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SED - REXUS 11/12 Team ADIOS

1. 29 RHX11 ADIOS SEDv5 3 07October2013 Final docx 4 1 2 EXP2 Determining of static loads ooooccconncconnoconnnnnos 30 4 2 EXperiment IOMA Susi AAA 31 421 Mechanical iii 31 4 2 1 1 Cable feed through and D Sub mountings ssseuuuss 31 42 12 Module Modulo 32 422 PICCIWIC Al WE 33 4 3 Experiment Components cccccsseeeceseeeceneeeceueeeceueeeceusessaueesseeeeas 33 4 4 Mechanical DOSIO Nui ida 34 AAA LOCKING MECHAnISN ee 35 4 4 2 FFED Free flying experiment device 36 A tab tite ttu a tite itu ose 37 zi MEN Nelle 39 4 4 5 Position of acceleration Sensors uuuuensnneenennenennenenne nennen 41 AAG Mass TEAUGION sun ino ded ode dido euDcidodua Bonos duod eo M beue 41 AAT nuca AN SS si 45 4 4 8 Drawing Number SySteM oocccccccnccccnnnoccnnnonocononncnnnnncncnoncncnnns 47 4 5 Electronics Desi ii 48 4 5 1 Block diagram of the ADIOS experiment 48 452 EXP ses 49 450 A R R 58 ADA AM pUJ een 62 4 6 Jer mal DESIGN yssen A 64 4 POWEL SSI MM esn ias 65 4 8 SOWIE DESIN seis a aA E A bae seins 66 4 9 Ground SUPPON EQuiID Messina 69 491 Telemetry SOIlWBlG u tire oerte od oe ors eoe sevo pe oor pes 69 5 EXPERIMENT VERIFICATION AND TESTING eene 71 s MEI due T USE 71 oua ESL PIT tap ee 73 Sn eier ine 73 922 NACUUM TOS A aia
2. Locking Mechanism Arm Plug Connector The residual accelerations onto the FFED are very small Depending on the sensor setup the noise could be higher than the measured data To avoid this loss in accuracy the FFED will be excited by an imbalance generator This generator probably known from the alarm of mobile phones gives a defined acceleration in variable frequencies which can be determined and compared The excitement will act for about 20 30 s and will be hardly measured at the outer structure neither it would affect other experiments First estimations showed that a maximum acceleration of 800 ug would suffice to excite the 2kg FFED This equates an imbalance of cm with a rotating disk of r 22 mm Picture 6 Overview of the Experiment An accurate calculation can be done after the exact knowledge of masses 4 1 2 EXP2 Determining of static loads The mechanical loads acting on the structure during the flight will be measured by strain gauges in critical points These points need to be determined by structural analysis by building a FE Model and simulating the acting forces Presumably several measuring points need to be set in several levels allotted on the inside of the module structures even at other experiment modules Due to the setup the strain gauges will be temperature compensated It need to be confirmed if it is necessary to amplify the signal before transmitting it to the DAQ in the ADIOS Module HX11 ADI
3. Page 151 N i advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH ADLR and SSC cooperation Picture 7 strain relief for cabling Procedure of application 1 2 Cleaning of the module surface Removing anodization in the area around the placement with 80 with abrasive paper Keep it dry and clean Use clean gloves Use provided clean paper tissues for cleaning the surface VERY accurately with chemically pure acetone very important do not use technically clean acetone 4 Do not touch the clean surface again 5 Using transparent adhesive tape to pick up the strain gauge and place on the structure Lifting up the adhesive tape until the matt finished backside of the strain gauge is visible Apply special glue read instructions of manufacturer on the strain gauge Press the strain gauge on the structure for several minutes see instructions of manufacturer Use rubber between tool and strain gauge Fixate the rubber with adhesive tape 10 Use tool to build up pressure onto the positioned measuring point 11 Heat the structure from the outside of the module at least in the area around the strain gauges to a temperature up to 80 C HX11 ADIOS SEDv5 3 07October2013 Final docx Page 152 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 12 Wait for at least 5 hours then remove the tool carefully 13 Remove adhesiv
4. Multi Material Body im Fachbereich Luft amp Raumfahrttechnik Montag 09 05 11 14 00 H rsaal 00201 7 A d Anuja Nagle M Sc amp Prof Dr Ing Thilo R th Mo VisMut Karosserieleichtbau f r die 06 06 11 Kleinserie von Elektrofahrzeugen 14 00 wissensbasierte Konstruktion von programmierten Strukturen Dauer jeweils 30 bis 45min Stefan Kr mer No Vibrations Good Vibrations Entwicklung einer passive Schwingungs d mpfungsplattform f r micro g Experimente auf H henforschungsraketen Picture 43 Presentation F amp E Research amp Development Conference FH Aachen No Vibrations Good Vibrations S Kramer i A Dauer ca 30m n kontakt thenent fh aachen de RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 109 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation Studium amp Lehre Rexus Projekt Studierende experimentieren mit Raketen unter Raumfahrt bedingungen AIT PIE TN UNIVERS TY OF APPLIED SCIENCES PeopleMover Magazin der Sektion Luft und Raumfahrttechnik im aifna net und des Fachbereiches 6 der FH Aachen alfha net Alumni Veranstaltungen Studium amp Lehre Forschung Intern One atap unc an Unities m de Frau arpas Prope t taperen unte Neues pter Aceton an tun ADS vanter Der unwerw Vut che Pro Wane wth pran retrum Moneta mapeo bo biu bu bo bas
5. Stefan Kramer Lysan Pf tzenreuter Nick Daab und Brigitte M ller Studierende der Luft und Raumfahrttechnik an der FH Aachen nehmen an einem Praxisprojekt der besonderen Art telt REXUS Raketen Ex perimente f r Universitats Studenten Ist ein deutsch schwedisches Stu dierendenpr ogramm das von der European Space Agency ESA und dem Deutschen Zentrum f r Luft und Raumfahrt DLR erm glicht wird Es bletet Studierenden die einmalige Chance wissenschaftliche und technische Experimente auf suborbitalen Raketenfl gen unter kurzzeiti gen Weltraumbedingungen durchzuf hren Das Junge Team um den studentischen Projektmanager Stefan Kramer und Betreuer Dipl Ing FH Engelbert Plescher f hrt ein Experiment fort das bereits Im Marz 2010 mit dem Raketentrebsatz REXUS 7 In Schweden gestartet wurde Ziel war die Entwicklung einer Experimen tlereinhelt die materlalw Issenschaftliche und biologische Experimente In der weitgehend storungsfrelen Umgebung im Weltraum erm glicht Mit magnetischer D mpfung und Federn fanden die Studierenden damals au erdem eine L sung um die Einheit vor den Ersch tterungen des Raketenflugs zu sch tzen und konnten dabel eine Isolationswirkung von bis zu 80 Prozent erzielen Stefan Kramer und sein Team wollen diese Isolationsw irkung nun optimieren und durch eine Neuanordnung der Magnete und nderungen bel der Daten bertragung Schwingungen und aerodynamische St rungen die die Schwerelosigkeltsphase beeinflussen
6. sees nennen 9 1 4 eam DelalS nacidas dd 10 ech A e ges tedio e PPP0P0P0O0O0OUO CONO QOO 0 90 95 6 0 5 40 9 0 9 250 00 10 1 42 Team Membe iaa des 11 VAS Team structure msn A 13 2 EXPERIMENT REQUIREMENTS cortina 15 2 1 FURCTONAl Requirements iecit reco cet eoe robora iide 15 2 2 Performance requirements eese nennen nnns 16 22 1 JAcceleratiori Sensors ee 16 222 Dial GallGes EX tia iaa adas 16 223 ASIA MON A A E 16 222 o ee ee 16 225 mbalance generator uses 16 2 3 Design REQUIEMENIS Au anna 17 BON SEUCHTE ana 17 2 3 2 Electronics Sensors Programming 17 2 4 Operational Requirements crsa a i NT 18 9 PROJECT PLANNING 2 oic rtu eds eoo uc esee eee ees 19 3 1 Work Breakdown Structure WBS coooccccccnccccnccocnccncnccocnconcncnnnnconons 19 due JC SO UNC CS suicido 19 32 1 ManPower eaa aaa naaa 19 322 WOMAN ios 20 329 A ee eee 21 324 e 22 33 OUlreach ADDO CN ser een 25 3 3 1 Public presentations 2 359 annes estne ei ed ues 25 3 3 2 Publications Papers and Abstracts 26 e Development and Testing of a System to Damp Vibrations for Micrigravity Experiments on Sounding Rockets Stefan Kr mer et al ERP Ds ee ee 26 3 4 RISK RECO Siria ico 26 35 MN esse nn 28 EXPERIMENT DESCRIP THON ass a 29 4 1 Experiment SEID nee er 29 4 1 1 EXP1 Verification of the damped System FFED
7. D 5 D 6 D 7 The internal bulkhead should stay as stiff as possible by reduced weight The Isolation shall work passively The locking mechanism shall prohibit any movements of the FFED during launch and landing There shall be easy access to electronic boards for maintenance and calibration Electronic access via Ethernet connector at assembled status The Experiment shall fit into a REXUS 300mm Module To economise weight the locking mechanism shall be build from carbon fibre composites 2 3 2 Electronics Sensors Programming D 8 D 9 D 10 D 11 D 12 D 13 D 14 D 15 D 16 D 17 D 18 The strain gauges should be mounted on the inside of the outer structure EXP1 and EXP2 shall work independent from each other If one fails the other one shall not be affected seriously The electronics shall be as simple as possible The electronic setup should be as light weight as possible The Electronics shall cope with 28 V Power consumption needs to stay beneath 3 A peak The data volume on the cRIO shall not exceed 0 7 GB for all data The strain shall be measured at three cross sectional areas where one is located near the motor adapter one is located in the Adios experiment and a third cross section near the nosecone adapter The sensors shall be temperature compensated The ACC Sensors shall be Shock resistant up to 20 g The four strain gauges of one cross section shall be attached to the struct
8. Page 101 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation o team requests an Ethernet umbilical gt use an access hatch instead Verification and testing o locking mechanism has to be tested o verify that the structure is strong enough once the mass has been reduced o verification matrix missing in SED o perform a thermal test Safety and risk analysis o mission risk how much mass is uncontained if the locking mechanism fails o if locking mechanism opens before launch the balance of the rocket can be ruined o Risk MS40 D is a bit high manufacturer cannot guarantee that they will survive take off Launch and operations o no problems Organisation project planning amp outreach o alotto discuss about project planning and organization o project management must be discussed with your project manager and a proper solution must be found Others movie team at Esrange possible but needs to be pre organized funding for acceleration sensors one board per sensor ok project management is a concern again CDR will be a critical step for the project 5 Final remarks Summary of main actions for the experiment team o Design must be developed further or better described before a full pass is given Resubmission of SED at the end of March including preliminary CDR content proposal of EXP2 sensor locations must be given to your project manager together with the SED resubmission locking mechanis
