Callisto - Auburn University · BRIC Final Build (Batteries Not Mounted) BRIC Flight Reliability...

CallistoAUBURN UNIVERSITY

MARCH 16TH, 2020

Adam BurkleyVehicle Team Lead

Vehicle Dimensions•Total Length: 132 inches•Inner Diameter: 6 inches•Outer Diameter: 6.2 inches•Estimated Mass: 55 lb

Vehicle Overview132 inches

24 inchesNose Cone Payload Section Main Parachute SectionBAE DBAE Drouge

Sec. ACS Sec. Booster Section

23 inches 2 inches 30 inches 2 inches 12 inches 7 inches 33 inches

Stability Margin•Static Stability Margin at Rail Exit: 4.16

•Static Stability Margin at Burnout: 4.93

•Center of Gravity from Nose Cone: 78.606 inches

•Center of Pressure from Nose Cone: 104 inches

Material Used•Carbon Fiber

• Used For:• Bulkheads, Fins, Centering Rings• Motor Tube, Booster Tube, Drogue Tube, Main Parachute Tube

•Fiberglass• Used For:

• Payload Tube• Altitude Control System Tube• Nose Cone• Couplers

Fins•The team used the clipped delta fin design.

•The thickness of the fins is 0.12 inches

•Easy to manufacture

•Works well in subsonic flight

•Team Experience

Nose Cone•The team decided on using a 4:1 tangent ogive nose cone.

•Performs well in subsonic flight

•Low coefficient of drag

Booster Section

Full Rocket Assembly

Motor Selection and Performance Predictions and Thrust Curve

•Motor Selection: AeroTech L2200G

•Thrust to weight ratio: 10.3:1

•Rail Exit Velocity: 84.9 ft/s

•Simulated altitude of 4726 ft(0 Mph Wind)• In 5 MPH Wind: 4719 ft• In 10 MPH Wind: 4702 ft• In 15 MPH Wind: 4667 ft• In 20 MPH Wind: 4635 ft

AeroTech L2200 Motor SpecificationsManufacturer AeroTech

Designation L2200G

Diameter 2.95 inches

Length 26.2 inches

Total Impulse 1147 lbf-s

Total Motor Weight 10.55 lb

Propellant Weight 4.95 lb

Average Thrust 504 lb

Maximum Thrust 677 lb

Burn Time 2.3 seconds

Tim JordanRecovery Team Lead

Recovery OverviewTwo Events

Drogue- Apogee and one second backup

Main- 550ft and 500ft

ParachutesMain Parachute: LeftStyle- HemisphericalDiameter- 10.5ftRipstop Nylon and 5/8inch tubular nylon shroud lines

Drogue Parachute: RightStyle- CircularDiameter- 30inRipstop Nylon and paracordShroud lines

Both have 5/8inch tubular nylonFor the shock cord

Ejection SystemBlack Powder Charges

Planned Charge sizes:

Main: 5 and 5.5 grams

Drogue: 3 and 3.5 grams

3D Printed Charge Cups

E-Matches

BAE (Barometric Avionics Enclosure)

Design maturity from PDR

Weight savings led to a minimalistic design

Encounters negligible forces so design changes don't risk failure to rocket

Electronics• StratoLogger CF-PerfectFlite

• Four altimeters• Featherweight GPS Tracker

• One GPS in nosecone

Attachment HardwareShear Pins- 4-40

U-Bolts

D-Rings

Flange Lock Nuts

Swivel Joints

Altimeter mount and nuts

Mission Predictions

Descent Times: Kinetic Energy:

Under Drogue(97.1 ft/s)- 45.8s Section 1 (Payload)-49.8 ft-lbs

Under Main(12.75 ft/s)- 43.1s Section 2 (Recovery)- 17.2 ft-lbs

Total - 88.9s Section 3 (ACS/Booster): 43.9 ft-lbs

Drift Totals:

5mph – 652ft 15 mph – 1957.3ft

10mph – 1305.1ft 20mph – 2609.4ft

Carter DavisPayload Team Lead

BRIC • The Boring Rotary Instrument

Carrier (BRIC) is a UAV with anonboard auger designed to collectextraterrestrial soil samples.

• The system features a dual motordriven pulley arm releasemechanism and a retractable auger.

• It is lightweight but durable, beingprimarily 3D printed using a blendof PLA and Onyx.

• The BRIC has undergone very fewminor changes since CDR.

BRIC Auxiliary Board

BRIC Final Build (Batteries Not Mounted)

BRIC Flight Reliability•The BRIC has received many flight tests both on test stands and on the field.

•The BRIC has been tuned to fly stable using the built-in software.

•The BRIC has been stowed and deployed four times in house and two times during demonstration flights.

•The BRIC underwent a static battery test where the system was left for four hours to prove a factor of safety of 2 for battery life.

•The BRIC was also run at various throttle speeds until the batteries died. This gave a very reasonable flight time of 9.5 minutes

UAVES• The Unmanned Aerial Vehicle

Ejection System is designed as asolution to problems the team hasfaced in previous years regardingdeployment.

• Instead of relying on aerodynamicforces to release the nosecone, theUAVES System manually pushes thenosecone and payload from therocket, using 2 ACME lead screws.

• This is a deployment method whichhas already proven more reliable inlaboratory and field tests thanmethods used in previous years.

UAVES Electronics

UAVES Electronics Module Render

UAVES Deployment

UAVES Flight Reliability•The UAVES system is arguably the most reliable.

•Through strength tests, UAVES has been proven to deploy a 55-pound load.

