Critical Design Review University of Alabama in Huntsville Charger - PowerPoint PPT Presentation

NASA USLI Critical Design Review University of Alabama in Huntsville Charger Rocket Works January 16 th , 2019

Agenda  Introductions and Team Overview  Mission Objectives  Changes since PDR  Vehicle Overview  Payload Overview  Program Management  Safety  Outreach  Budget  Requirements Compliance 2 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Introductions  Zachary Ruta, Program Manager  Hope Cash, Safety Officer  Marcus Shelton, Chief Engineer  William Hankins, Vehicle Team Lead  Colton Connor, Payload Team Lead  Tanner Schmitt, Deputy Safety Officer  Jade Kirkwood, Vehicle Safety Lead  Connor Gisburne, Payload Safety Lead  Dr. David Lineberry, Faculty Advisor  Mr. Jason Winningham, NAR/TRA Team Mentor, Level III Certification  Bao Ha, UAH Graduate Student Teaching Assistant 3 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Mission Statement The objective of the Charger Rocket Works (CRW) team is to construct a safe and successful Level 2 high powered rocket with deployable unmanned air vehicle as a payload through applying engineering judgement and skills. Additionally, CRW will engage with the community in STEM education events and promoting rocketry to diverse groups. 4 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Mission Objectives Vehicle : The rocket will deliver the payload to an altitude of approximately 4800 ft., descend safely and within the Mission Performance Requirements set by NASA, and be recovered in a reusable state. Payload : The payload will deploy from the rocket, fly to a target location, and drop a beacon on target zone all while meeting the desired NASA requirements for the USLI competition. Safety : Comprehensive safety methods will be implemented in all aspects of fabrication, testing, and launches of hardware using in-depth analysis and written procedures and checklists. Outreach : The CRW team will meet a minimum of 200 students through hands- on activities as per the request of NASA and will promote STEM and rocketry to diverse groups. 5 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Vehicle 6 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Vehicle Overview Parameter Value Vehicle Length 124 in Body Tube Diameter 6.17 in Motor Selection L1420R Major Vehicle Materials Fiberglass, Aluminum, ABS Plastic Center of Gravity Location 76.13 in Center of Pressure Location 91.14 in 7 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Vehicle Overview Drogue Deployment at Apogee 3  Drogue deployment charge at apogee  Backup drogue deployment charge at apogee plus 1 sec Main Deployment 4 2 Launch  Main parachute deployment  Motor ignited at 600 ft AGL  Vehicle accelerates  Backup main deployment at 550 ft AGL Pre-Launch 1 Landing 5  Rocket assembled  Payload deploys  Rocket placed on pad  Rocket recovered 8 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Vehicle Changes since PDR  Upper airframe bulkhead redesigned to include payload hardware  The main and drogue parachutes positions have been swapped  Motor selection changed from 1520T to 1420R  Extended lower body tube to accommodate  Fin Can spars replaced with the fins  Boat Tail converted to motor retention ring 9 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Full Scale Vehicle Status  Bulkheads and thrust plate CNC machined  Body tubes, nose cone, and fin material have arrived and are ready for alterations  Parachutes have been selected and prepared for launch.  One fin can has been printed but had failure point, will be reprinted  Second part order ready to be submitted 10 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Upper Airframe Overview  The upper airframe contains many important components  The drogue parachute  The payload bay  The nose cone  The tracker 11 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Upper Airframe – Nose Cone  The selected nose cone is a 4:1 ogive nose cone from Madcow Rocketry  The exposed length is 26 inches with a 6 inch coupler  A blind hole will be tapped into the nose cone’s aluminum tip  A threaded rod will be inserted into this hole  The threaded rod will be used to secure the nose cone bulkhead, where the tracker and the payload’s deployment sheath attaches 12 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Upper Airframe - Main  FEA was conducted to ensure upper airframe (UA) bulkhead could withstand loading  FEA results indicate a generally good design, will require some hang testing  UA bulkhead attached to upper body tube with six #4-40 bolts  Eye bolt mounts through face of UA bulkhead  Shock cord is attached to the eye bolt  Payload deployment mechanism attaches to UA bulkhead 13 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Avionics Coupler - Overview  2x G10 fiberglass bulkheads per end  G12 fiberglass tube (not shown)  G12 fiberglass switch band  Twin threaded rod load bearing path  Forged 1/4-20 eye bolts  Redundant main and drogue ejection charges Coupler V4 Mk II 14 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Avionics Coupler - Electronics  Twin redundant Stratologger CF Altimeters  2x SPST key switches control avionics  Redundant main and drogue deployment charges  Power supplied by 2x 9v lithium batteries http://www.perfectflite.com/SLCF.html https://www.digikey.com/p roduct-detail/en/c- k/Y101132C203NQ/CKN115 17-ND/484276 15 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Avionics Coupler - Structural  Load transferred from 1/4-20 eye bolts to bulkheads  Upper and lower bulkheads are epoxied together  From the bulkheads load is transferred through (2x) 1/4-20 304 SS threaded rods  Washers and lock nuts used to secure all eye bolts and threaded rods 16 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Avionics Coupler - Mounting  Avionics mounted to fiberglass bulkhead suspended on threaded rods  Altimeter mounted on standoffs with nylon screws  Battery holders mounted with stainless steel screws  Quick connectors allow easy removal and assembly of avionics 17 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

GPS Tracking  Xbee-Pro S3B Radio Transmitter with Antenova GPS  Located in nose cone  Powered by CR123 lithium ion battery  Used with success on previous CRW flights  Transmitting frequency: 902 to 928 MHz  Transmits to distances up to six miles away 18 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Lower Airframe Overview  The lower airframe contains:  The main parachute  The motor  The fin can assembly 19 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Fins and Fin Can  Fins:  Adjusts CP for stability  G10 fiberglass sheet  Fabricated in-house  Through-wall mounting  Fin Can:  Removed full spars since PDR  3D printed in-house  Fixed to airframe with 8 #4-40 bolts Current Previous 20 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Thrust Plate  Changes since PDR:  Increased thickness  Added cutouts  Transfers force from motor  Supported by FEA Previous Current 21 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Retention Ring  Load Path:  Boost Phase  Fabricated in-house  Motor case  Retains the motor  Thrust Plate during the coast phase  Body Tube of the flight  Coast Phase  Retention Ring retains motor 22 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Aft Bulkhead  Functions as recovery retention system  Main parachute attached via eyebolt  Diameter: 6 in  Aluminum thickness: 0.25 in  Fixed to body tube with 6 #4-40 screws 23 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS

Motor Trade Study  25 motors simulated using OpenRocket  Velocity off the rail, apogee, and stability off the rail were the three FOM Velocity off Max Max Stability Motor Manufacturer # of Grains the rail Apogee Velocity Acceleration off the rail (ft/s) (ft) (ft/s) (g's) (cal) L1520T-P Aerotech 3 65.2 3719 509 7.3 2.82 L1390G-P Aerotech 3 60.2 3915 517 7.0 2.72 L1350-CS CTI 3 61.2 4500 564 6.6 2.80 L1420R-P Aerotech 4 63.4 4817 592 6.9 2.50 L1365M-P Aerotech 4 61.3 4965 594 6.4 2.55 L1395-BS CTI 4 63.3 5302 629 7.3 2.66 L2375-WT CTI 4 80.8 5463 687 11.6 2.73 L1115 CTI 4 62.6 5406 593 7.0 2.63 24 Wednesday, January 16, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS