NASA USLI Flight Readiness Review University of Alabama in Huntsville Charger Rocket Works March 13, 2019
Agenda ❖ Introductions and Team Overview ❖ Mission Objectives ❖ Changes Since CDR ❖ Vehicle Overview ❖ Payload Overview ❖ Program Management ❖ Safety ❖ Testing and Verification ❖ Outreach ❖ Budget 2 Wednesday, March 13, 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 Lead ❖ Colton Connor, Payload Lead ❖ Tanner Schmitt, Deputy Safety Officer ❖ Brooklyn Kirkwood, Vehicle Safety Lead ❖ Connor Gisburne, Payload Safety Lead ❖ Dr. David Lineberry, Faculty Advisor ❖ Jason Winningham, NAR/TRA Mentor, Level III Certified ❖ Bao Ha, Graduate Student Teaching Assistant 3 Wednesday, March 13, 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, March 13, 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, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Vehicle 6 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Vehicle Overview Parameter Value Vehicle Length 124in Body Tube Diameter 6in Vehicle Weight 50.095lb Motor Selection L1420R Predicted Apogee 4982ft 7 Wednesday, March 13, 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, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Vehicle Changes since CDR ❖ Key Switch has been added to nose cone such that nosecone avionics can be powered on externally ❖ Conserves battery life and ensures signal will be lost during flight ❖ Tracker bracket redesigned to allow more mounting surface for the avionics ❖ Is now a 3D printed part ❖ 3D printed component infill increased from 25% to 35% to increase strength 9 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Nose Cone and Body Tube ❖ Body tube cut from 60in G12 fiberglass tube via wet-saw ❖ Metal tipped 4:1 ogive nosecone purchased from Madcow ❖ Bulkhead and key switch holes hand drilled 10 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Upper Airframe Bulkheads Nosecone Bulkhead ❖ Upper airframe bulkhead functions as recovery retention system and payload attachment bulkhead ❖ Drogue parachute attaches to upper airframe bulkhead via eyebolt ❖ Nosecone Bulkhead functions as nosecone avionics and payload attachment bulkhead ❖ Diameter: 6 in Upper Airframe Bulkhead ❖ Aluminum thickness: 0.25 in ❖ Fixed to body tube with six #4-40 screws ❖ CNC machined from 6016-T6 Aluminum 11 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Coupler ❖ Coupler 13 in. long with 1 in. switch band cut from excess body tube ❖ G12 fiberglass bulkhead holes drilled using 3D jig and drill press ❖ SPST key switches used to power avionics on pad ❖ Keys not removable when system powered off ❖ Key locks printed to prevent accidental powering during transport to pad 12 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Lower Body Tube ❖ Cut from a 60in G12 fiberglass tube on a wet- saw ❖ Fin slots cut using plunge router ❖ Holes for bulkhead and fin can were hand drilled 13 Wednesday, March 13, 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 ❖ CNC machined from 6016-T6 Aluminum 14 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Fins and Fin Can ❖ Fins: ❖ Adjusts CP for stability ❖ G10 fiberglass sheet ❖ Cut with wet saw ❖ Through-wall mounting ❖ Installed with eight #4-40 bolts per fin ❖ Fin Can: ❖ 3D printed in-house with PLA ❖ Fixed to airframe with eight #4-40 bolts 15 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Thrust Plate ❖ Transfers force from motor ❖ CNC machined from 0.190 in. 6016-T6 Aluminum 16 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Retention Ring ❖ Load Path: ❖ Boost phase ❖ Motor case ❖ Thrust plate ❖ Body tube ❖ Coast phase ❖ Retention ring retains motor ❖ 3D printed from ABS plastic ❖ Retained the motor during coast phase of the flight ❖ Attached to the fin can using 2 #4-40 screws 17 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Recovery System ❖ Drogue Parachute ❖ FruityChutes CFC-18 ❖ 1 in. tubular nylon, 50 ft. ❖ Terminal Velocity: 83.1 ft/s ❖ Main Parachute ❖ FruityChutes IFC-144 ❖ 1 in. tubular nylon, 50 ft. ❖ Terminal Velocity: 11.2 ft/s 18 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Avionics ❖ Two Stratologger CF ❖ Drogue: Apogee / Apogee + 1s ❖ Main: 600 ft. / 550 ft. ❖ Inertial Measurement Unit (IMU): ❖ Features accelerometer, gyroscope, magnetometer, and pressure sensor ❖ Located in nose cone ❖ Featherweight Raven3 altimeter ❖ Records pressure (altitude), acceleration, and temperature ❖ Located in nose cone 19 Wednesday, March 13, 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 20 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Mass Statement and Margin ❖ Wet Mass: 50.095 lbm ❖ Burnout Mass: 39.995 lbm ❖ Difference from CDR estimates: 2.874% ❖ Some 3D prints strengthened with greater infill percentage ❖ Added nose cone tracker and avionics assembly 21 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Flight Profile ❖ Predicted Apogee: 5012 ft. ❖ Max Velocity: 582 ft/s ❖ Max Acceleration: 249 ft/s 2 ❖ Velocity off Rail: 57.6 ft/s ❖ Thrust to Weight Ratio: 6.91 ❖ Time of Flight: 99.7 s ❖ Time to Apogee: 18.4 s 22 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Flight Profile ❖ Variable Wind Speeds: ❖ 5 MPH: 5009 ft. ❖ 10 MPH: 5021 ft. ❖ 15 MPH: 5006 ft. ❖ 20 MPH: 4963 ft. 23 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Trajectory Verification ❖ Rocksim: 5012 ft. ❖ OpenRocket: 4963 ft. ❖ RASAero II: 4999 ft. ❖ Custom Code: 4982 ft. 24 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Trajectory Verification ❖ Variables: ❖ Motor Impulse (±1%) ❖ Rocket Mass (±0.25 lbf) ❖ C D Error (±0.04) ❖ Temperature (±15 o F) ❖ Wind Speed (±2 MPH) ❖ Normal Distribution ❖ Average: 4982.7 ft. ❖ 27.5% fall outside CRW Requirement ❖ 0% fall outside SLI Requirement 25 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Stability Margin ❖ CP location: 91.1 in. ❖ CG location: 77.2 in. ❖ Stability Margin: 2.25 26 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
Kinetic Energy Vehicle Component Mass [lbm] Kinetic Energy [lbf-ft] Upper Airframe 17.56 34.20 Coupler 4.35 10.47 Lower Airframe 15.85 30.87 27 Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS
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