2010 2011 AIAA OC SECTION FRR PRESENTATION APRIL 4 2011 Student Launch Initiative AIAA OC Section Agenda Team Introduction Finalized Vehicle Motor type and selection Rocket flight stability ID: 587614
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STUDENT LAUNCH INITIATIVE
2010 – 2011AIAA OC SECTIONFRR PRESENTATIONAPRIL 4, 2011\
Student Launch Initiative
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AgendaTeam IntroductionFinalized VehicleMotor type and selectionRocket flight stabilityParachute and descent ratesTest plans and proceduresBlack Powder testDual DeploymentFull scale lunchLessons learned – VehiclePayloadPayload integrationLessons learned – PayloadEducational Outreach
Questions2
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Modified Since Original Posting Almost Everything 3
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Finalized Vehicle – Black BrantParameterDetailsLength/Diameter87.5 inchesDiameter4 inchesMaterial (body and fins)Fiberglass
Shock Cord1” tubular Nylon 15 feetMotor Diameter / Retention 54mm Aero Pack Quick-Change
4
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Forward Section – Black BrantParameterDetailsNose Cone20” Long holding triangular piece of 1/8” plywood with GPS mountedForward Bulkhead3 ply x 3/32” = 9/32” fiberglass 4” back from front end of body tube with “U” bolt for shock cord attachment via 1200 lb test quick link
Forward Cavity17” x 4” (16” unobstructed) containing 72” main parachute, 1” tubular nylon shock cord, Kevlar Protectors for parachute and shock cord, and black powder chargesEjection Charge
2.17 grams of black powder gives 20 psi and 250 lbs of force to shear 3 2” nylon shear pins and eject the main parachute5
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Avionics Bay – Black BrantParameterDetailsBay Two 8” couplers (16” total) with 8” body tube centered and epoxied in placeBulkheads3 ply x 3/32” = 9/32” fiberglass (one is smaller diameter to align with inside of coupler with two terminal blocks for e-matches on each end and one 5250 lb test closed stainless marine eyebolt
Threaded RodTwo ¼” threaded rods run the entire length of each side of the bay and are secured on the outside of the bulkheads with nuts / wing nutsElectronicsAll electronics are mounted on two 1/8” plywood
sleds approx 4” x 16:6
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Rear Section – Black BrantParameterDetailsCentering RingsTwo 2 ply x 3/32” = 6/32” fiberglass 4” diameter centering rings hold the 54mm fiberglass engine tube in the 4” fiberglass body tube – the forward ring has a “U” bolt for shock cord attachment via quick link. One additional centering ring is in the tail coneRear Cavity17” x 4” (8” usable with the engine in place)
containing 24” drogue parachute, 1” tubular nylon shock cord, Kevlar Protectors for parachute and shock cord, and black powder chargesEjection Charge1.74 grams of black powder gives 15
psi and 200 lbs of force to shear 3 2” nylon shear pins and eject the drogue parachute7
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Finalized Vehicle – Black BrantParameterDetailsCenter of Pressure / Center of Gravity62.02 inches / 52.48 inches (from tip of nose cone)Stability Margin2.36Launch Rail type / Length
1 inch / 6 feetRail Exit Velocity55 ft/secWeight
liftoff/descent17.75 lbs / 13.85 lbsPreferred motor (K635) Average Thrust635 Newtons (142.75 lbs)Thrust to weight ratio8.04:1Maximum Ascent Velocity
686.10 ft/sec (.60 mach)Maximum Acceleration434.94 ft/s/s
Peak Altitude
5266 ft
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Velocity Vs Time Graph9
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Static Margin Diagram10
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Construction Details 11
Student Launch Initiative
AIAA OC SectionProcessDetails
All fiberglass surfaces are fully scuffed and scratched before they are
epoxied
.
After scuffing the surfaces are fully cleaned with Isopropyl alcohol to remove dust and any oils or other
contamination. All parts are
epoxied
together using West Systems Epoxy.
