandVertical Stand

$3,871.54Subtotal:

$930.00Metal SupplyBulk metal for frameBulk metal

$23.88Home DepotCalibration materialsCalibration materials

$525.00Justin StabbWeldingService

$466.25Home Depot/Lowesscrews, bolts, nuts, washers, concrete, cable

Misc. Construction Equipment

$211.62McMaster Carraluminum disc and rodFlying Rocket Coupling Materials

$1280.006Omega Eng. Inclarge and small S-types, beam types

Load Cells

$288.12McMaster Carrthrust bearings and outer rings, pillow blocks

Bearing Assembly Components

$146.672Motion IndustriesU-joint and bootU-Joint Components

TotalQtyVendorDescriptionItem

Vertical Stand

Final Budget Final Budget –– Horizontal StandHorizontal Stand

$950.98Subtotal:

$15.906McMaster-CarrHigh-Pressure 316 SS Threaded Pipe Fitting 3/8" Pipe Size, Hex Head Plug, 3000 PSI

Threaded Pipe Fitting

$642.0212McMaster-Carrpillow-blocks, SS steel shaft, shaft mounts

Horizontal Stand Replacement Materials

$224.500.5GraingerGenerator

$68.562Omega/McMaster-Carrwire, hi-temp tapeThermocouple Materials

TotalQtyVendorDescriptionItem

Horizontal Stand

Final Budget Final Budget –– DAQ SystemDAQ System

Item Description Vendor Qty Total

Connectorspins, sockets,

receptacles/cap, plugsDigikey 25 $58.91

Thermocouple DAQ

4-channel DI-1000TC with

RS-422 interface and RS-

232 to RS-422 Adapters

Dataq Instruments 1 $554.00

AmplifiersINA114 Instrumentation

Amplifier chipsDigikey 21 $175.14

Linear Regulatorspositive & negative 12V

RegulatorsDigikey 26 $14.74

PCBs

Load Cell Amplifier &

Accelerometer Circuit

Boards

ExpressPCB 3 $177.00

Terminal Block Terminal Blocks for PCBs Digikey 8 $29.88

ResistorPot 250K ohm 3/4”

Rectangular Ceramic MTDigikey 2 $3.80

Load Cell Connector

4-pin Environmentally

Protected Twist Lock

Connector

Omega Eng. Inc. 1 $24.00

$1,037.47

DAQ System

Total:

Final BudgetFinal Budget

• Projected Expenses $6,415.00

• Actual Expenses $5,856.00