9. SF10 Motors Damage during flight A 3 Experiment shut down TC30 cRIO Damage during test A 3 Spare part already on stock MS10 cRIO Programme failure during 2 Loss of data Software ue MS20 cRIO Damage during ascent 3 Total loss of all data VE10 cRIO Damage during ug phase A 4 Reliable structure Loss of locking control cage MS30 cRIO Damage during descent A 2 Reduced EXP2 Performance MS40 Sensors Damage during launch 3 Loss of data lm o s D MS50 Sensors Damage during ascent A 2 WER Loss of data dem o D TC40 Damage during test Spare parts MS60 Damage during flight Loss of data TC50 Imbalance Damage during test A 1 Spare parts Generator MS70 Imbalance Damage during flight A 12 Reduced EXP1 Generar performance RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 28 Te EuroLAauncH advanced isolation on sounding rockets no vibrations good vibrations A DLR and SSC cooperation Time Schedule 3 9 qas aooe nr c not uBieduie youney unf 3 eseud uv IEN Idy ZLOZ NO c zJ qe4 uer ZIOZ no H zag Busey AON MO LLOZ NOP das Yasm LIEX3 EN afeys Asoyevedaud Emm uononpoJd l 409 Bry nf un LLOZ NO E 9 eseug IEN Idy LLOZ HO Z ZIN q33 ue LLOZ HO L zag AON MO OLOZ NO Fr EEE EBEEBEEBEBEEEEEEEBEER mn 7 HH Twn ED 0 16 EX 4 oS AD T e e e e rr er CI DI C24 CJ 04 4
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11. The preparations have been fulfilled without any problems The Experiment has survived the half year waiting period without any influences The team assumed changes in the calibration of the measuring equipment but these concerns have not come true The Experiment was ready for launch again in time and conducted all pre flight test successfully First analysis of the data after the RXS 11 flight showed that the conditions of reduced gravity have been very poor although the damping mechanism of EXP 1 obviously has worked All measurement points of EXP 2 have delivered data until the end of the flight ADIOS has worked perfectly 7 3 Results A detailed presentation and discussion of the results of the experiments 1 and 2 can be found in Chapter 8 3Appendix D and 8 3Appendix E in the framework of the submitted papers for the 21 ESA Symposium on Rocket and Balloon related Research 7 3 1 Experiment 1 The acceleration data shows clearly the strong disturbance induced by the wobbling effect of the payload after motor separation The graphs in Figure 10 indicate the acceleration in flight axis of the vehicle in order to the time after driving the LM of the ADIOS Experiment 1 The red line represents the X Axis of the undamped wall It is directly influenced by the vibrations of the outer structure The green line belongs to the ACC sensor carried by the FFED A band filter washed out the deep frequent perturbation by the movement of the vehic
12. 5 2 2 u g phase 956 980 791 10 Hz ug Phase 100 50 500 1500 Hz 1000 Figure 10 shows the spectrum of vibrations while g phase RX11_ADIOS_SEDv5 3_07October2013_Final docx Se Se A EuroLAauncH A DLR and SSC cooperation 9 The vibrational energy seen in Fig 10 is partly stored from excitations while ascent and partly caused by pay loads The frequency ranges in which more energy is mea sured can be considered to be structural resonances for which are characterized by low damping and energy sto ring effects These measured frequencies are well related to the se cond and fourth calculated Eigenfrequencies As assumed before after reconfiguration the data was not sufficient to verify the different Eigenforms The final result therewith is that several resonances were measured which can not be definitly related to spe cific Eigenforms 5 2 3 Descent 10 Hz Descent 100 50 500 1000 1500 Hz Figure 11 shows the spectrum of vibrations while de scent of REXUS 11 During descent much energy in a wide frequency range was measured Like at ascent much energy was measu red at low frequencies which also should be related to temperature shifts due to aerodynamic drag At higher frequencies several discrete events were measured which can relate to structural resonances tumbling movements of the whole payload and also to aerodynamic effects 6 CONCLUSION AND OUTLOOK It can b
13. Graduated FH Aachen Luft und Raumfahrttechnik Picture 4 Team ADIOS HX11 ADIOS SEDv5 3 07October2013 Final docx Page 13 no vibrations go od vibrations E UROLAUNCH A DLR and SSC cooperation 1 43 Team structure At the moment the Team consists of ten team members studying at the FH Aachen Participants of the former project VibraDamp are supporting the team with knowledge and the experience regarding the REXUS Project DLR SSC ESA E Consulting EuroLaunch 3 O Dipl Ing Engelbert Plescher A nd Contact FH Aachen a Dipl Ing Rudolf Vetter ADIOS Project Management pi 3B Stefan Kr mer Md ADIOS Team member Structure Science Programming amp DAQ Electronics Outreach PR i 3 Joana Hessel F Lysan Pf tzenreuter B Eng t 9 Vladimir Klassen O Dominique Daab j Brigitte M ller f ca en S s arta A omen ce Stefan Kramer EA Georg Gdalewitsch EA Tobias Wagner Consulting ao Stefan Kr mer 3 r Press Office 2 Tobias Wagner VY a Fabian Baader p Frederik M rz FH Aachen n Consulting da Y 4 olf Vetter Lysan Pf tzenreuter B En ce soso Rudolf Vetter CA donat g Consulting ravam MbraDamo M 1 Andreas Gierse VibraDamp Figure 1 Team structure The management is the major link between the Team ADIOS and the EUROLAUNCH Consortium the DLR RY and the DLR Space Agency on the one hand side and the team members on the other hand side Acquiring sponsors and han
14. HX11 ADIOS SEDv5 3 07October2013 Final docx not finalized in time the project was redesigned to VIBRADAMPII and successfully tested on REXUS 7 in 2010 VIBRADAMPII contained a free flying ex periment device FFED which was de and recoupled while ascent and descent using three geared motors The FFED was hold in the center of the rocket while p g phase using six steel springs and it was damped using the eddy current effect Two three axis accelerometers were used to analyse the mechanical behavior of the de coupled system and the effectiveness of the decoupling from the rocket structure Results were presented in 1 In 2011 based on VIBRADAMPII a new student team DIOS4 ADvanced Isolation On Sounding rockets for med with the objective to further develop the VIBRA DAMPII system to TRL 7 status A big effort was spend on lightweight constructions and a highly reliable de and relocking mechanism Also the damping system was fur ther developed to a two stage damping The object of research was enhenced to the field of vibrations and disturbances of the rocket structure Therefore a modal analysis measurement system was de veloped The development of this system and the results are presented in this paper 2 MOTIVATION AND AIMS While ascent and descent the rocket structure is excited by aerodynamic loads Forces and the frequencies of this disturbances depend directly on speed air density spin rate and the angle
15. Junctionbox Cpu Name Remarks S 4 Dm Data Terminal Ready 6 DR JDataSetReady S 8 CIS Jdertosnd 4 9 Ri Ringindicaton o Table 6 connector pin configuration Cabling At FH Aachen we have a LI F12YC11Y0 3x2x0 25mm cable with a length of several hundred meters That cable will be split into the single strands which have 6 different colours The aperture of 0 25mm equates to the AWG 24 American Wire Gauge The cable coating is heat resistant which was tested in the climate camber Picture 31 cable DC DC converter Each experiment is supplied by a Traco TEN 20 2423 DC DC converter with a demand of 20W It provides a voltage of 15V at a current of 667mA A Traco TEN 30 2413 DC DC converter which has a demand of 30W provides an output voltage of 15V at a current of 2A That DC DC converter supplies the CompactRio module HX11 ADIOS SEDv5 3 07October2013 Final docx Page 56 gt advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH A DLR and SSC cooperation Picture 32 Traco Power DC DC converter Optocoupler On PCB1 an optocoupler is used to convert the liftoff signal LO of the REXUS service module to a TTL signal which is linked to the CompactRIOs serial interface Test box Fuse box The Test box is used to safeguard the service module of the REXUS rocket For the first initiation it is switched between the
16. The application has already been tested under different conditions There are to different types of testing 1 Static test The RX Module with the applicated strain gauges will be mounted to a rack and bended by a load 2 Dynamic test The RX Module will be put on the shaker including the strain gauges and an additional mass 5 2 5 Functional Electronic Test Functional test Electronics Laboratory for space technology FH Aachen Electronic circuits Bread boards and prototypes Table 14 Functional Electronic Test The functional tests have been done parallel to the development of the circuits Every change in the design has been followed by a test of the circuit on the bread board and later on the prototype Every single PCB will be tested completely 5 2 6 Functional Test Assembled Mode Functional test Assembled Mode Laboratory for space technology FH Aachen and later at ESRANGE Function of Electronics and Mechanics in combination HX11 ADIOS SEDv5 3 07October2013 Final docx Page 77 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation Test campaign 5 days and again 1 day at ESRANGE duration Table 15 Functional Test Assembled Mode In the final assembled mode the whole experiment will be tested before the payload integration and the bench test 5 3 Test Results The test results will be divided again into the results of the two experiments The Protocols of the c
17. device acts different than the device on its own or whi le it is fixed to the other parts of the rocket Also all ground based tests can not consider external loads like vibrations of the rocket motor or aerodynamic loads An in flight modal analysis system needs many sen sors all over the rocket structure Such a system has to consider quantitatively unknown boundary conditions The most important conditions are the fast change of the rocket skin temperature up to 10 and the electro magnetic pollution from other experiments due to the necessity of long signal cables 3 2 Sensors Acceleration sensors are very expensive and have a high transvers sensitivity if accelerated perpendicular to the measuring axis Strain gauges are cheap and small and used succesful ly for modal analysis in many applications A disadvanta ge of strain gauges is the high sensitivity to temperature changes Due to the very small size a big advantage of strain gauges is the possibility to applique them to the outer structure of the rocket motor HX11 ADIOS SEDv5 3 07October2013 Final docx EuroLauncH A DLR and SSC cooperation 4 TECHNICAL REALISATION The development process included several simulations and preliminary design circuits Here this process is gi ven chronologically 4 1 Modal and aerodynamic simulations 4 1 1 Master Thesis by Lysan Pf tzenreuter FEM CALCULATIONS ON THE REXUS 11 ROCKET 3 The aim of these simulations
