Charger Rocket Works PDR: 2009-2010


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Charger Rocket Works 2009-2010
University Student Launch Initiative
Preliminary Design Review Presentation

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Charger Rocket Works PDR: 2009-2010

  1. 1. University Student Launch InitiativePreliminary Design Review<br />Submission: December 4, 2009<br />Presentation: December 10, 2009<br />
  2. 2. Overview<br />Preliminary Design Review (PDR) Objectives<br />Mission Statements<br />Project Overview<br />Vehicle Criteria<br />Structures<br />Propulsion<br />Payload & Recovery Criteria<br />Verification and Testing Approach<br />Safety Tools<br />Risk Mitigation<br />Questions/Discussion<br />
  3. 3. PDR Objectives<br />Introduce vehicle and payload design to USLI engineering review board <br />Confirm vehicle and payload design meet USLI competition requirements<br />Evaluate safety and mission assurance plans<br />Demonstrate flight operations can be executed safely<br />Detail cost and schedule for production, testing and operations<br />Address risks and impacts to vehicle, cost, and schedule<br />
  4. 4. Mission Statement<br />USLI Mission Statement:<br />The NASA University Student Launch Initiative is a competition that challenges university level students to design, build, and fly a reusable rocket with a scientific payload to one mile in altitude. The project engages students in scientific research and real-world engineering processes with NASA Engineers.<br />(Cited from the NASA Education Website)<br />Charger Rocket Works Mission Statement:<br />Further our understanding of the science and engineering of high powered rocket thru developing and flight testing. Build a knowledge base with which to achieve even greater heights. Reach out to educate and inspire others to pursue a future in science, technology, engineering, and mathematics. <br />
  5. 5. Project Overview<br />Bellerophon & Pegasus<br />Greek hero Bellerophon slew the Chimera on the back of the winged horse Pegasus.<br />Pegasus : booster stage – homage to UAHuntsville’s mascot<br />Bellerophon: payload - autonomous hybrid lander <br />Bellerophon<br />Pegasus<br />
  6. 6. Project Overview<br />Team Objectives<br />Develop in-house airframe manufacturing capability*<br />Develop a safe and reusable rocket with operations procedures** <br />Reach closest to 1 mile in altitude***<br />Recover Bellerophon and Pegasus intact<br />Successfully demonstrate a mechanical recovery release system<br />Successfully demonstrate the Bellerophon hybrid lander<br />Reach out to 500+ students in the local area<br />
  7. 7. Project Overview<br />Mission Description<br />Bellerophon & Pegasus launch preparation and walk-out<br />Avionics and payload power up (1.5 hr max pad-stay)<br />Launch, powered flight, & coast<br />Bellerophon & Pegasus separate at apogee and descend on drogue<br />Bellerophon parasail deploys at 700 feet altitude and begins flight maneuvers<br />Pegasus main parachute deploys at 500 feet altitude <br />Bellerophon & Pegasus touch down and are recovered<br />Flight data is downloaded and stored for reduction<br />Official altitude is recorded for competition <br />
  8. 8. Vehicle CriteriaStructures<br />Accomplishments since proposal:<br />4 inch mandrel delivered for subscale and 98mm motor tubes* <br />Carbon fiber airframe manufactured in-house for subscale*<br />Successfully flight tested subscale rocket**<br />Verified in-house tube manufacturing as viable path forward for full scale rocket development<br />Vacuum bag capability being matured*<br />Work In Progress<br />Developing procedures for in-house airframe manufacturing**<br />Developing fiberglass laminated phenolic honeycomb core material for centering rings and bulkplates<br />Preparing 6 inch mandrel for full scale rocket tubes*<br />Strength testing carbon fiber tubes**<br />
  9. 9. Vehicle CriteriaStructures<br />Subscale Design Description (flight tested)<br />4 inches diameter & 68 inches overall vehicle length<br />10 lbs pad weight<br />Carbon fiber airframe & phenolic coupler<br />Four G-10 Garolite clipped delta fins<br />Urethane 5:1 ogive nosecone<br />54mm phenolic motor tube<br />¾ inch plywood centering rings and bulkplates<br />First Flight Performance:<br />0.99 calibur static stability margin – balanced (field)<br />0.28 drag coeffiecient<br />3540 feet altitude<br />Many lessons learned <br />
  10. 10. Vehicle CriteriaStructures<br />Full Scale - Design Description (Baseline)<br />6 inches diameter & 102 inches overall vehicle length<br />32 lbs pad weight (with Aerotech L1150R loaded)<br />Carbon fiber airframe & fiberglass coupler<br />Four G-10 Garolite clipped delta fins <br />6 inch diameter fiberglass 5:1 ogive nosecone<br />98mm carbon fiber motor tube<br />¾ inch birch plywood centering rings & baseplates<br />Baseline Performance Predictions:<br />1.43 calibur static stability margin – hand calculated<br />0.34 drag coefficient<br />
  11. 11. Vehicle CriteriaPropulsion<br />Accomplishments since proposal:<br />Static test fired 4 motors<br />Developed procedures for conducting static test firings**<br />Validated subscale computer model with flight data (Cd)**<br />Verified subscale model stability with hand-calculations**<br />Baselined full scale competition motor – Aerotech L1150R*** <br />Work In Progress:<br />Optimizing full scale computer model<br />Ordered full scale demonstration motor for verification test<br />Baseline Performance Predictions:<br />Thrust to Weight Ratio of 7.2 <br />Velocity off the pad of 60 ft/sec<br />Maximum Altitude of 5280 ft<br />
  12. 12. Payload & Recovery Criteria<br />Integrated Payload and Recovery<br />Systems are closely linked <br />Promotes commonality & improves reliability<br />Reliability & Redundancy<br />Bellerophon & Pegasus use mechanical release device (baseline)<br />Mechanical releases triggered by altimeter activated servos<br />Bellerophon & Pegasus use independent altimeters<br />Altimeters have dedicated batteries & switches<br />Pegasus Recovery System (Full Scale)<br />Drogue: B2Rocketry 24 inch parachute(75 ft/sec decent rate)<br />Main: B2Rocketry Cert-3 XXL parachute (15 ft/sec decent rate)<br />D-Bag: B2Rocketry XXL deployment bag<br />
  13. 13. Payload & Recovery Criteria<br />Support Line Anchor<br />Bellerophon Hybrid Lander<br />Nosecone contains GN&C system<br />Autonomous / manual override capable<br />Drogue: B2Rocketry 24 inch parachute (75 ft/sec decent rate)<br />Parasail: 2.75 AR & Spans 8 feet <br /> (15 ft/sec static decent rate)<br />Control Lines<br />Servos<br />
  14. 14. Payload & Recovery Criteria<br />Accomplishments since proposal:<br />Flight tested prototype mechanical release device<br />Flight tested prototype hybrid lander with R/C servos<br />Work in Progress:<br />Mature mechanical released device design<br />Mature requirements for parasail configuration<br />Building payload mass simulators for iterated subscale flight testing<br />Developing hybrid lander ground test schedule to support flight test schedule <br />Developing autonomous flight controller<br />
  15. 15. Verification and Testing Approach<br />A – Mission:<br />Subscale rocket flight test<br />Flight test mechanical release device with two parachutes (no parasail)<br />Mass simulator for R/C parasail control & nosecone payloads<br />Flight test of deployment bags<br />B – Mission:<br />Subscale rocket flight test<br />Flight test mechanical release device with parachute/parasail (static)<br />Mass simulator for R/C parasail control & nosecone payloads<br />Flight test of deployment bags<br />C – Mission:<br />Subscale rocket flight test<br />Flight test mechanical release device with parachute/parasail (static)<br />Integrated Flight test of R/C parasail control system<br />Mass simulator for nosecone payloads<br />Flight test of deployment bags<br />
  16. 16. Verification and Testing Approach<br />D – Mission: <br />Full scale rocket flight test – sub altitude<br />Flight test of mechanical release device two parachutes (no parasail)<br />Mass simulator for R/C parasail control & nosecone payloads<br />Flight test deployment bags<br />E – Mission:<br />Full scale rocket flight test – 1 mile<br />Flight Test of mechanical recovery mechanism with parachutes and parasail (static)<br />Mass simulator for R/C parasail control & nosecone payloads<br />Test deployment bags<br />F – Mission “Full-Up”:<br />Full scale rocket flight test – 1 mile<br />Flight Test of mechanical recovery mechanism with parachutes and parasail <br />Integrated Flight Test of R/C parasail control & nosecone payloads<br />Test deployment bags<br />
  17. 17. Verification and Testing Approach<br />Flight Test Schedule:<br />Dec.12-13, 2009: A – Mission<br />Jan. 16-17, 2010: B – Mission <br />Feb. 13-14, 2010: C – Mission/ D – Mission <br />March 6-7, 2010: E – Mission <br />March 27-28, 2010: F – Mission <br />April 10-11, 2010: (Optional)<br />Ground Test Schedule:<br />In development to support flight test objectives <br />
  18. 18. Safety Tools<br />Safety Briefings: <br />A now standard practice before conducting any construction project, and ground or flight test. <br />Participating individuals are briefed of responsibilities, procedures, likely hazards, and actions to take in the event of an accident or hazard.<br />Participants are briefed on the need and the proper use of safety equipment.<br />Written Procedures:<br />Developed for all construction projects, ground and flight tests. <br />Improved knowledge base, effectiveness, and safety between leaving and incoming team members.<br />MSDS:<br />Available in the lab and audited once at the beginning of the semester <br />
  19. 19. Safety Tools<br />Existing Procedures:<br />Static Motor Test Firing Stand Setup and Test Conduction<br />Carbon Fiber Tubing Layup and Curing <br />Launch Day Checklist<br />Procedures in work:<br />Black Powder & Ground Based Recovery Testing<br />Parachute Folding Procedures<br />Mechanical Release Testing<br />Launcher Assembly and Usage <br />
  20. 20. Risk Mitigation<br />Identified risks to vehicle, schedule, & cost<br />Potential outcome of failure<br />Steps taken to mitigate those risks<br />Need to rank risk from most likely to least<br />
  21. 21. Recovery Risks:<br />Risk Mitigation<br />
  22. 22. Subscale Photos<br />Bellerophon & Pegasus at the Childersburg, AL Proving Grounds<br />
  23. 23. Questions/Discussion<br />Recovery<br />