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Flight Readiness Review (FRR)

Flight Readiness Review (FRR)

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Flight Readiness Review (FRR)

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  1. Flight ReadinessReview (FRR) Charger Rocket Works University of Alabama in Huntsville NASA Student Launch 2013-14 Kenneth LeBlanc (Project Lead) Brian Roy (Safety Officer) Chris Spalding (Design Lead) Chad O’Brien (Analysis Lead) Wesley Cobb (Payload Lead)

  2. Prometheus Flight Overview Payloads Here

  3. Technology Readiness Level http://web.archive.org/web/20051206035043/http://as.nasa.gov/aboutus/trl-introduction.html

  4. Outreach • Adaptable for different ages and lengths • Supporting activity • Water Rockets • Completed • Science Olympiad • Challenger Elementary • Discovery Middle • Horizon Elementary • Numbers • Education Direct: 466 • Outreach Direct and Indirect: 723

  5. On Pad Cost

  6. Design Team Members:

  7. 5 1 2 3 4 Hardware Changes: Printed Nylon Transition coupler to accommodate nose cone mold error Flat bulk head and additional coupler joint Flat bulk head ABS plastic Brackets secured with Chicago screws • Design Details: • 34lbs • 40Gs acceleration • Geometric similarity to NASA Nanolaunch prototype • Nanolaunch team requested maximum use of SLS printed aluminum

  8. Interfaces (1)

  9. Interfaces (2)

  10. Thrust Ring • Machined 5086 Aluminum • Will be Analyzed with FEA

  11. Fin Assemblies Currently have sets of fin brackets in abs plastic and fiber reinforced nylon. • ABS has been proof loaded to 75 lbs • 3D printed Laser sintered nylon brackets have been ordered • Bolted to body • Binding post fin attachment

  12. Body Tube • Three body tube pieces joined with nylon printed couplers • Carbon composite • FEA, destructive testing and hand calculations done to assess strength • Large margin of safety and low weight

  13. Payload Shaft • 7075-T6 Aluminum threaded shaft 3/8-16 • Preloaded in tension • FEA and hand calculations show significantly over strength requirements

  14. Payload Shaft Load Paths • Carries thrust loads into payloads and recovery forces into lower rocket, as well as providing assembly method for payloads, body tubes and recovery harness • Red Arrow indicates motor loads from thrust ring through body tube • Green arrow indicates motor loads passed through payloads • Blue arrow indicates recovery forces passed through payload shaft • Orange arrow indicates motor case retention force

  15. Coupler Rings • Sintered nylon (potentional to be reinforced with aluminum or carbon fiber) • Aft coupler retained by payload shaft preload. Also, one side will be epoxied to the body tube. • Fore coupler retained by nose cone shaft and shear pins

  16. Nose Cone Assembly • All components retained by shaft similar to payload shaft • Carbon fiber nose cone shroud and bulkhead • Bulkhead is secured with tension from the nose cone payload shaft (seen on next slide) • Contains pitot pressure and accelerometer/ gyro data package

  17. Nose Cone Assembly • Coupler is designed for slip fit and secured with shear pins. Secured with tension in the payload rod. • The new design allotted more space for the recovery system

  18. Pitot Probe • Allows measurement of static pressure along with supersonic AND subsonic total pressure • Unique and original design which could only be made with 3D printing techniques • Helps fulfill our Nanolaunch request to explore selective laser sintering in original ways. Old Design

  19. Pitot Probe Manufactured out of glass reinforced nylon. • Secured with threaded insert epoxied into center (blue part) • Connection ports are now open to attachment by epoxying tube directly • The change allowed for simplified 3D printing New Design

  20. Vehicle Success Criteria

  21. Analysis Team Members:

  22. General Rocket Mission Performance Criteria

  23. General Rocket Flight Performance Criteria

  24. Flight Simulations

  25. Mass Statement

  26. Prometheus Simulation • RockSim Software Package • Motors • Primary: CTI4770 – 98mm • Secondary: AeroTech K1499 – 75mm • Estimated Dry Mass at 27 lbs • Launch Conditions for Salt Lake City • ASL – 4210 feet • Temperature – 72 ˚F