18. em em I een m a E mdan T qu P T rus zat Pa ci E iui e 1 ES ed 2 ET a u pr pa m er a E T FT ul ne p B Figure 3 Work breakdown structure of ADIOS status 07 October 2013 A frequent update of the status icons shows the progress of the single processes he caption shows the meaning of the status icons lt is also attached in Appendix D E g red flags show critical processes and green ticks the already finished work packages 3 2 Resources 3 2 1 Manpower The actual team size has been enlarged up to ten members HX11 ADIOS SEDv5 3 07October2013 Final docx Page 20 no vi brations good vibrations EUROLAUNCH A DLR and SSC cooperation The team members do their work on the project voluntarily High motivation and the goal the launch campaign in sight is forcing the team to spend an uncountable amount of time to the project The fields of specialisation of the single members represent their skills and major interests Andreas Gierse Member of the further project VibraDamp is heavily supporting the team in the field of electronics Dipl Ing Rudolf Vetter Team manager of VibraDamp is consulting the ADIOS management and gives advice in the field of structure dynamics Mr Dipl Ing Engelbert Plescher is the reliable and important link to the university He provides the team with his experience and expert knowledge in the field of technical aspects as well as project management Mr Ple
19. go od vibrations E UROLAUNCH A DLR and SSC cooperation Launch and operations o Need to clarify your mass estimate o Need to work on the arm plug solution with your payload manager Organisation project planning amp outreach Found a good solution for the organization for EXP 1 EXP 2 needs lots of work Good progress on the budget Access to the teamsite is very useful Outreach approach is great O O O d Others o Need to have a helicoil and hole to add shielding is it possible to do this in the other sections Yes but needs to have a very good proposal for EXP 2 o Is there a curing oven available for the assembly of the strain gauges Can find one for this in Bremen 5 Final remarks A clear proposal for experiment 2 must be submitted so that the inclusion of the sensors in other modules is possible 6n of July 2011 The sensors for experiment 2 can be included in other experiment modules but shall not be included in MORABA system modules or the nosecone All comments in bold must be acted upon for an SED resubmission SED to be resubmitted on 18 of July 2011 including experiment 2 proposal CDR conditional pass SED resubmission Source 2 CDR Minutes by Review Board RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 105 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation APPENDIX B OUTREACH AND MEDIA COVERAGE Sie bien ere sich hier Montag 10 Ja
20. no vibrations good vibrations EuroLauncH A DLR and SSC cooperation 1 INTRODUCTION 1 1 Scientific Technical Background In designing a rocket one is faced with the challenge of developing a lightweight structure on the one hand which is able to withstand the high mechanical loads during launch and landing on the other hand Observing both requirements is hardly achievable without a good knowledge of all acting forces and resulting loads onto the structure during the flight of the rocket For that tension shall be measured during launch and landing because those are the critical phases with high mechanical loads During the reduced gravity phase there is no tension measurement necessary because the acting forces are very small But they might be too high for experiments which rely upon a high microgravity quality For those a passively damped experiment container will be designed which shall isolate the experiment against external forces using the eddy current principle for damping Because this experiment container shall be a Free Flying Experiment Device FFED it has to be fixed to the outer structure during launch and landing to prevent any movement of the FFED and therefore any disturbances or even damages caused by the FFED This will be done using a locking mechanism 1 2 Experiment Objectives The ADIOS Experiment is divided in two different experimental parts with different goals The primary part EXP1 is the further devel
21. start sending strain to ground station b Unlocking the FFED and starting acceleration DAQ signal triggered when SOE on sending acceleration instead of strain c Time triggered imbalance generator running 3 frequencies d Locking the FFED and stopping acceleration DAQ signal triggered when SOE switches to off sending strain again 7 Shutdown routine after landing before power off During the whole process the cRIO will send status information and measured data to ground via serial port Because of the low bandwidth it is not possible to send the complete data and because of the very limited processor power it is not possible to build packages This would be a risk for running the software storing all the data in flight safely and was not an option As a result the transmitted data is not useable for any statement according our measurement results but during flight it indicates our software is working well The status information is transmitted properly so the ground station can reproduce the given LO and SOE signals as well as the information of power on and end of program shut down The internal data stream of the cRIO is shown in the following diagram The cRIO is interacting with the FPGA Chassis linked to the A D Modules NI9205 and the motor control units NI9505 HX11 ADIOS SEDv5 3 07October2013 Final docx Page 68 EuroLAauncH A DLR and SSC cooperation Figure 9 Data interactions The
22. Astronautical Engineering and on update status http www fb6 fh aachen de lur studienprojekte rexus adios Posters and Handouts Flyer in updated versions are in process 3 3 1 Public presentations Research and Development at the FH Aachen The Team has presented the ADIOS Project at the Research and Development Symposium of the Faculty of Aeronautical and Astronautical Engineering The schedule is attached in the Appendix B ELGRA Symposium A delegation of three members of the Team ADIOS is going to participate in the Symposium of the K de European Low Gravity Research Association AY ELGRA in September 2011 in Antwerp Belgium ER OA The Team has represented the project during an oral k x presentation at the student sessions and with a poster at the poster sessions The poster is attached in APPENDIX B The participation fees and travel costs will be partially financed by the FH Aachen and by the ESA education office The Team is applying for the Student Session at the biennial ELGRA oymposium in Rome Italy in September 2013 Space Utilisation Lecture SUT Prof Dachwald FH Aachen Prof Willnecker FH Aachen DLR Stephan Ulamec DLR In the framework of the SUT lecture a presentation about REXUS Requirements and the ADIOS Experiment has been held by Stefan Kr mer on the 14 of November 2011 HX11 ADIOS SEDv5 3 07October2013 Final docx Page 26 no vibrations go od vibrations E URO
23. Logo has been created by Sabina Zits a Communication Design student of the department of Design of the FH Aachen RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 15 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 2 EXPERIMENT REQUIREMENTS 2 1 Functional Requirements The essential requirements to the experiment to achieve reliable data are EXP1 Verification of damped System FFED F 1 F 2 F 3 F 4 F5 The experiment shall measure the accelerations on the damped FFED during reduced gravity phase using a tri axial acceleration Sensor The experiment shall measure the accelerations on the undamped structure during reduced gravity phase using a tri axial acceleration sensor The damping system shall isolate the FFED from influences due to the rocket The locking mechanism shall prohibit any movements of the FFED during launch and landing For verification the FFED shall be excited by a defined imbalance in a broad bandwidth of frequencies EXP2 Determination of static loads F 6 The mechanical loads onto the structure due to launch and landing shall be determined by a separate tri axial acceleration Sensor F 7 The mechanical loads onto the rocket structure shall be determined by strain gauges mounted in three levels of the module structures during the whole flight Infrastructure F 8 All acquired data shall be stored on a reliable data storage device F 9 The acqu
24. Photo and Packaging Table A Source 10 Note ASTRIUM Intranet by Peter Kern ASTRIUM In Halle 11 the photo and packaging table is now operational A new camera and a pc for the transfer of the images to a flash memory is installed Any ideas for improvment are welcome O rao n0 Tobias Wagner ADIOS Team 19 03 2012 RX11_ADIOS_SEDv5 3_07October2013_Final docx EuroLAauncH A DLR and SSC cooperation F6 Archiv F62 FAV IHAB FSL MELFI LBICA MPLM IHAB MSG MELFI MSL MFEU MSL Cartridges Batch 2a MPLME MSL EML MSG PCDF MSL EML MSL EML PRAREL Archiv RFR SIMBOX Space DRUMS X RAI Z SCDE RFR SCA SIMBOX TO51 A ction X RAI Z SCDF Friedrichshafen and Page 117 P 4 As 00000000000 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation STUDIENANGEBOT FACHBEREICHE DIE HOCHSCHULE FORSCHUNG A REXUS 11 geht nicht an den Start Kontakt und Team lt Zur ck zu Aktuelles Kurzprofil der Hochschule 23 03 12 Von Ruth Bedbur Publikationen Bildmaterial Corporate Design Der eigentlich f r Mittwoch geplante Raketenstart wurde bis auf Weiteres verschoben Aufgrund einer Fehlfunktion der Rakete REXUS 12 wird die Schwesterrakete REXUS 11 mit den Experimenten der Studierenden vom Fachbereich Luft und Raumfahrttechnik der FH Aachen leider UNIVERSITY OF APPLIED SCIENCES FH AACHEN nicht von der Ra
25. Test Eine weitere Gefahr selen Sonnenst rme Sie sto en regelm ig Milliarden von Tonnen hochenergetischer Teilchen aus die nicht nur Astronauten und Satelliten Im Umfeid der Erde In Gefahr bringen sondern auch zu Stromausfallen auf der Erde f hren k nnen Die Weltraummission soll zeigen ob Sonnensegel dabel helfen k nnen fr h zeitiger als bisher vor diesen Tellchenschauern zu warnen Gefanrdete Kraftwerke k nnten dann abgeschaltet Satelliten In Sicherheit gebracht werden Gemeinsam mit Fachleuten aus aller Weit m chte Prof Dachwald die Antriebstechnologle des Sonnensegels vorantreiben 2009 rlef er dazu das International Symposium on Solar Salling Ins Leben bel dem alle drel Jahre ber den Stand der Sonnensegeltechnologle diskutiert wird Das nachste Symposium soll Im Juni 2013 In Glasgow Schottland stattfinden Auf der Spur von au amp erirdischem Leben Noch kosmische Zukunftsmusik Ist die Mission IceMote Die kleine Einschmelzsonde soll sich Irgendwann durch Gen dicken Elspanzer des Mars oder des Jupitermonds Europa schmelzen und dort nach RX11_ADIOS_SEDv5 3_07October2013_Final docx au erirdischem Leben suchen Im letzten Jahr wurde der Prototyp erfolgreich unter Leitung von Prof Dachwald auf dem Morteratsch Gletscher Im Schwel zer Oberengadin getestet Derzeit erarbeitet und baut das studentische Projektteam eine zweite verbesserte Generation des IceMole Dieser soll s ch 2012 erneut In eine dic