•Through tensile testing, the UAVES system was demonstrated to withstand a failure load of 300 pounds.

•Through battery testing, the UAVES was proven to have a factor of safety of 2 for battery life.

•UAVES was proven effective and reliable in the payload demonstration flight.

AOS / ARS• The Active Orientation System and

Active Retention System both aredesigned to assist with deployment ofthe payload.

• In past years, the payload has landedupside down, and a passiveorientation could not effectively andreliably counter this. The AOS isdesigned to automatically correct thepayload's orientation.

• The ARS is designed to retain therocket during flight and descent, toensure it only deploys when thepayload section is oriented andejected correctly.

AOS/ARS Electronics

AOS/ARS Control Board Render

AOSAOS/ARS Final Build

AOS/ARS Flight Reliability•The AOS/ARS system has been proven reliable from many in house and field tests.

•The AOS/ARS has undergone a full electronics and mechanical functionality test.

•This test proved the mechanical design was sound and there were no bugs in the electronics system.

•This system has been stowed and ejected more than 15 times through various testing of other systems without damage or malfunction.

•This system has been battery tested to a factor of safety of 2 in house.

•This system was successful during the payload demonstration flight.

Austen LeBeauAltitude Control Team Lead

ACS Components

ACS Electronics

ACS Flight Reliability•All internal components undamaged after both verification flights

•Grid fin torn off after first flight, most likely on touchdown

•Grid fin suffered scarring on surface after second flight

•Fins did not deploy due to bug in the code

•Vertical speed estimation algorithm did not perform adequately

•System is sensitive to vertical speed, Kalman filter will be implemented and tested at competition

Data Analysis• Data gathered from flight used to

implement a Kalman filter prototype• Simple, linear model• Newtonian kinematic equations• Not ideal, but much better estimations

Lindsey WaggonerTesting Team Lead

Completed TestsAltitude Control Tests◦ CFD analysis◦ Grid fin structural integrity test◦ Battery life test◦ Launch simulation

Payload Tests◦ AOS flip test◦ UAVES strength test◦ BRIC flight test/full system demonstration◦ Battery life test◦ Failure point analysis◦ Flight time test

Completed TestsStructures and Propulsion Tests◦ Materials testing

Recovery Tests◦ Ground separation tests◦ Full scale parachute test◦ Battery life test

Mission Tests◦ Sub-scale proof of concept launch (nominal, 4529 feet)◦ Full scale test launches (one failed; one nominal, 4665 feet)

Full-Scale Flight ResultsDemonstration Flight #1

• February 15

• Hopkinsville, KY (Music City Missile Club)

• Clear skies, 54 degrees, 10 mph winds

• Apogee: 4509 feet

• ACS inactive, main payload inert

• Failure due to main at apogee

Demonstration Flight #2

• February 22

• Samson, AL (SouthEast Alabama Rocketry Society)

• Clear skies, 57 degrees, 7 mph winds

• Apogee: 4665 feet (ACS set to 4400)

• All payloads active

• Successful launch, recovery, and payload demonstration

Full-Scale Flight Results

Vehicle Requirements Verification• Vehicle delivers payload to an apogee between 3500 and 5500 feet

• Validated using simulations and demonstration flight data

• Vehicle is recoverable and reusable• Vehicle was recovered with only slight damage after each demonstration flight

• Design follows all NASA requirements• Only three independent sections• Coupler/nosecone shoulders are within required range

• Vehicle can be assembled in 2 hours, and can remain launch-ready for 2 additional hours• Validated during demonstration flights and ground battery tests of all systems

• Vehicle uses a single stage, commercially-available solid motor with a 12V direct current firing system and is within the required impulse class

• Stability and velocity at rail exit are within required ranges• 2.754 calibers, 89.898 ft/s

• No prohibited features in use

Payload Requirements Verification• Required payload can be launched, recovered, and deployed to collect an ice sample

• Ground tests performed of all subsystems• Vehicle demonstration flight validated ability to be launched and recovered

• Additional payload has been documented thoroughly and tested to ensure safety

• All payload hardware is launched within vehicle

• Payload is registered with FAA and follows all local, federal, and NAR regulations

• Robust mechanical retention and deployment system in use

• No part of the payload is jettisoned

Example Test ProcedureUAVES Lead Screw Coupler Failure TestProcedure:1. Secure threaded rods to the carbon fiber flat plate in normal launch configuration.

2. The end of the threaded rod opposite the carbon fiber plate will be placed between the grips of the apparatus, and the worm drive gearmotor will be placed into the opposite grips of the apparatus.

3. The load and strain will be zeroed out on the computer interface and a tensile test will be initiated.

4. The data will be plotted until the maximum load is reached. The machine will automatically end the test.

5. If the maximum load is less than the required load, the test will be repeated with additional hardware securing the rod to the motor, including a knurled-tip worm screw and a notched motor drive shaft.

Example Test Procedure

Jackson TreeseSafety Officer

Safety SummaryFinalized personnel hazard analysis, FMEA, and environmental concerns tables with verifications and post risk assessment codes.

Finalized procedures for assembly of rocket on launch day.

No launch concerns.

Grant TurnerSTEM Outreach Lead

2019-2020 Outreach

Auburn University Engineering Day• E-Day is Auburn's largest engineering outreach event held annually.

• This year, it's estimated around 5,000 prospective engineering students came to campus for E-Day. The Rocketry team was able to interact with the majority of these students.

• Students were able to learn about the Auburn Rocketry team, and get hands-on interaction with this year's competition rocket.

Project Timeline

Budget and Funding

Questions?