Since the bulkheads were only 3/32” thick, three bulkheads were glued together for added strength
Fillets are applied to all joints for added strengthSlide12
Construction Details cont’d 12
Student Launch Initiative
AIAA OC SectionProcessDetails
The Avionics bay uses closed eye bolts since the stresses at ejection can open eyes that are not continuous or welded shut
“U” Bolts are used on the centering rings and top bulkhead also for strength
To assure things fit properly we dry-fit parts together and inserted an engine casing – centering
ring “U” bolt, quick link, shock cord
.
To assure fins aligned properly
we used a fin jig
Fiberglass tape was applied to the body tube – fin joint to help reinforce that area
Whenever possible, ferrules were crimped on to the end of wires to keep the strands together and make certain there is good connectionSlide13
Motor Selection 13
Student Launch Initiative
AIAA OC SectionMotor PropertiesPreferred SelectionAlternate Selection
ManufacturerCesaroni 5 grainCesaroni 5 grainMotor TypeK635 Red
Lightning
K490 Green
Max, Average Thrust
(
Newtons
)
656
Newtons
490
Newtons
Total Impulse
1749.5 Newton-seconds
1978 Newton-seconds
Mass
of Motor Before / After Burn
4.38/1.45 lbs
4.08/1.44 lbs
Max Altitude
5266 ft
5208 ft
Max Velocity
640 ft/sec
686 ft/sec
Max Acceleration
434 ft/s/s
434 ft/s/s
Time to Apogee
18.13
17.66Slide14
Cesaroni K635 Red Lightning(Preferred)14
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Brandname
Pro54 1994K635-17A
Manufacturer
Cesaroni Technology
Man. Designation
1994K635-17A
CAR Designation
1994-K635-17A
Test Date
7/6/2003
Single-Use/Reload/Hybrid
Reloadable
Motor Dimensions mm
54.00 x 488.00 mm (2.13 x 19.21 in)
Loaded Weight
1989.90 g (69.65 oz)
Total Impulse
1749.50 Ns (393.64 lb.s)
Propellant Weight
1281.00 g (44.84 oz)
Maximum Thrust
728.70 N (163.96 lb)
Burnout Weight
658.40 g (23.04
oz
)
Avg Thrust
656.00 N (147.60 lb)
Delays Tested
17 - 7 secs
ISP
139.30 s
Samples per second
1000
Burntime
2.66 s
Notes
Red Lightning™Slide15
Cesaroni K490 Green(alternate)15
Student Launch Initiative
AIAA OC SectionMotor Data
BrandnamePro54 1990K490-16AManufacturerCesaroni Technology
Man. Designation
1990K490-16A
CAR Designation
1990-K490-16A
Test Date
1/7/2010
Single-Use/Reload/Hybrid
Reloadable
Motor Dimensions mm
54.00 x 488.00 mm (2.13 x 19.21 in)
Loaded Weight
1854.1 g
Total Impulse
1978.4 Ns (44.8 lb-s)
Propellant Weight
1155.4 g
Maximum Thrust
590.9 N (132.8 lb)
Burnout Weight
652.9 g
Avg Thrust
485.5 N (109.2 lb)
Delays Tested
16 - 6 secs
ISP
174.16 s
Samples per second
1000
Burntime
4.08 s
Notes
Green
3
™Slide16
Parachute Size & Descent RatesRocket mass = 221.65 ozDrogue chute diameter = 24 in.Main chute diameter = 72 in.Calculated projected velocity for each chute with online calculator and by handv2 = 2FD / (ρ)(CD)(A)CD = 1.00FD = mg = (6.285 kg)(9.8 m/s
2)Hand: vdrogue = 60.99 ft/s Online: vdrogue = 68.57 ft/sHand:
vmain = 17.43 ft/s Online: vmain = 19.59 ft/sRequired: Drogue 50-100 ft/s Main: 17-22 ft/s16
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GPS TRACKING17
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AIAA OC SectionTransmitter in Vehicle Big Red Bee Beeline GPS RF: 17mW on 433.920 MHz Battery and life: 750mAh 10 Hrs Size: 1.25” x 3” 2 ouncesGround Station
Receiver: Yaesu VX-6R TNC: Byonics Tiny Track 4 GPS: Garmin
eTrex
Vista
Beeline receives GPS position
Encodes as AX.25 packet data
Sends as 1200 baud audio on 433.92 MHz
VX-6R receives at 433.92 MHz and extracts audio
TinyTrack
4 converts audio to digital NMEA location data
Garmin
displays the digital location data on human screenSlide18