26. The mechanical loads onto the No more structure due to launch and landing shall be needed determined by a separate tri axial acceleration sensor EXP2 The mechanical loads onto the rocket M plan structure shall be determined by strain gauges mounted in three levels of the module structures during the whole flight Infrastructure All acquired data shall be Test stored on a reliable data storage device finished 9 Infrastructure The acquired data shall be sent R T particularly via telemetry F 10 Infrastructure The control and DAQ shall work autonomously HX11 ADIOS SEDv5 3 07October2013 Final docx 71 NO 7 O 7 N a a a l m C1 I Page 72 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation EXP1 The two tri axial sensors need to measure accelerations with an accuracy up to 10 6 g P 2 EXP1 P 2 The measuring range should be 2 g P 4 The ACC Sensor shall be resistant against static loads of launch 20 g P 5 Strain gauges measure the strain with a sample rate of 4000 Hz Datasheed reviewed Test Plan 5 4 5 Verified by calculation No more Umbilical access needed The Isolation setup by magnets and springs shall reach an isolation of min 90 on the FFED The Power consumption shall be in average TR beneath 1 A The imbalance generator shall give a defined T vibration to the FFED The Isolation shall work passively D 3 The locking mechanism shall
27. X70 4190 xuusemuejune pun OLOZ LL 8L S SMAU YES SMAUY XP9 24989 OU FL Uy ZEZ ap uayoee yn yolaJaquoe y uayoe y H4 uninbojoxuuejuney cz LON 1jueunni283J Jeunw 8 solay Yy mawy dyy dwegesgia YQUx3 SMNOPuUBH J3 504 82u818ju02 Swen wee SF u5eanno SOIQV Ist Outreach li Source 12 RX11 ADIOS SEDv5 3 07October2013 Final docx Page 120 no vibrations good vibrations EUROLAUNCH DLR and SSC cooperation APPENDIX C PAPERS AND PUBLICATIONS ADvanced Isolation On Sounding rockets ADIOS No Vibrations Good Vibrations A Gierse S Kramer Dipl Ing FH R Vetter FH Aachen University of Applied Science Department of Aerospace Engineering Hohenstauffenallee 6 52064 Aachen Deutschland 1 Introduction Nowadays nearly all kind of experiments can be operated on a great variety of microgravity providing systems like rockets drop towers parabolic flights satellites as well as space stations Duration and quality of the ug environment depends on the chosen platform On board of the ISS and other piloted missions many experiments are affected by perturbations due to vibrations caused by astronauts running aggregates and other experiments Same problems may occur on every mechanical system which deals with non disturbance tolerant experiments Using the term micro gravity presumes small amplitudes of acceleration in all axis To decrease these residual forces acting onto the exp
28. after flight Straingauge 20 16 gt 896 jTempSeso 20 6 12 3369 A 7 15 22 132 19 ooo tf A oo gt sas Table 8 Power consumption ADIOS experiment 4 8 Software Design The software is responsible for DAQ and controlling the locking and unlocking procedures All tasks will be programmed using LabVIEW 2010 The software design used for ADIOS will be an adjusted version of the running programme used for the VibraDamp experiment For the software on ADIOS we thought about using a modified version of VibraDamp s software but after some tests we struggled with significant RX11 ADIOS SEDv5 3 07October2013 Final docx Page 67 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation performance problems So we were forced to do a bigger modification and had to reprogram the software partially to handle all tasks with the limited power of the cRio s 40 MHz processor One big point to decrease the load of the central processor was to outsource as much processes as possible to the FPGA The programme will be executed in the following way Booting cRIO 9014 initializing modules and connected hardware Initialize Serial Port for data transfer Start signal monitoring LO SOE Prepare DAQ Create and open files and folders Waiting for LO signal E YS ox Parallel execution of a Strain Measurement
29. cRIO the files will be replaced by software 4 9 Ground Support Equipment 4 9 1 Telemetry Software To receive display and safe the data which is sent during the flight a telemetry receiving program has been written Directly after the lift off strains and temperatures are measured Because of lack of downstream capacity the transmitted data is only a part of the measured data set Two strains and two temperatures are sent each with a sample rate of 500Hz The sample rate fulfills the Nyquist Criterion The values have a size of 16Bit Thus 32kBit s is broadcasted The ground station receives the data and transmits it via serial port in an ASCII format to the user s laptop During the weightless phase acceleration data is transmitted instead of strains and temperatures Acceleration data of six sensors is sent each with a sample rate of 300Hz With 16Bit per value it makes 28 8kBit s The sample rates are higher than the Nyquist frequency After the weightless phase the strain and temperature data is sent in the same way as at the beginning The strains temperatures and accelerations are displayed on graphs in real time The figures are transmitted in a defined order to allocate them to the right graph Also status information is sent and displayed to know what the cRIO is doing at that time All the received data is saved in a log text file RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 70 advanced isolation on sounding
30. feretur 13Hz feccitationtt 34 Hz Jexcitationtti 56 Hz The ADIOS platform only works during free flight phase Despite the time of j4 gravity the FFED need to be locked to avoid shocks to the experiment These motors open up the space for the FFED to ensure movements of the structure relative to the locking mechanism during the u gravity flight phase To cope with this a reliable locking mechanism has been developed Two solid aluminium rings driven by three strong geared electric motors clamp FFED in the initial position Before the payload enters the dens atmosphere the FFED is locked savely again The motors are dimensioned to re lock the FFED after the experimenting time even when it moves out of the centre The ADIOS platform is currently designed to fit into a 14 standard rocket module The structure is mounted to the wall by six aluminium brackets The platform config uration shown in figure 7 still contains the measurement setup for the ADIOS performance evaluation The size of the FFED can easily adapted to the given volume of a possible experiment The current setup is fail save If the locking mechanism does not open during the g phase the experiments container feels the reduced gravity of the initial platform Would the locking mechanism fail during re locking the FFED had no possibility to escape and can only move in between the few millimetres of opening space 4 5 The ADIOS Technical Level Concerning
31. g Strain gauges 3 2 EXP 2 4 1 3 Y Temperature I 3 2 1 me FEM Analysis of Rocket Structure 4 1 4 Limit Switch 142 DAQ Hardware y 3 3 1 V ELGRA i 1421 B CompactRIO 4 3 Calibration 4 4 Testing Legende priority 1 e priority 2 D mot 3 m priority 5 priority 6 started 4 in progress P haf finished en nearly Finished RX11_ADIOS_SEDv5 3_07October2013_Final docx 5 2 1 Dee 152 2 B EXP2 5 3 Motor control usen 5 4 Communication i 5 4 1 Downlink 5 4 2 g Telemetrie S W 15 4 3 Data analysis S W 5 5 Testing Page 157 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation 6 7 1 DAQ Hardware mc an 6 7 1 1 1 2 Layout circuit 6 7 1 1 1 2 1 Amplifier 5211122 Y Fiter 6241143 E Order acceleration sensors 6 7 1 1 1 4 design circuit diagram 6 7 1 1 1 5 generate PCB layout 6 7 1 1 1 6 1 Order circuit components 6 7 1 1 1 7 Verify amplification factor 6 7 1 1 1 8 Verify oscillation characteristics 6 7 1 1 1 9 Production of circuit boards 6 7 1 1 1 10 Testing of circuit 6 7 1 2 Start Data Storrage 6 7 1 2 1 cRio 6 2 2 Y design circuit diagram 6 7 2 1 EY lock unlock FFED LI 6 7 3 all limit switch 4 6 8 Experiment 2 6 8 1 DAQ Hardware e 6 8 1 2 power supply see above in junc
32. of attack of the rocket and therewith vary in a wide range Due to the fact that this effects have an influence on the flight safety many calculations were done while a sufficient measurement system was not available Page 139 ed isolation on sounding rockets advanc no vibrations good vibrations Due to the low material damping of a typical rocket structure the energy of the aerodynamic exitations re mains in the structure during u g phase and lowers the quality of the microgravity conditions For the purpo seful further development of the ADIOS FFED system the movements and disturbances of the rocket structure have to be well known Weight reduction of the rocket and payload structu res is only possible if the loads are well known This would by advantageous as it could increase the possible payloads mass at invariant apogee and w g time 3 STATE OF TECHNOLOGY 3 1 Modal analysis Modal analysis of rocket motors and payloads are no wadays commonly used to avoid dynamic interactions during flight Numerical analysis of complex nonline ar structures are prone of errors and hence only used for development At acceptance and qualification tests shakers are used to analyse the structures This experi mental tests are also not free of errors The main syste matic error is the connection of the analysed structure to the excited part of the shaker mechanical impedance The sum of the shaker mass and the mass of the tested
33. service module and the ADIOS experiment The 15 pin D sub connector 28V wires pin 1 and pin 9 are conducted to a fast 2 5A fuse The fuse is mounted on PCB4 which is located in the Test box Fuse box The housing of the Test box Fuse box has an input and an output 15 Pin D sub connector Sensors On the ADIOS experiment two tri axial 29 sensors ASC 5511LN will be used For every sensor three single amplifiers will be mounted on one circuit board PCB2 The two sensors are powered one Traco power DC DC converters HX11 ADIOS SEDv5 3 07October2013 Final docx Page 57 dvanced isolation on sounding rocke no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation Picture 33 ASC 2g acceleration sensor Schematic of EXP1 PCB2 The circuit was build and tested on a breadboard It also will be tested on a pendulum when the test sensor arrives The principle depends on a simple one stage amplification To realize a gain factor of about 1000 an analog Device OP177 will be used The OP177 is offering a cut off frequency of nearly 100Hz at a closed loop gain of 70dB at 20 15V Traco 1 E onp 03 au i i a Schematic 3 acceleration amplification PCB2 HX11 ADIOS SEDv5 3 07October2013 Final docx Page 58 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation 4 5 3 EXP2 Electrical components CompactHIO A second module NI 9205 is used for the DAQ of the stra
34. strain gage application Picture 2 Enlarged picture of the applicated sensors RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 148 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation For the EXP2 of the ADIOS experiment following requirements are defined 1 The strain shall be measured at 3 cross sections each with 4 strain gauges The first measurement cross section should be near the motor separation adapter recovery module at 200 mm The second measurement stage shall be inside the CaRu module located 120 mm from bottom of this module The third measurement cross section shall be inside the ADIOS module 92 mm from bottom The strain gauges at sections 1 and 2 shall be one axial to measure the strain in flight direction The strain gauges in the 3 section shall be T Rosettes to measure the Strain in flight and lateral direction 7 Each cross section shall be equipped with 2 temperature sensors 8 The strain gauges and temperature sensors shall be positioned in one cross section as shown in Figure 3 The required space inside the external modules shall not exceed 20mm x 20mm 10 The cable harness shall not being cut at the separation planes of the rocket 11 The cable feed through shall be at 180 Additional Requirements to the performance of the strain gauges x io I The strain gauges shall be calibrated for aluminium The strain gauges shall
