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Iowa State University PDR Presentation
2017-2018
1
Overview● Project Overview
● Design
● Subscale
● Safety
● Project Plan
● Conclusion
2
Project Overview
3
Team Structure
4
Mission OverviewRequirements:
• Reach an apogee of exactly 5,280 ft
• Safely recover rocket and land within 2,500 ft of the launch pad
• Fully reusable for another launch on the same day
• Perform 1 experiment onboard
• Visual recognition of ground targets
5
Design
6
Rocket Overview
7
Vehicle Requirements● Launch vehicle will deliver payload to altitude of 5280 feet
○ Preliminary simulations predict apogee of 5280 feet or higher
● The vehicle will be designed to be reusable and recoverable○ No major components will need replacing○ Recovery system ensures safe landing
● Total impulse of launch vehicle cannot exceed that of an L-class○ Total impulse of AeroTech L2200 below L-class limit
● Full-scale rocket model must be tested and recovered prior to FRR○ Test launch planned for February 17th
● All airbrakes should fail in the safest manner as possible○ Airbrakes on opposite sides are coupled○ Airbrakes will fail closed
8
Rocket Specifications:
• Length – 117 in.
• Body Diameter – 6 in.
• Weight - 48 lb
Rocket Features:
• Carbon fiber air brakes
• Split fin design
• Dual-parachute recovery system
• Onboard flight data processing and recording
9
Rocket Specifications
10
Nose ConeParachute Bay 2 (120”
Main)
Avionics Bay
Parachute Bay 1 (24” Drogue) Motor Mount
Flight Computer Bay
OpenRocket Diagram
• Center of gravity: 79.2 in (from nose cone)
• Center of pressure: 92.5 in (from nose cone)
• Stability margin: 2.19
11
Stability
Mass Statement● Nose Cone: 4.92 lbs
● Main Section: 18.05 lbs
● Motor Mount: 25.17 lbs (with motor)
Total estimated weight of 48.14 pounds
12
Section: Nosecone Parachute
bay 1
Avionics
bay
Parachute
bay 2
Flight
computer
bay
Motor
mount
Motor
Weight
(lb):
4.92 7.39 5.04 5.62 3.75 10.88 10.54
Mission Performance Predictions
13
Windspeed(mph)
Velocity off rod(ft/s)
Apogee(ft)
Velocity at detach(ft/s)
Optimum delay(s)
Max Velocity(ft/s)
Max accel.(ft/s^2)
Time to apogee(s)
Flight time(s)
Ground hit velocity(ft/s)
5 91.2 5646.3
76.8 16.4 669.3 429.8 18.7 102 17.8
10 90.6 5613.5
76.8 16.3 669.3 429.8 18.7 102 17.8
15 91.2 5567.6
75.5 16.2 669.3 429.8 18.5 100 17.78
20 91.2 5561.0
76.7 16.2 669.3 429.8 18.5 102 17.68
Mission Performance Predictions (cont.)
14
OpenRocket simulation for 10 mph wind
Materials
• 6” Bluetube airframe with couplers
• Five ½” birch plywood bulkheads
• Fiberglass nose cone and main fins
• Carbon fiber air brakes
• 3D printed exterior fins
• Aero-Epoxy
15
• Filament wound fiberglass
• Aluminum tip
• 33” long
Von Karman vs. Ogive
• More aerodynamic at subsonic
velocities
• Reduces drag
16
Nosecone – 5.5:1 Von Karman
• 75 mm Blue Tube motor tube
• Aeropack flanged retainer
• Load transfer through aft
compression
• 5 ½” Centering ring assemblies
17
Hardware
Split fins
• 4 sets of fins (8 total)
• Material
• G10 fiberglass
•Light
•Durable
Geometry optimization for fin flutter
• 45 different fin designs tested
18
Main Fin Design
Motor Thrust Curve● AeroTech L2200
● Total weight: 10.54 pounds
● Average thrust: 494.58 pounds
● Max thrust: 697.31 pounds
● Total Impulse: 1147.42 lb *sec
● Burn Time: 2.3 seconds
● Thrust to Weight Ratio: 9.89
19
Experimental Overview
20
System RequirementsNASA Derived Requirements
# Name: Requirement Verification
4.4.1 Team will design an onboard camera system to identify and differentiate 3 randomly placed targets.
A Raspberry Pi system and Pi cameras will acquire, store, and assess in-flight images during the flight.
4.4.2 Data to be analyzed in real time to identify and differentiate three separate targets.
Pi boards will use the input from the cameras to process and differentiate between the three targets on the ground.
4.4.3 Teams will not be required to land on any of the targets. We will be using a dual-deployment parachute recovery system without a targeted landing system.