  27. Final Motor Selection - CTI M4770-P • ISP – 208.3s • Loaded Weight: 14.4lb • Propellant Weight: 7.3 lb • Max Thrust: 1362 lbf

  28. Prometheus’ Static Margin • Launch Static Margin – 1.7 • Burnout Margin – 4.5 CG at 85.8” CP at 93.6”

  29. Prometheus Simulation • Max Altitude – 15,700 feet • Max Velocity – 1600 feet per second • Max Acceleration – 40 Gs

  30. Prometheus’ Static Margin • Pre-Launch Static Margin: 1.7 • Burnout Static Margin: 4.5

  31. MonteCarloAnalysis Altitude: Mach: Accleration:

  32. Drift Analysis • 500 Cases for each cross wind. • High probability of landing within the 5000 foot requirement

  33. Variation in Flight Time • Time variance directlyaffects the radial landingdistance. • Dependent on high speedcoefficient of drag for drogue

  34. Plan B Motor: Aerotech K1499 • Altitude – 2100 feet • Velocity – Mach 0.25 • Acceleration – 16 G’s

  35. Fin Flutter Analysis

  36. The Equations for Fin velocity • t = thickness of fin • AR = aspect ratio • l = taper ratio • G = shear modulus. • C = root chord • P = air pressure • a = speed of sound

  37. The Equations for Fin Velocity • S - Wing Area • b - Semi-span • Cr - root chord • Ct - tip chord • T - Temperature of air • Area = 0.5(Ct + Cr)b • AR = b2/S • l = Ct/Cr

  38. Prometheus Fin Given:

  39. Assumptions • Shear Modulus: 5E5 psi • Isotropic Layup • Applied Max Velocity of 2000 ft/s • Solved for Material Thickness

  40. Conclusion • At exactly t = 0.17 inches, max V = 2071 ft/s • Designed Max V = 2000 ft/s • Projected Max V = 1600 ft/s • The safety range is accounted for with current design and material of Prometheus

  41. Buckling Analysis • Used Euler’s Buckling Equations

  42. Recovery System • Single Separation Point • Main Parachute • Hemispherical • 12 ft • Cd 1.3 ( flight test) • Nylon • Drogue Parachute • Conic • 2.5 ft • Cd 1.6 (flight test) • Nylon

  43. Deployment Bag • NomexFabric • Kevlar Thread • Fiberglass Rod Inserts for Rigidity • Shroud line “daisy chained” and coiled in bag section. Bag Section Fiberglass Rod inserts

  44. Main Parachute • 12 Feet Semi-Hemispherical • Ripstop Nylon • Custom Seam • 14 Gores • Shroud Lines: 0.125in x 550lb Paracord

  45. Sewing Technique • Multi Method Gore Stitch • Straight stitch • Zigzag stitch • Biased Tape Reinforced Joints • Edges hemmed using serge roll. • Joints Reinforced with Nylon Straps. Seam Cross Section

  46. Construction Materials

  47. Recovery System Deployment Process • Stage 1 • 2 seconds after apogee • nose cone separates • release the drogue • Stage 2 • The Tender Desenders release • Stage 3 • Main parachute falls out deployment bag/burrito Eye bolt Drogue L.H.D.S Main Parachute InDeployment bag/Burrito Tethers Black Powder Charge

  48. Deployment Process Stage 1: Drogue Deployment Stage 2: Tether Separation Stage 3: Final Decent

  49. GPS Tracking • GPS Module: Antenova M10382-Al • GPS lock from satellites • Transmits data through XBee RF module • 8 ft accuracy with 50% CEP (Circular Error Probable) • 3.3 VDC supply voltage • 22 to 52 mA current draw • Since CDR, redundant GPS Unit: “Tagg Pet Tracker” no longer included

  50. Radio Transmission • RF Module: XBee-PRO XSC S3B • 900 MHz transmit frequency • 20 Kbps data rate • 9 mile LoS range • 250 mW transmit power • 3.3 VDC supply voltage • 215 mA current draw • 1.5+ hr battery life at max sensor sample rate • Laptop ground station