35. strain gauges as shown in Figure 3 Since the rocket is always RX11 ADIOS SEDv5 3 07October2013 Final docx Page 146 no vibrations go od vibrations E UROLAUNCH A DLR and SSC cooperation rotating a circumferential temperature gradient is not expected Hence one temperature sensor for each stage would be enough To have redundancy there shall be two of them at each stage Using four strain gages and two temperature sensors at each stage six harnessed cables are going from the CaRu module to the ADIOS module They shall be guided through the modules together with the other cables coming from the service module at the cable feed through at 180 Rexus Structure Strain Gages Temperature sensors Figure 3 Strain gauge positioning in one stage Due to the planned measurement setup the strain gauges will provide only very small voltages The disturbances and the noise caused by cut cables can be much higher than those signals Therefore the cables shall not be cut and equipped with connectors To get an idea how much space one strain gauge and one temperature sensor will need Figure 4 shows an example of the application of both sensors onto the structure of the VibraDamp module 400 mm height Figure 5 shows an enlarged picture of the application HX11 ADIOS SEDv5 3 07October2013 Final docx Page 147 EuroLauncH A DLR and SSC cooperation gt 4 gt j A ag Picture 1 Example of
36. zu den Sternen abzuheben Source 3 Press release 10 January 2011 9 RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 106 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH A DLR and SSC cooperatio Studierendenprojekt der FH Aachen ERSITY OF APPLIED SCIE REXUS 11 12 FH AACHEN Advanced Isolation on Sounding Rockets Schwingungs Isolations Adva Riese Experiment auf einer SO at 1018 Forschungsrakete ON So UN 0 N Studentische Mitglieder gesucht in den Bereichen ROC Kets gt Mechanischer Entwurf und Konstruktion gt Programmierung der Messdatenerfassung Voraussetzung Studium in einem ingenieur q f A O W y technischen Fachbereich Bachelor Projects Thesis M gliche Ziele Master Research Semester gt Praxisprojekte Thesis gt Bachelor Masterarbeit gt Projekterfahrung P EuroLauncn tha P Contact Raumfahrtlabor Kontakt FH Aachen Fachbereich Luft und Raumfahrttechnik stefan kraemer alumni fh aachen de Raumfahrtlabor rexus fh aachen de T 49 241 6009 52394 FH AACHEN NIVERSITY OF APPLIE Picture 41 First and second recruitment poster RX11_ADIOS_SEDv5 3_07October2013_Final docx advanced isolation on sounding rockets no vibrations good vibrations CJ Compass 1 O Compass 2 O FLUMO Projekt El tcaMole t 158 18 Nurfl gler Projekt C REXUS ADIOS 3 Zeitplan ADIOS L3 VibraDamp suf REXUS 7 L3 Prog
37. 0C Rev 1 6 March 2009 SSC Esrange Esrange Safety Manual EU A00 E538 20 March 2006 European Cooperation for Space Standardization ECSS Space Engineering Technical Requirements Specification ECSS E ST 10 06C 6 March 2009 European Cooperation for Space Standardization ECSS Space Project Management Risk Management ECSS M ST 80C 31 July 2008 European Cooperation for Space Standardization ECSS Space Engineering Verification ECSS E ST 10 02C 6 March 2009 Project Management Institute Practice Standard for Work Breakdown Structures second Edition Project Management Institute Pennsylvania USA 2006 Team VibraDamp UAS Aachen Student Experiment Documentation SED VD 05 F 12 02 2009 FH Aachen News Page Bedbur Ruth Zu den Sternen http www fh aachen de newsarchiveinzel html amp tx_ttnews pS 1293836400 amp tx_ttn ews pL 2678399 amp tx ttnews arc 21 amp tx ttnews pointer 2 amp tx ttnews tt _news 2916 amp tx_ttnews backPid 231 amp cHash 5f2e7b5e37 accessed 23th March 201 1 Diploma Thesis UAS Aachen Aerospace Department Entwicklungen einer Pr fstruktur mit einem Schwingungs isolationssystem mit magnetsicher D mpfung und Test beim Parabelflug einer REXUS Rakete Rudolf Vetter 2010 Diploma Thesis UAS Aachen Aerospace Department Entwicklungen einer ber hrungslosen D mpfung zur Verminderung von Resonanz berh hungen eines Systems zur Schwingungsisolation eines Schmelzofens in der R
38. 2 Test Plan 5 2 1 Shaker Test Test number Test type RX11 ADIOS SEDv5 3_07October2013_Final docx Page 74 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation Tested item 1 RX Module including Bulkhead with Electronics LN Test campaign 2 day incl preparation shaker duration Table 10 Shaker Test To avoid damage to the ACC Sensors the first run of the qualification shaker test will be done without the flight hardware sensors It is important to proof that the Eigen frequencies will not have impact on the highly accurate ACC sensors The principle of the locking mechanism is already tested and flight proofed Nevertheless it is necessary to test the locking mechanism as far it is constructed The shaker test will verify the clamping behaviour during launch phase 5 2 2 Vacuum Test Test facility Laboratory for space technology FH Aachen Tested item Structural parts CFC Bulkhead Electronic boards Strain gauge amplification Acceleration amplification Power supply cRio Motors COTS RS 232 to RS 422 Test level procedure Qualification and duration 3x10 bar 15 min Test campaign duration Table 11 Vacuum Test RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 75 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation The Vacuum test covers two different responsibilities The first one is the vacuum compatibility of the single pa
39. 3 Mode superposition for REXUS 11 Maximum deformations over length of the rocket Based on the data given in the REXUS BEXUS technical overview and the SEDs of the single student teams first estimations about the structural behaviour of the REXUS rocket during the whole flight were made using ANSYS 13 Mechanical APDL Since the rocket is losing weight during flight because of burning propellant and following motor separation several phases of flight has to be considered to specify where how and how many strain gauges has to be applied to the rocket structure Figure 1 shows the estimated resulting strain shortly after Lift Off Figure 2 shows the estimated resulting strain during the landing phase As shown in those figure the location of maximum strain coloured in red is moving from bottom of the recovery module to upper part of the nosecone during flight 123 56 Y Z ALE LT 358E 05 716E 05 107E 04 143E 04 179E 05 ste te 895E 05 125E 04 g Figure 14 Estimated resulting strain in flight direction during launch phase RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 90 EuroLauncH A DLR and SSC cooperation Recovery Module Service Module ADIOS GGES CaRu Romulus 464E 10 112E 04 225E 04 337E 04 449E 04 61E 05 168E 04 281E 04 393E 04 i Figure 15 Estimated resulting strain in flight direction during landing phase RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 91 u advanced isol
40. 74 5 2 3 Thermal Environmental Test esses 75 524 F rnctional Sensor Testi ea 75 525 Functional ElScironic Teste 76 5 2 6 Functional Test Assembled Mode 76 93 TOSDPIOSDIUS a coa 77 6 LAUNCH CAMPAIGN PREPARATION 220022220022200022nne nenne nenne nennen 78 6 1 Input for the Campaign Flight Requirement Plans 78 6 1 Dimensions and Massa 78 68 1 2 o se see 78 8 123 BICCIIGANINIGCH ACCS incas 78 RHX11 ADIOS SEDv5 3 07October2013 Final docx 6 14 Stan GAUGES css 78 6 2 Electrical interfaces applicable to REXUS eeeeeesesessss 79 6 3 Galmbaldh Prepara iii 80 6 3 1 JISLOLIOO S sis 80 0 39 2 LISTO Spare palle nennen 80 6 3 3 List of campaign attending team members 80 6 4 Launch Site Requirements cccccccccsseccseeeceeeeceeeeceeeecseeeseeeeseeesaaees 81 6 5 Preparation and Test Activities at Esrange ssssuse 82 6 5 1 Assembly of spring SetUP oocccocccoccoconcconccncnocanononccnnnonanonaness 82 6 5 2 CRODHA AION rss 82 6 58 A PIS ia 82 6 6 Timeline for countdown and flight oocccocnccocnncccnnononononnnnnnnnnnas 83 8 7 POSERIIAN ACUVINGS ame 83 7 DATA ANAL SIS PLAN Eesti 85 Fal Dada Analysis Planass a a 85 72 EAU dea 86 O IO SUIS do 86 hok A o o 86 fade SEXD
41. 8 prior to flight o o Ca 28 EU 1667 22 A A AA Lo AZ EO M d O O Y ignition Lift off CompacttiO 100 af 100 28 during flight Straingauge OD 20 te 3200 896 JTempSeso 1 20 6 12 o S w a 72 1080 Lee 1 A Y 43 Unlock CompactRio a aj 10 tT loo Motor 8 83 77 5 72 jSmagage 20 o 320 8969 jTempSeso 20 6 120 336 oo o o 789 2484 310 217 es ji N 1 20 N 0 0 5 Measurement time CompacttIO 100 1 io po Motor 8 3 77 wt OO jJeseos2g 1 70 86 gt 156 jSmaigage 20 16 32 8969 _ 1 Seer A EU A ED EEG oo mbalanegen 100 Relock CompacrRO 100 af 100 a 3 loo Motor 8 3 20 7 jSmamgage 20 16 320 8969 jTempSeso 20 6 1320 336 o a 21 84 Le A es O o jSmaigage o o 320 e Semeri y 6 102 apo o po O a 3 325122 30 1 50 a gt ll 132 sec after landing CompactIO 100 1 ooo a
42. Andreas Gierse Dominique Daab Joana Hessel Fabian Baader 2011 Student Experiment Documentation for Adios on Rexus 11 RX11 ADIOS SEDv5 3 07October2013 Final docx Page 129 no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation 6 Lysan Pf tzenreuter Michael Lauruschkat Andreas Gierse Rudolf Vetter 2010 VIBRA DAMP RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 130 EuroLauncH A DLR and SSC cooperation advanced isolation on sounding rockets no vibrations good vibrations APPENDIX D RESULTS EXP 1 Paper on Experiment 1 21 ESA Symposium on Rocket and Balloon Related Research DEVELOPMENT AND FLIGHT TESTING OF A SYSTEM TO ISOLATE VIBRATIONS FOR MICROGRAVITY EXPERIMENTS ON SOUNDING ROCKETS Stefan Kr mer Dominique Jonas Daab Brigitte Miiller Tobias Wagner Fabian Baader Joana Hessel Georg Gdalewitsch Engelbert Plescher Bernd Dachwald Michael Wahle Andreas Gierse Rudolf Vetter and Lysan Pfiitzenreuter Dept of Aerospace Engineering FH Aachen University of Applied Sciences Hohenstaufenallee 6 52064 Aachen Germany Email stefan kraemer alumni fh aachen de REXUS fh aachen de ZARM Fallturm Betriebsgesellschaft mbH am Fallturm 28359 Bremen Germany Email Andreas Gierse gmx de EADS Astrium Claude Dornierstrasse 88090 Immenstaad Germany Email Rudolf Vetter astrium eads net DLR German Aerospace Center Space Administration K nigs