21
System RequirementsExperimental Team Derived Requirements
# Name: Requirement Verification
T1.1 Clear image to identify targets on the ground. The cameras will be hard mounted to the side of rocket for the greatest stability during ascension.
T1.2 A full range image of the ground below the rocket. Five cameras are to be mounted to gain the greatest view of the targets on the ground.
T1.3 Analysis of the image(s) from the Pi cameras. Programed Raspberry Pi boards will take in, store, and differentiate the pi camera data.
22
Changes Since Proposal● Removed Gimbal Concept
○ Reduced mass and complexity○ Added Mission Assurance through increased Field of View
Change Old Version New Version Rationale
Camera Mounting Gimbal System Hard Mount Reduction of mass and costs
Number of Cameras Two cameras Five cameras Greater field of view with chosen method of mount
23
Target Detection System -Computational HardwareRaspberry Pi 3 Model B
CPU Quad Cortex A53 @ 1.2 GHz
GPU 400MHz VideoCore IV
RAM 1 GB SDRAM
Storage Micro-SD
Wireless 802.11n / Bluetooth 4.0
Video Output HDMI / Composite
24
Raspberry Pi Camera Module V2
● Resolution
○ 8 megapixel native resolution high quality Sony IMX219 image sensor
○ Cameras are capable of 3280 x 2464 pixel static images ● Quality
○ Capture video at 1080p30, 720p60 and 640x480p90 resolutions ○ Software is supported within the latest version of Raspbian Operating
System
○ 1.12 µm X 1.12 µm pixel with OmniBSI technology for high performance (high sensitivity)
○ Optical size of 1/4"
Target Detection System - Camera Hardware
25
Target Detection System - Power Supply Hardware
● UPS HAT module board & Battery
○ Cascading design to save mounting space
○ Retains GPIO pins for additional expansion board possibilities
○ 2.8 x 2 x 0.7 “
○ 62.37 grams
● Li-Ion Battery
○ 2500 mAh
○ 3.7 V
○ 2 Amps
26
Target Detection System Software
● The Raspberry Pi receives image stored
on a microSD card by the Pi camera
● Image is converted from RGB to HSV
● Copies HSV channel in grey channel and
processes
27
Electronics Bay● 12 inch coupler bay located between parachute bays
● Contains hardware
○ Raspberry Pi’s and Batteries
● Horizontally stacked circular plates
● Passageways for camera and battery wiring
● Five cameras mounted on rocket exterior
28
Camera Mounting● Full ground tracking field of view below rocket desired
● Minimum of 5 downward facing cameras
● Mounting angle of 24.4 degrees
295 Cameras vs. 6 Cameras
Camera Ducts● Mounting Point for Pi Camera’s
● Reduce drag from mounting the cameras directly
● Contain and protect cameras during launch and landing
30
23.86 mm
25 m
m 11 cm
Moving ForwardTesting and Verification:
● Ensure Program works● Stationary testing on platform
● Scaled down targets to simulate altitude view
● Each test will last for estimated launch duration
Next Steps:
● Look into reducing required number of Raspberry Pi’s● Continue development of software
● Test software in a simulated environment
● Iterate and continue to improve software
31
Apogee Control
32
Changes Since Proposal
Change Old Version New Version Rationale
Battery number and type 1 9V battery 2 LiPo batteries redundancy and longer lasting
Flight computer Arduino Pro Mini Arduino Duo used Analytic Hierarchy Process to choose between board options and Arduino came out on top, the Due has higher clock speed than the Pro Mini
33
34
Simulated Air Brake Deployment
Flight Computer Bay● Parts housed:
○ Flight computer and sensors
○ Airbrake servo governed by
flight computer
○ Servo winch
○ Pulleys
● Construction:
○ U-bolt with wing nuts
○ Finnish birch plywood
● 13.5 inches long
35
● Air brakes actuated by a servo controlled by the flight computer
● Flight computer continuously performs apogee calculations
● If the expected apogee is greater than 5,280 ft, the airbrakes will be
actuated
● This process is repeated until apogee is reached
36
Air Brake Functions
Flight Computer Comparison Results
-All Consistency Indices are below the .1 standard
0.4780 Arduino Due
0.2965 Raspberry Pi 3
0.2255 BeagleBone Black
37
Sensor Choices● Barometers
○ BMP180 (I2C)
● GPS Modules
○ U-blox Neo M8N (UART)
● Accelerometer
○ MPU6050 (3 axis) (I2C)
38
Control Flow
Flow diagram of flight computer code39
Target Computer Setup ● Purpose
○ Run Simulations for the airbrakes
● Program
○ Simulink Real time
● Host computer to target computer connection
○ Ethernet cable
● Target computer to target monitor
○ VGA cable
40
Results Conditions for 2016-2017 rocket run through simulation:
Max altitude● Simulation: 4921 ft● Actual apogee: 4916 ft
Max velocity● Simulation: 564 fps
41
Recovery
42
Recovery Systems
● 24” Drogue parachute opens at apogee
● 120” Main parachute opens at 800 feet
● Black powder ejection charges
● Rocket separates to deploy parachute
● Parachutes secures to rocket through
u-bolts
43
Parachute Bays● Shock cords - kevlar and nylon● Attached to u-bolt assemblies● Anti-zippering ball on shock cords
Parachute bay 1
● Drogue parachute - 24”● Between avionics bay and motor mount
Parachute bay 2
● Main parachute - 120”● Between avionics bay and nose cone
44
Configuration 1 (Drogue):● Descent rate: 106 ft/s● Parachute: 24” elliptical ● Shock cord: 33 ft nylon
Configuration 2 (Main):● Descent rate: 15 ft/s● Parachute: 24” elliptical and 120”
elliptical ● Shock cord: 27 ft nylon
45
Configuration 1 - Drogue
Rocket Weight (on descent) 44.4 lb.