PayloadG-Wiz Partners HCX flight computer - measures acceleration of the rocketToshiba hard drive – test subject; we will run a Linux script on the hard drive over and over again; the time the hard drive takes to run the script each time is measuredSimple net computer/Linux computer – the mini computer that will execute the Linux script on the hard drive; it will be initialized automatically; the flight data will be recorded on a flash drive inserted into this computerPower converter – Keeps a steady flow of power to the payload components18
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Payload DetailsProgram Source Code#!/bin/shPATH=/binwhile truedo date >>/var/ftp/LEXAR/log.txt time dd if=/dev/zero of=/dev/sda2 bs=65536 count=32 skip=64>>/var/ftp/LEXAR/log.txt 2>&1 time sync >>/var/ftp/LEXAR/log.txt 2>&1 time dd
if=/dev/zero of=/dev/sda2 bs=65536 count=32 skip=128>>/var/ftp/LEXAR/log.txt 2>&1 time sync >>/var/ftp/LEXAR/log.txt 2>&1 tail -n 10 /var/ftp/LEXAR/log.txt
done19
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Program Output (Log File)
Fri Feb 11 22:36:49 UTC 2011
8+0 records in
8+0 records out
real 0m 0.10s
user 0m 0.00s
sys 0m 0.06s
Fri Feb 11 22:36:49 UTC 2011
8+0 records in
8+0 records out
real 0m 0.20s
user 0m 0.00s
sys 0m 0.06s
Fri Feb 11 22:36:49 UTC 2011
8+0 records in
8+0 records out
real 0m 0.16s
user 0m 0.01s
sys 0m 0.05s
On power up, the Linux computer starts executing a shell script that repeatedly writes and reads 32 K Bytes of zeros to the hard drive, logging the time this takes to a flash thumb driveSlide20
Payload Integration20
Student Launch Initiative
AIAA OC SectionThe payload will be screwed onto the assemblyBatteries are held by a combination of battery holders and zip tiesWires are crimped, except for those going to the battery holders, which are tinned
Power to the components are controlled by key switchesSlide21
Test Flight #1 Payload Results21
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AIAA OC SectionObserved ResultsThe script started properly and began to measure and record timesThe script continued to run properly, but shortly after launch the file system on the hard drive became corrupted so accesses stopped and no meaningful data was recordedThe hard drive was not damaged and could still be used (with reformatting)Changes before next flightThe file system will no longer be used – we access the raw sectors on the disk – yielding the following advantages.There is no file system code There is no risk of erroring out due to a corrupted file systemWe have more control over the seeking of the hard drive
Code runs much faster since without the file systemSlide22
Recovery Electronics22
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AIAA OC SectionFlight Computer #2 G-Wiz Partners HCX 56G 1.10” x 5.50” 45 grams Accelerometer based altitude Pyro output at Apogee Pyro output at 900 ft altitude 9VDC at 65ma for 3 hour battery life Separate CPU and
Pyro batteries Two Safety interlock switch on body tube (1-CPU and 1-Pyro)
Flight Computer #1
PerfectFlite
MAWD
.90” x 3.00” 20 grams
Barometric pressure based altitude
Pyro
output at Apogee
Pyro
output at 900 ft altitude
9VDC at 8ma for 28 hour battery life
One battery for both CPU and
Pyro
Safety interlock switch on avionics bay
Slide23
Recovery - Dual DeploymentElectronics: MAWD Perfect Flight, HCX G-Wiz PartnersThe electronics will “back” one another up in case one pyro (either drogue or main) does not fire.Drogue Parachute will be deployed at apogeeMain Parachute will be deployed at 900ftThe electronics have been tested several tests have been done:Christmas tree light test Vacuum Chamber testSecond flight in the scale rocket (MAWD Only)Third Flight in scale model (MAWD Only)First Flight in full scale model (MAWD and HCX)