43. Based on the data given in the REXUS BEXUS technical overview and the SEDs of the single student teams first estimations about the structural behaviour of the REXUS rocket during the whole flight were made using ANSYS 13 Mechanical APDL Since the rocket is losing weight during flight because of burning propellant and following motor separation several phases of flight has to be considered to specify where how and how many strain gauges has to be applied to the rocket structure Figure 1 shows the estimated resulting strain shortly after Lift Off Figure 2 shows the estimated resulting strain during the landing phase As shown in those figure the location of maximum strain coloured in red is moving from bottom of the recovery module to upper part of the nosecone during flight 1 23 56 Y Z A om ie 358E 05 716E 05 107E 04 143E 04 A 49E 05 537E 05 895E 05 125E 04 Figure 23 Estimated resulting strain in flight direction during launch phase Recovery Module Service Module ADIOS GGES CaRu Romulus REE AAA U EHRE 3 32 464E 10 112E 04 225E 04 337E 04 449E 04 561E 05 168E 04 281E 04 393E 04 Figure 2 Estimated resulting strain in flight direction during landing phase HX11 ADIOS SEDv5 3 07October2013 Final docx Page 145 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation To consider moving maxima strain gauges have to be applied on several stages of the rocket Bes
44. Damp 1 has been tested successfully on the REXUS 7 flight in March 2010 The new developed system was completely passive despite of the locking mechanism for launch and landing This system makes it possible to decouple an experiment from the rocket structure above frequencies of about 0 5 Hz Basing on the results and lessons learned of VibraDamp a third student team formed in 2010 which set the goal to increase the performance by a redesign of the system A much more lightweight construction saves valuable payload mass The theoretical threshold frequency is lowered down to 0 28Hz for a decoupling above this frequency and the measurement setup has been adapted for the verification purpose The new ADIOS Advanced Isolation on Sounding Rock eis system verifies the technical setup developed for VibraDamp The function of the improved system was demonstrated during the REXUS 11 flight in November 2012 In addition to the ADIOS system verification an in flight modal analysis of the REXUS vehicle has been con ducted in the context of a second experiment by the FH Aachen student team 2 MOTIVATION Experiments with high requirements on the quality Of p gravity are often guests on sounding rockets But reaching high altitudes above the aerodynamic influences of the lower atmosphere is not a surety of low disturbances Structural vibrations can cause unexpected errors on p gravity experiments The sources of the disturbances can be fo
45. EIMENL2 c 88 8 ABBREVIATIONS AND REFERENCES eese 91 8 1 AbDbreviallonsausssieseeie nee 91 8 2 HON 93 8 3 Listor tables and PIC sisi 95 Appendix A Experiment Reviews ccccceccceeeceseeceeeceeeceuseeeeeceeseuseceeesenenaees 99 Appendix B Outreach and Media Coverage uuss2usuenennnenennnnennn nenne nennen 105 Ao A 110 Appendix C papers and publicatioOnNsS cccoocccccooccnccconnnnccononcnononanononenonos 120 AppenabeD R SullS EXP m 130 Appendix E Results exp Lit baaa 138 Appendix F Strain gauge requirement proposal cccccececseeeeeseeeeeseeeesaaeees 144 Appendix G Additional Technical Information 002420020ne nennen 153 RX11 ADIOS SEDv5 3 07October2013 Final docx Page 6 advanced isolation on sounding rockets no vibrations good vibrations EuroLruncH ADLR and SSC c ABSTRACT ADIOS ADvanced Isolation On Sounding rockets is a development project for a cost effective u gravity platform on sounding rockets The previous project VibraDamp has been successfully tested on REXUS 7 This abstract will discuss the advancement in flight readiness of the platform by a design update Due to movements and vibrations induced by other experiments on a sounding rocket the quality of the u gravity is extensively reduced To decouple an experiment with stringent requirements on the u gravity a group of students of the FH Aache
46. Einschmelz sonde zu entdecken Vor allem wegen Ihres hohen Praxisbezugs In Lehre und Forschung geh rt die FH Aachen Im Bereich der Luft und Raumf hrttechnik zu den f hrenden deutschen Hochschulen Jede M cke w re Im Weltall ein Elefant Nur ein Augenzwinkern nicht langer als drei Sekun den schon war die Rakete fast vollst ndig von der Bllanache verschwunden erinnert sich Rudolf Vetter der live beim Raketenstart der REXUS 8 Im Raum fahrtzentrum Esrange bel Kiruna In Nordschweden dabei war Der Junge FH Student hat gemeinsam mit seinen Kommilitonen Lysan Pf tzenreuter Michael Laumschat und Andreas Glerse vom Fachbereich Luft und Raumfahrttechnik am Programm REXUS teilgenommen das Studierenden erm glicht wissen schaftliche und technische Experimente auf suborbita len Raketenfi gen kurzzeitig unter Weltraumbedin gungen durchzuf hren REXUS Raketen Experimente for Universitats Studenten Ist ein deutsch schwedi sches Studierendenprogramm der European Space Agency ESA und des Deutschen Zentrums f r Luft und Raumfahrt DLR Vor dem Hintergrund dass manche materlalwissen schaftlichen und biologischen Experimente nur In einer weitgehend storungsfrelen Umgebung im Weltraum durchgef hrt werden k nnen bauten die Studierenden eine Experimentiereinnelt die entkop peit von der Raketenstruktur Tests In Schwerelosig keit erlaubt Das System reduziert die Ersch tterungen der Rakete durch Schwingungen und
47. EuroLAauncH A DLR and SSC cooperation SED Student Experiment Documentation Document ID RX11 ADIOS SEDv5 3 07October2013 Final docx Mission REXUS 11 ADIOS Team Name no vibrations good vibrations Experiment Title ADvanced Isolation On Sounding rockets Team Name University Student Team Leader Stefan Kramer FH Aachen Team Members Lysan Pfutzenreuter FH Aachen Brigitte Muller FH Aachen Dominique Daab FH Aachen Joana Hessel FH Aachen Fabian Baader FH Aachen Tobias Wagner FH Aachen Georg Gdalewitsch FH Aachen Andreas Gierse FH Aachen Johannes Stahl FH Aachen Version Issue Date Document Type Valid from 5 3 07 October 2013 Final Report Submission date 07 October 2013 Issued by Stefan Kramer Approved by Mark Fittock RX11_ ADIOS SEDv5 3 07October2013 Final docx Change Record Version Date Changed chapters 2011 01 11 New Version Blank Book 2010 2011 01 26 All PDR All Post PDR Version 2011 05 26 All CDR 2011 09 01 Chapter 3 2 4 IPR 4 2 1 1 4 4 4 5 2 6 Appendix A B C SGRP 2011 11 21 3 2 3 3 6 3 6 5 Pre Campaign APPENDIX B APPENDIX C 2012 04 12 4 8 2013 10 07 Final report RX11 ADIOS SEDv5 3 07October2013 Final docx CONTENTS PN gate ee aes oe bee pe ot nesses o aaa 6 1 INTRODUC TION iaa ad 8 1 1 Scientific Technical Background ooncccconcnccnccnccncnnonncononacnnnnnnnononcnnnnnros 8 1 2 JEXPernmentOBECIVES al 8 1 3 Experiment Overview
48. Final docx Page 92 advanced isolation on sounding rockets no vibrations good vibrations FRR GSE HK H W ICD I F IPR LO LT LOS Mbps MFH MORABA NI OP PCB PDR PST SED SNSB SODS SOE SSC STW S W T TBC TBD TRL WBS EuroLauncH A DLR and SSC cooperation Flight Readiness Review Ground Support Equipment House Keeping Hardware Interface Control Document Interface Interim Progress Review Lift Off Local Time Line of sight Mega Bits per second Mission Flight Handbook Mobile Raketen Basis DLR EuroLaunch National Instruments Oberpfaffenhofen DLR Center Printed Circuit Board electronic card Preliminary Design Review Payload System Test Student Experiment Documentation Swedish National Space Board Start Of Data Storage Start Of Experiment Swedish Space Corporation EuroLaunch Student Training Week Software Time before and after launch noted with or To be confirmed To be determined Technology Readiness Level Work Breakdown Structure RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 93 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH peration 8 2 1 2 3 4 5 6 7 8 9 10 11 A DLR and SSC coo References EuroLaunch REXUS User Manual 2010 European Cooperation for Space Standardization ECSS Space Project Management Project Planning and Implementation ECSS M ST 1
49. LAUNCH A DLR and SSC cooperation NI User Symposium 2011 Aachen The Team has been represented by Stefan Kramer at the National Instruments User Symposium in Aachen on the 2 of December 2011 with an 30 minutes presentation about REXUS and ADIOS in combination with NI Components 21 ESA Symposium for Rocket and Balloon related Research The Team ADIOS is going to present the results of the two experiments in the framework of the ESA Symposium by an oral presentation The symposium takes place in Thun Switzerland between the 9 and 13 of June 2013 3 3 2 Publications Papers and Abstracts Abstracts for the Abstract Book of the ELGRA Symposium 2011 in Antwerp Publicated at ISBN Paper for Journal Microgravity Science and Technology ISSN 0938 0108 Journal no 12217 Springer Verlag Paper for 21 ESA Symposium on Rocket and Balloon Related Research e Development and Testing of a System to Damp Vibrations for Micrigravity Experiments on Sounding Rockets Stefan Kramer et al EXP1 e Experimental In Flight Modal Analysis of a Sounding Rocket Structure Andreas Gierse et al EXP2 3 4 Risk Register Table 3 Risk Register Affected Risk amp consequence if Parts not obvious TC10 Damage during test un Spare parts TC20 Damage during test RHX11 ADIOS SEDv5 3 07October2013 Final docx Spare parts already on stock Page 27 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation
50. LAUNCH A DLR and SSC cooperation To dimension the magnets the required effective damping Ces y has to be determined in advance The effective field strength Bsp is a function of the material thickness d the effective damping c the magnetic material constant of the counter material s and amp Ceff Bose det 8 P lod 8 In order to avoid magnetic disturbances to the experi ments the field strength of the chosen permanent mag nets stays below the level of the earth magnetic field al ready in a distance of a few millimetres 4 4 The ADIOS Experiment Setup The ADIOS platform uses a free flyer containing the sensitive experiment which is hold in position by six tiny three dimensional beam springs shown in figure 5 This leads to a six degree of freedom mounting of the FFED The spring wires are bent by 90 to all three axis of motion resulting in beam like displacements which are easy to calculate The length of the spring legs I II and III in figure 5 are design parameters for the natural frequency of the system It accords to the deepest frequency which can be isolated by the ADIOS system The springs are mounted to the rocket structure on the one hand side while they are fixated to the FFED on the other hand side in a 120 interval After unlocking the system the springs pull the FFED out of the storage position The permanent magnets for the eddy current damper function are mounted in flight direction dire
51. Mm ftw 0D P ao i Figure 4 preliminary time schedule RX11 ADIOS SEDv5 3 07October2013 Final docx Page 29 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 4 EXPERIMENT DESCRIPTION 4 1 Experiment Setup The experiment ADIOS is divided into two sub experiments Those experiments will work independently and will not influence each other in case of malfunction of one experiment The only malfunction which would affect both experiments would be a failure of the cRIO 4 1 1 EXP1 Verification of the damped System FFED The experiment consists of a FFED locked between two disks during the launch and impact phase The FFED is the damped container which easily can be customized for an experiment with a higher requirement on reduced gravity or micro gravity in an excited system like a rocket or a space station Parts of the container need to be built from a metal to enable the eddy current principle in reaction with the magnets mounted on the locking mechanism In the weight of the FFED is not improved to have a similar mass like a real experiment To achieve the goal of minimized influences due to the outer structure onto the FFED the knowledge of the effective residual acceleration inside the FFED is essential This verifies the working principle and improves the TRL of this type of a passive damping system HX11 ADIOS SEDv5 3 07October2013 Final docx Page 30 EuroLruncH ADLR and SSC c