Parachute Size 24 in.
Descent Rate 84.45 ft/s
Configuration 2 - Main and Drogue
Parachute Size 120 in and 24 in.
Descent Rate 14.76 ft/s
Forward Section Avionics Section Motor Mount
Section Weight 4.91 lb. 16.16 lb. 16.8 lb.
Impact Energy 16.67 ft-lb 54.85 ft-lb 57.02 ft-lb
Parachute Configurations
Avionics Bay● Coupler also houses the Electronics Bay
● Copper tape lined
● Altimeters
○ AIM USB
○ Perfectflite Stratologger
● Recovery system comprised of redundant altimeters,
power supplies, and ejection charges
● Ejection charge masses will be calculated by CDR
46
Drift calculation
Regardless of wind speed, rocket will remain within launch field maximum radius
47
Safety
48
Safety ● Team Members
○ Team Safety Officer - Nick Holaday
○ Second Safety Officer - Briana Staheli
○ Technical Communication - Sarah Kreutner
● Team Responsibilities
○ Maintain record of trainings and briefings for all CySLI team members
○ Prepare Risk Assessment Tables
○ Prepare Build and Launch Procedures
○ Oversee all safety concerns and legal compliances
49
Risk Severity
50
Risk Probability
51
Risk Assessment Matrix
52
Facilities and Safety Policies● Policies
○ Use of Facilities
○ Iowa State Safety Policies
○ Team supervision during build
● Facilities
○ Make 2 Innovate Student Lab
○ Boyd Engineering Lab
○ M:2:I Conference Room
○ Howe Hall Computer Lab
53
CySLI Website https://m2i.aere.iastate.edu/cysli/
Maintained with all current team information, Student Launch Initiative documentation, and M:2:I documentation by Technical Communication Lead, Sarah
54
Risk Assessment● Lab and machine
○ Hazards that could occur due to the laboratory equipment and machinery
● Rocket
○ Hazards that could be caused to or by the rocket
● Avionics
○ Hazards that could occur due to the avionics system of the rocket
● Experimental
○ Hazards that could occur due to the experimental factor of the rocket
● Environmental
○ Hazards that could occur due to the environment around the rocket
55
Compliance with Laws● Iowa State Rocketry Laws
● Minnesota State Rocketry Laws
● NAR and TRA requirements
● Required NAR supervisor will be Gary Stroick
56
Handling of Rocket Motors● Purchase and Storage
○ Online Vendor- Off We Go Rocketry
○ Due to ISU safety policy, purchased and handled by Team Advisor Gary Stroick
○ M:2:i Director Matt Nelson will handle in between delivery and launch
○ Shipped with HAZMAT safety precautions
● Handling and Transportation
○ Fullscale delivered and handled by Gary Stroick
○ Project Lead Becca will handle subscale motor
○ Properly secured and stowed away during all transit
57
Range Safety Regulations
1. Certification
2. Materials
3. Motors
4. Ignition Systems
5. Misfires
6. Launch Safety
7. Launcher
8. Flight Safety
9. Launch Site
10. Launch Location
11. Recovery System
12. Recovery Safety
58
Documentation ● Identifying hazards
○ Each subteam provided a list of possible hazards
○ Comply with NAR, and NFPA 1122 model rocket safety codes
● Procedure Approval sheets
○ Signatures needed from all members of build and launch team
○ Ensures knowledge of safety requirements during build and launch
● Log sheets
○ Log flight info and data during check before launch
● Supervision
○ Safety officers present during all build and launch events
59
NASA Safety Regulations● All CySLI team members have agreed to follow the specific NASA SL Handbook regarding Launch Safety.