23
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Previous Recovery Electronics Tests24
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AIAA OC SectionElectronicsTestStatusChristmas Tree Lights substituted
for e-match – control from softwarePerfectFlite MAWD
No
software control
N/A
G-Wiz Partners HCX
Manual control from
software
OK
G-Wiz Partners HCX
Test flight from stored altimeter data
OK
Christmas Tree Lights substituted for e-match – control from vacuum in chamber
PerfectFlite
MAWD
2.6” avionics in homemade
chamber (pickle jar)
OK
PerfectFlite
MAWD
4” avionics in homemade chamber (large
T
upperware)
OK
G-Wiz
Partners HCX
2.6” avionics in homemade chamber (pickle jar)
OK
G-Wiz Partners HCX
4” avionics in homemade chamber (large
Tupperware)
OK
Flight
Test
Status
Scale #1 (1938 ft)
Motor ejection – MAWD
as altimeter only
OK
Scale #2 (1740 ft)
Dual Deployment – MAWD only
PARTIAL –
both chutes deployed together
Scale #3 (1581 ft)
Dual
deployment – MAWD only
OKSlide25
Black Powder ChargeCalculating the black powder charges is a two step processPressure needed to shear pins (#2 screws - 3x35lbs each) and eject the parachute. We will use 200lbs (drogue) and 250 lbs (main) to shear pins, overcome friction and eject. Surface Area = π * r 2 = 3.14 * 22 = 12.56 in2 For 200 lbs / 12.56 in2 = 15.9 PSI 250 lbs / 12.56 in2 = 19.9 PSIAmount of black powder to reach that pressureGrams of Black Powder = C * D2 * L
Where: D = Diameter of the airframe in inches L = Length of the airframe in inches C = 0.006 for 15psi and 0.008 for 20 psi. For a 4” diameter airframe of 17” long, we require 200 lbs (16 psi) = .0064 * 42in * 17in = 1.74 grams
250 lbs (20 psi) = .008 * 42in * 17in = 2.17 grams 25
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Black Powder Charge TestThe table below shows the testing our team has done with black powder charges26
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AmountSuccessful?Sustainer without parachute1.74Yes
Sustainer with
parachute
1.74
Yes
Main without
Parachute
1.43
Yes
Main with
parachute
1.43
No
Main with
parachute
1.74
No
Main
with parachute (packed tighter, ejection charge relocated)
2.00
YesSlide27
Other Previous Testing 27
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StatusBattery Life MAWD36+ hrs
2.5 hrs
OK
HCX (CPU/PYRO)
2.5/6.7+ hrs
2.5 hrs
OK
GPS
18.7+
2.5 hrs
OK
Scientific Payload
3.7+
2.5 hrs
OK
GPS Range
3 miles
1 mile
OK
Scale Rocket (3
rd
flight)
Good Flight
Good Flight
OK
Dual Deployment on Scale Rocket
OK
OK
OKSlide28
1st Full Scale Flight Analysis28
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AIAA OC Section First Flight Cesaroni K400 (Total thrust: 1597 – Burn 3.2s) Wind was very heavy (15 MPH) Vehicle was stable although it did weathercock All ejection charges fired at the proper times Drogue deployed just after apogee as programmed
Main ejection charge did not fully deploy the parachute Reached 3339 ft at apogee Partiall successful flight (see curve from MAWD)Slide29
Corrective ActionsAfter the first flight we did several additional ground tests to deploy the main until it fully and easily deployed:Increase the black powder charge to 2.5 gramsMove the black powder charge so it pushes the parachute out from behindThe parachute needs to be rolled much tighterThe shroud lines need to be wrapped around the outside of the parachute to hold its tight packingThe attachment point of the parachute is now right at the avionics bay instead of 1 foot away along the shock cordThe Nomex shield protecting the shock cord has been replaced by a sleeve to minimize obstructionsThe Nomex shield protecting the parachute needs to be packed around it like a burrito.