52. OS SEDv5 3 07October2013 Final docx Page 31 advanced isolation on sounding rockets E L no vibrations good vibrations EuroLauncH ation A DLR and SSC cooper 4 2 Experiment Interfaces 4 2 1 Mechanical 4 2 1 1 Cable feed through and D Sub mountings The cable mountings will be placed at 180 and a mounting for the D Sub connectors will be provided in this position The D Sub mounting provides space for five connectors D Dub 15 Pin The cable harness is fixed by cable guides Picture 8 Cable guide which are glued to the RX Module wall NY laz f Nba Y AA rmm dy Picture 7 Cable Feed Through at 180 Picture 8 Cable guide HX11 ADIOS SEDv5 3 07October2013 Final docx Page 32 no vibrations go od vibrations E UROLAUNCH A DLR and SSC cooperation 4 2 1 2 Module Module The structural connection is given and unchanged by the supplier of the RX 300mm Module The ADIOS Module will provide the required space for cablings in the connection section between ADIOS and the service module RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 33 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 4 2 2 Electrical The interface between the RX service module and the ADIOS experiment is a D SUB 15 female connector It will be plugged to a junction box which distributes the electrical power to several components and includes the power supply for the CompactHIO itself e Signa
53. RX11_ADIOS_SEDv5 3_07October2013_Final docx 7 7 1 anced isolation on sounding rockets no vibrations good vibrations Page 85 EuroLauncH A DLR and SSC cooperation DATA ANALYSIS PLAN Data Analysis Plan Due to the two experiments the data for each experiment must be processed in particular Therefore following boundary conditions need to be considered e The sampling rate of EXP1 ACC sensors is 800Hz o DAQ starts and ends with SOE e The sampling rate of EXP2 Strain Gauges is 12000Hz o DAQ starts with LO until t 1000s e The official Timeline for flight is included RX 11 Timeline v3 0_13Mar12 Time s Altitude km Event Altitudes from REXUS 11 Traj calculation Key 1T 600 0 332 Experiments PowerOn CaRu 2T 600 0 332 TV Channel Caru GGES 3T 300 0 332 RAIN mission mode activation via uplink ADIOS 4T 240 0 332 GGES SOE RAIN 5T 120 0 332 RXSM switch to internal power Tscobe 6T 0 0 332 Lift off Tscobe pyro hatch Vit 0 0 332 CaRu LO TV Channel 8T 0 0 332 GGES LO 9T 0 0 332 RAIN LO 10 T 0 0 332 ADIOS LO 11 T 0 0 332 Tscobe LO 12iT 26 21 Bumout Imp Orion 13 T 65 TV Channel Caru gt Recov 14 T 67 RAIN pyro firing RECOV 15 T 70 Yo yo despin 16 T 74 Motor Separation 17 T 78 TV Channel Recov gt Tscobe 18T 78 Tscobe pyro hatch power on safe timing for peak consump close to motor sep as poss 19iT 86 Tscobe Exp SODS boom deployment 8 secs later than hatch 20 T 90 ADIOS SOE activation u
54. S ooccocccccccnccocnccocnccocnncncncconnnonnnnnnnnncnnnnnnnnoss 62 RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 99 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation APPENDIX A EXPERIMENT REVIEWS PDR Minutes 13 Flight REXUS 11 Payload Manager Mark Fittock Experiment ADIOS Location DLR Oberpfaffenhofen Germany Date 9 02 2011 1 Review Board members Mark Fittock MoM DLR RY Markus Pinzer DLR MORABA Macus Hoerschgen DLR MORABA John Richardson DLR RY Martin Siegl MoM DLR RY Helen Page ESA ESTEC Andreas Stamminger Chairman DLR MORABA Olle Persson SSC Mark Uitendaal SSC Koen DeBeule ESA ESTEC 2 Experiment Team members Stephan Kraemer Lysan Pfuetzenreuter Brigitte Mueller Dominique Jonas Daab 3 General Comments Presentation o easy and understandable but requires prior knowledge from Vibradamp a lot of detail still missing also from version 1 8 communicate your work to us SED a little bit light regarding EXP2 diagrams and graphics adequate there is a flow chart for the software but it is outdated whole document is in English but flowchart is in German please correct that slides are good don t say this is my part of the presentation big improvement over SED in terms of content resubmission will be required 4 Panel Comments and Recommendations HX11 ADIOS SEDv5 3 07October2013 Final docx Page 100 no vi b
55. SS advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH ration ADLR and SSC coope The VibraDamp 400mm RX Module will be replaced by a 300 mm RX Module Due to this change it is possible to save up to 0 95 kg The FFED will be designed smaller and hence lighter The casing material will be changed from 2 mm to 1mm AL sheet metal A cut out also used as access hatch will save weight as well The redesign of the brackets saves up to 50 in weight Regarding the financial budget it is compulsory to work with highest cost effectiveness It is needed to evaluate the price and workload to build the Picture 19 Old and new design of the LM aluminium rings carbon fibre composites in comparison with the processed VibraDamp parts RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 43 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation Picture 20 Alternative CFC LM design Picture 21 Mounting of locking mechanism HX11 ADIOS SEDv5 3 07October2013 Final docx Page 44 u advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation 47 mm 58 mm 24mm 128 mm 55 mm Figure 5 Structural levels The bulkhead and the locking mechanism are mounted on the structure The mountings therefore are shown in the following picture RX11_ADIOS_SEDv5 3_07Octobe
56. The B llhoff Group Germany has Sponsored the required O anm HELICOILS for fhe structural parts including the needed tools for BOLLHOFF HX11 ADIOS SEDv5 3 07October2013 Final docx Page 24 no vibrati ons good vibrations E UROLAUNCH ADLR and SSC cooperation processing the threads The delivery is amounting about 300 BCE Special Ceramics La BCE will supply the Team ADIOS BCE PRAZISIONSBAUTEILE US HOCHLEISTUNGS KERAMIK with three ACC Interfaces for the wall mounting of the acceleration sensors AAA SS ES AA Special Ceramics Erich Frank Schrauben Metall und Normteile e K i Schrauben Frank has delivered the whole amount of more than 700 screws nuts and bolds Metall und Normteile LEITERPLA E amp K Leiterplatten Heinsberg 3 The Company E amp K Leiterplatten GmbH provides the eae Flight Hardware PCB s for the ADIOS Experiment E Gy PRINTPANELEN HX11 ADIOS SEDv5 3 07October2013 Final docx Page 25 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 3 3 Outreach Approach The outreach plan is an important part of the project There are several ways of represent the project in the public and media FH Aachen There was already an interview by the department of PR of the FH Aachen and it was published at the 10 of January on the FH Aachen webpage Appendix B The own homepage is online on the webpage of the FH Aachen Faculty of Aeronautical and
57. act rio overview diagram for power and data handling missing more detail in block diagrams required Power distribution to different experiments not clear operational amplifier frequency to be adapted to reasonable value use optocouplers to avoid noise on the signal lines power consumption much higher than Vibradamp please check What will the peak consumption be nomenclature describe what compact rio modules are what their names are module of modules is hard to understand expected data rate needs to be defined team would like to sample with 40khz per sensor requires on board storage solution clarify timeline with regard to measuring the landing put it in the timeline EXP2 temperature compensation for the sensor how will this be conducted Thermal needs to be considered better for that thermal range for each component maybe use wheatstone bridge to compensate the sensor running program from Vibradamp will be adjusted when do measurements start for how long why are measurements starting again after stop of the experiments clarify the timeline wrt to software call the signals SOE SODS don t give them any other names what has worked on the previous may not run on this one perform tests can you fall back from C if you do not get on with Labview use the signal lines from the service module wisely make sure you are able to clear the memory by command RX11_ADIOS_SEDv5 3_070ctober2013_Final docx
58. aerodynamische Str mungen beim Flug mithlife von magnetischer D mpfung und Federn Jede M cke ware da oben ein Source 6 Dimensionen 2011 TITELTHEMA STUDILIM INTERN wa w res x Elefant bringt Vetter die Sensibilit auf den Punkt Die Studierenden hal Sie konnten In ihrem Experimente zentige isolationswirkung erzielen Auch beim n chsten Raketenstart Anfang 2012 Ist die FH Aachen wieder mit einer Experimentiereinhelt an Bord Das Team um den neuen studentischen Projekt leiter Stefan Kramer konnte sich In einem Wettbewerb gegen sieben deutsche Teams und zahlreiche weitere ESA Tellnehmer durchsetzen Wir m chten die beim letzten Raketenstart erzielte Isolationswirkung optimieren erklart Kramer Daf r werden wir die Magnete neu anordnen und eine andere Daten bertra gung w hlen Koordinator des Projekts Ist Diplom ingenieur Engelbert Plescher vom Fachbereich Luft und Raumfahrttechnik Er betreut die Studierenden und hat selbst schon gemeinsam mit dem DLR eine Messplattform entwickelt und auf einem Raketen nug verifiziert Huckepack Ins Weltall Neben den suborbitalen Raketenfl gen werden an der FH Aachen auch wissenschaftliche Experimente unmittelbar Im Weltraum durchgef hrt Am 28 April 2008 schickte ein Team von Studierenden unterst tzt von Professoren und Mitarbeitern des Fachbereichs den selbst gebauten Pico Satelliten COMPASS 1 Ins AIL Seitdem sendet er erfolgreich und v
59. allee 6 52064 Aachen Germany REX US fh aachen de 3DLR German Aerospace Center Space Administration K nigswinterer Str 522 524 53227 Bonn Germany ABSTRACT Knowledge of the dynamic mechanical charac teristics of a microgravity platform together with data of the dynamic loads while flight enables its further development Benefits are the possible weight reduction of the platform structure and an improved p g quality due to vibration control and purposeful decoupling Within the framework of the Adios student ex periment a new type of measurement system for in flight modal analysis was developed and tes ted Aim of this setup was the in flight validation of the system and the validation of a FEM Model of the REXUS 11 rocket The achieved Signal to Noise Ratio was suffi cient for data analysis Beside the determined re sonance frequencies of the rocket structure sever al events like motor separation and pyro firings of other experiments were measured Furthermo re the resolution of the measured low frequency mechanical stress was higher than anticipated Based on these results a further development of the measurement system seems worth the ef fort 1 INTRODUCTION In 2008 students of the FH Aachen University of App lied Science formed a team called VIBRADAMP to develop a passive mechanical decoupling system for experiments on sounding rockets in the framework of the REXUS 5 campaign While this experiment was