This was agreed to in the Safety Agreement Form and re-discussed during all briefings.
1.6.1. Range safety inspections of each rocket before it is flown. Each team shall comply with the determination of
the safety inspection or may be removed from the program.
1.6.2. The Range Safety Officer has the final say on all rocket safety issues. Therefore, the Range Safety Officer has
the right to deny the launch of any rocket for safety reasons.
1.6.3. Any team that does not comply with the safety requirements will not be allowed to launch their rocket.
60
Subscale
61
Subscale testing● Launching subscale test on
November 11th
● Pearson Farms in Mitchellville, Iowa
62
Subscale testingSubscale will be ⅓ size
63
Subscale Testing● Testing aerodynamic properties of the airframe
○ Replicate placement of CG and CP● Testing altimeter (Stratologger CF)
○ Ride-along mode
64
Verification Plan
● Verification Checklist to ensure proper assembly and preparation
○ Subscale construction
■ Parts are securely epoxied together
○ Loading the motor
○ Packing the parachute
■ Correct packing
■ Untangled shroud lines
■ Secured to airframe
65
Subscale Launch Safety● Safety Briefings
● Subscale Build
● Build/Launch Procedure Sheets
● Subscale Procedure for Launch
○ Prep Black Powder Charges
○ Recovery Charge and Coupler Installation
○ Motor Installation
○ Safety Tests (Shake Test)
66
Project Plan
67
68
ScheduleCompetition Timeline
Description Completion DatePDR Q & A 10/12/2017Website and PDR Due 11/3/2017CDR Q & A 12/6/2017CDR Due 1/12/2018FRR Q & A 2/7/2018FRR Due 3/5/2018Launch Week 4/4/2018-4/7/2018PLAR Due 4/27/2018
69
Equipment Costs $5,800
Material Costs $1,150
Travel $4,000
Total $10,950
Budget
Questions?
70
Backup Slides
71
Rocket Design Backup Slides
72
Nose ConeVon Karman vs. Ogive
● Most Aerodynamic at subsonic
velocities
● HAACK series nose cone
● C value = 0
● High aspect ratio 5.5:1
73
Motor Mount● Construction
○ Centering rings epoxied to inner tube
○ Then, epoxied to inside of airframe
○ Fins are epoxied in place using fin mounting jig
● 26 inches long
● Motor retainer
○ Prevents motor movement during flight
74
Fins● Flutter velocity of fore fin is 898 ft/s
● Flutter velocity of aft fin is 1153 ft/s
● Safety margin of 27.0%
● Waterjetted from G10-Fiberglass
● Through-the-wall fin mounting
● Fins aligned with fin mounting jig
75
Secondary Fins● Reduces drag caused by exterior pulleys
● Aesthetic cover
● Help guide cables to airbrake surfaces
76
● 120” Main● 24” Drogue● ⅜” U bolts● ⅜” Quick links / ¼” quick links● ½” nylon shock cord● Kevlar shock cord protector● Kevlar chute protectors● Anti-zipper ball● Slider release ring ● Deployment bag
77
Recovery Hardware
Drag-V=sqrt((8*m*g)/(pi*rho*C*D^2)
Main parachute
V = sqrt((8*222.714*9.8)/(pi*1.22*2.2*3.048^2)) = 14.929 m/s
Drogue parachute
V = sqrt((8*222.714*9.8)/(pi*1.22*1.55*.371612^2)) = 145.889 m/s
78
Apogee Control Backup Slides
79
Why the M8N?
80
Flight Computer -Used the Analytic Hierarchy Process to help with flight computer decision
Arduino Due Raspberry Pi 3 BeagleBone Black
Processing Speed - + +
Code Portability + - -
Community + + -
Sensor Use Ease + - +
81
Simulink Mother blockMain block with sub-blocks
● Rocket Motor Block● Dynamic Block● Drag Block
82
Motor Thrust BlockIntegrates Thrust Profile to obtain:
● Burned Impulse● Fraction of Impulse Burned● Motor Mass
83
Dynamics BlockUses mass, thrust, and drag to obtain:
● Acceleration● Velocity● Altitude
84
Drag Block
Uses velocity and altitude to find:
● Drag with respect to change in altitude
● Equation:
85
Safety Backup Slides
86
Forms, Briefings, and Trainings ● Forms
○ Safety Compliance Form
● Briefings
○ Introductory Safety Briefing
○ Build Briefing
○ Subscale Launch Briefing
● Trainings
○ Personal Protective
○ Fire Prevention
○ General Shop Safety
87