29
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2nd Full Scale Flight Analysis30
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AIAA OC Section Second Flight Cesaroni K500 (Total thrust 1596N – Burn: 4s) Wind was very light/moderate (5-8 MPH) Vehicle was stable and flew straight All ejection charges fired at the proper times Drogue deployed just after apogee as programmed
Main deployed at 900 feet as programmed Reached 4059 feet Successful flight (see curve from MAWD)Slide31
Second Flight Full Scale Launch31
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Lessons Learned from Scale Model Test Flight32
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Was it successfulSimplify wiring, color code everything, allow extra space, use ferrules to keep the wires togetherThe scale model avionics was too crowded, hard to trace. Some wires did not make good contact in terminal blocks
Yes it was successful but we learned
we have to be careful so we don’t stress the key switches
Gel
coat must be ground down to fiberglass underneath before applying epoxy
The scale rocket was wobbly near apogee
– inspection showed the lower 1/3 of the fins were not attached
Yes it was successful because a
subsequent flight after fix was stable again
Always use shear pins to avoid drag or impulse separation
We did not use shear pins and we deployed the main when the drogue deployed
Yes because a
subsequent flight deployed drogue and main separately as designed
Stick with your plan and do not
let on-site “mentors” sway you
We
listened to an on-site mentor when he said we did not need shear pins – rocket was too small
Yes – with all of our research,
engineering, and design we did know better than he didSlide33
Recovery Lessons Learned from Full Sized Vehicle Test Flight33
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Was it successfulAlways test in conditions closest to the final conditionsWe tested our black powder charge without the parachute in place to verify the airframe would separate. We should have had he packed parachute in place to assure deploymentYes –
in subsequent ground tests
successful on flight #2
The parachute must be very
tightly packed, with shroud lines wrapped around the outside
The main parachute did not deploy
fully on our first test flight
Yes – in subsequent ground tests
successful on
flight #2
Charges should be place so that the parachute
is pushed out by the charge
The main parachute did not deploy fully on our first test flight
Yes – in subsequent ground tests
successful on flight #2Slide34
Payload Lessons Learned from Full Sized Vehicle Test Flight34
Student Launch Initiative
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Was it successfulThe file system can become corrupt – when testing the hard drive access sectors directoryThe file system became corrupt during launch, but the hard drive was OK – we are testing the hard driveSuccessful on 2
nd
launch
The battery holders need extra support and retention for the battery. Tie
wraps need to be extra tight
Two plastic
battery holders broke during launch – one battery was disconnected. Tie wraps were not tight enough
Successful on 2
nd
launch
Results
are more meaningful when accuracy is greater by flushing caches allowing quicker execution
Results were hard to determine
Yes during
ground testsSlide35
WebsiteAIAAOCRocketry.orgSLI 2010-2011DocumentsCalendarPhotos/VideosManualsMSDS35
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Educational OutreachCloverdale 4-H clubGirl Scouts workshop Presentations to Sunny Hills High School Science classes to get involved Articles published/ will be published in the Orange County Register, The Foothill Sentry, and the Sunny Hills High School AccoladeWe will have a booth at Youth Expo, April 9th to April 11th, we will reach a few hundred kids.36
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Thank you for letting us be part of SLIQuestions?37
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