60. anced isolation on sounding rockets no vibrations good vibrations A DLR and SSC cooperation Mass reduction list E86TT T8S gt TT ops p p u jou 2 ft Joc Fr je B je 00 m m FE BunUNOW HEM 10101 10020 2 10 Sora W jos pe TE Ucow vororiosonvy fa E wewimemBunwnowwewHc T0000010sOQv w jo JE AAA dee A ER OE MTAA E 0 wr Jn pe quoofsuon wur 33 ES BRST TH O 2000 E smono um wnummv __T09 TvwonogBummnxoo to z tosoiavjor_ A pex ps quoxauonuug 245 510 302 ui wnulwn Yy 09 1w do 3uty N7 Z00 TO Z TO SOLA 094 Tr oto It Ba TOTES 330 dor Fura w1 200 10210 soraw joo per e 1939 yim ssor Seu AT TV UREA ssor Seu BOS uma ed SOI BI payeunsa sssid dueaeign 1uBiam sssid dee o o o ha 9 m 3 un Ui wins 0333 6aqns ST Q qns peayying xog 91401933 0334 x09 21u04129 3 9 n poIN Xy 3 041u02 1010 N 9 npoIN OIYI np a v a npow orgs Zumunow JOOWy JOO 51999018 H8 S1999818 W1 je xeul aqn Josuas squ Sui o002 O M O1yd Suly saoeds pesyang ap wona Bun wi eoo T0r2 T0 sonaw on E er RR AA Os do Suly ws uey93ln 8u1r4201 3uieN uononpai sseyy ion list Mass reduct Table 20 RX11 ADIOS SEDv5 3 07October2013 Final docx
61. and SSC cooperation ote r ri m n vibrations good wire ons ADvanced Isolation On Sounding Rockets ADIOS Project ADIOS Tearnimembersy et IDs E UNIVERSITY DF APPLIED SCIENCES FH AACHEN Wate Y 4 Ms A oem A w 9 0939 ua mm er an cago VER Steter dr drow Na aon po ee se a Fate o be ee nn en o Suse ww i tree fecuty of Aervapace ingewearmg Te et en et toos Rente te Acte limit of Agchet Scences EIE riotunea feneties 6 0 E c e e atat Lepra ew 2064 Aachen Germary Mi Am t c 9 m Rem Oe 0 9 mene de t acera in vom aac hen de mido set 0 9 IIA Part ts ad Luar tee t omm VL bam tess c a oo o e wm Motivation Techox al hactground Aa acc o mem Sets Au em ey Q saam b o ora 0 o a4 mot v IM NL aL M B SEEMS LS ie LLLI ALI Lara of um fuas oe cette y 0999 s se c o 5 P o oo a Fe e 9 Oe e sn OO we tque a tamm 4 cuum a te ern tem o 9 ee HO utut etm u 9 wo e IT tet cma ap md TIT a m u deorum mte pev oce I a S cos 7 De Oe w m U 3 ue A 04 Pow mas a o 0 s ra de A Y Te sd ee Ue Wo Menos X te ren pies eti ros w aree ca im onam amp ee wa gere mmt ha DLL nada lir et LL S A 9 e tt en Yen mene dr pa semat B arm wm oo 9 e S o9 oo T o lte ss n ma Aurem puet bnt OL ixl died md m ss els mm mb 4 hal ETA he e UI MA Hee APTA be ent ALIAS a PUN eee OW t u tiris en masen eir mn mn
62. as junge Team um den studentischen Projektmanager Stefan Kr mer f hrt ein Experiment fort das bereits im M rz 2010 mit der REXUS 7 vom Raumfahrtzentrum Esrange bei Kiruna in Nordschweden gestartet wurde Vor dem Hintergrund dass manche materialwissenschaftlichen und biologischen Experimente nur in einer weitgehend st rungsfreien Umgebung im Weltraum durchgef hrt werden k nnen baute ein Team von Studierenden um Rudolf Vetter dem damaligen studentischen Projektmanager eine Experimentiereinheit die relativ entkoppelt von der Raketenstruktur diese Tests in Schwerelosigkeit erlaubt Da die Schwerelosigkeitsphase beim Raketenflug durch Schwingungen und aerodynamische Str mungen gest rt wird entwickelten die Studierenden ein System das mithilfe von magnetischer D mpfung und Federn die Ersch tterungen der Experimentiereinheit stark reduziert Die Mission war erfolgreich Die angehenden Luft und Raumfahrtingenieure erzielten eine 60 bis 80 prozentige Isolationswirkung Im M rz 2012 soll die n chste REXUS Generation in Schweden an den Start gehen Wir m chten die beim letzten Raketenstart erzielte Isolationswirkung optimieren erkl rt Kr mer Daf r werden wir die Magnete neu anordnen und eine andere Daten bertragung w hlen Die Studierenden sind gl cklich dass sie durch die Unterst tzung der Hochschule an solchen Praxisprojekten teilnehmen k nnen Kr mer Wir k nnen es kaum erwarten endlich mit unserer experimentellen Nutzlast
63. at an re mr dejar e el pn go tmr je hn owe qum y wt e me Fn IA on ae A cms Al A 9 tt ten tee eee ee a we it m N te pate w be modi onm ee ee A A A ee 239 tn ao o4 eee ne x i Technical Specifications The current experiment Me m rmm orm un soa ee PB tu A r lo sas e j o in tt _ TH PE emm en mm A my AA AI A o palT LI PE E EA S aA LP RAT HP UEP TA L LA id atts i gt bo 4 cea E Ga LLL mer d yum u Source 7 ELGRA Symposium Poster Session RHX11 ADIOS SEDv5 3 07October2013 Final docx Page 114 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation a Kontakt Telefonbuch Vorlesungs erzeichnis Downloadcenter Einrichtungen Forschung Entwicklung und Technologietransfer Publikationen Campus ffice gt News Archiv Mittwoch 02 November 2011 17 26 Yon Ruth Bedbur Rubrik Mews FH schickt Experimente auf Raketenflug in den Suborbit Im M rz n chsten Jahres startet im Raumfahrtzentrum Esrange bei Kiruna in Nordschweden die RESUS 11 Rakete Mit an Bord sind zwei Experimente die FH Studierende am Fachbereich Luft und Raumfahrttechnik entwickelt haben Sie nehmen am REXUS Programm Raketen Experimente f r Universit ts Studenten des Deutschen Zentrums f r Luft und Raumfahrt DLR der Swedish Space Cooperation SSC sowie der European Space Agen
64. atic of EXP2 PCB3 Four circuit boards are used PCB3 for EXP2 Every circuit board has four strain gauges amplifiers and two amplifiers for the temperature sensors The strain gauges and the temperature sensor are operated with a constant current of an JRC Dual High Current Operational Amplifier NIM4556AD The flowing current is compared to a common sensor signal very high 4mA 20mA and has a very constant value Thus the measuring cable is highly resistant against irradiation That technology is immune to the inductance of the measuring cable which allows cable length up to 100m too The housing of the NJM4556AD shelters two operational amplifiers The first operational amplifier provides the constant current which flows through the sensor The second operational amplifier is an analogue summer and is able to amplify the output signal The first operational amplifiers output voltage changes if the resistance of the sensor varies Now the offset voltage is compensated with the analogue summer The residual voltage is amplified and the output value is stored in the CompactRio module To ensure exact measurement the circuit has to be calibrated in Kiruna RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 62 d advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH ADLR and SSC cooperation x M H M dapat bl e ho Lal P Schematic 4 circuit EXP2 PCB3 Picture 39 lay
65. ation on sound g rockets no vibrations good vibrations EUROLAUNCH A DLR and SSC cooperation 8 ABBREVIATIONS AND REFERENCES 8 1 Abbreviations This section contains a list of all abbreviations used in the document Add abbreviations to the list below as appropriate In version 5 of the SED final version delete unused abbreviations ADIOS AIT asap A D BO BR CAD CDR CFC COG cRIO CRP DAQ DLR EAT EAR ECTS EIT EPM ESA Esrange ESTEC ESW EXP1 EXP2 FAR FFED FH Aachen FST FRP ADvanced Isolation On Sounding rockets Assembly Integration and Test as soon as possible Analogue Digital transformation Bonn DLR German Space Agency Bremen DLR Institute of Soace Systems Computer Aided Design Critical Design Review Carbon Fibre Composites Centre of gravity compactRio NI Campaign Requirement Plan Data Acquisition System Deutsches Zentrum fur Luft und Raumfahrt Experiment Acceptance Test Experiment Acceptance Review European Credit Transfer System Electrical Interface Test Esrange Project Manager European Space Agency Esrange Space Center European Space Research and Technology Centre ESA NL Experiment Selection Workshop Experiment part 1 Isolation of FFED Experiment part 2 measuring mechanical loads Flight Acceptance Review Free Flying Experiment Device Aachen University of Applied Sciences Flight Simulation Test Flight Requirement Plan HX11 ADIOS SEDv5 3 07October2013
66. aumfahrt ADVANCED TITUS Manuela Franke Nov 2001 HX11 ADIOS SEDv5 3 07October2013 Final docx Page 94 no vi brations good vibrations E UROLAUNCH 12 13 14 15 A DLR and SSC cooperation Bachelor Thesis UAS Aachen Aerospace Department Autonome Experimentsteuerung mittels LabVIEW f r ein Raketenexperiment Lysan Pf tzenreuter 2010 RX_PDR_minutes vi1_ADIOS_O3Mar11 doc ADIOS Strain Gauge Requirement Proposal Stefan Kr mer Lysan Pf tzenreuter FH Aachen 2011 RX11_ADIOS_SGRP_v1 6 pdf RX CDR minutes ADIOS DLR ESA SSC Review Board Experiment Critical Design Review Mark Fittock 2011 RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 95 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation 8 3 List of tables and pictures Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Contact details of the Team members 2002240022400nenn nenne nennen 10 Possible workload of each team member 20 BUGIS str DELIS coeunt its 21 Experiment summary table o oocccocccccccnccncncnncnconcncnncncnncnnnncnnnanonnos 34 Garbo bre ia lela Srta 34 connector pin configuration oocccocnccncccncnn
67. by the imbalance generator of the ADIOS experiment setup have been almost completely isolated While the peaks of the red graph clearly represent the three excitation fre quencies of the imbalance generator the green graph does not show any transmission of these vibrations in the out lined frequency band from 1 Hz to 100 Hz The band width between 0 Hz and 10 Hz is strongly superposed by so called pink noise due to the measuring and ampli fication system In this data set the natural frequency of the damping system is not recognisable Therefore the disturbance by low frequent movements was too high 6 CONCLUSION The ADIOS platform offers an enhanced reduced gravity in six degrees of freedom by one order of magnitude In view of the application on sounding rockets an effective decoupling of the experiment from the rocket structure is already reached above 0 5 Hz The passive system comes with a reliable locking mechanism for launch and landing RX11 ADIOS SEDv5 3 07October2013 Final docx s EuroLAauncH A DLR and SSC cooperation Hz Figure 9 Fourier transformed signal of the accelerations in flight axis showing the excitation frequencies by the imbalance generator RED undamped rocket structure GREEN decoupled experiment containment as well as for storage Designed and demonstrated for sounding rockets the principle can be used for different type of ji gravity platforms Usually very low frequency movements are c
68. ch details are for which experiment Presentation o Generally good clarify the difference between the two experiments larger size of text o Amount of data downlink was there but not clear in the SED O O 0 4 Panel Comments and Recommendations Requirements and constraints o Missing compliance to the vehicle o Operations requirements need to be reviewed Mechanics o EXP1 looks fine now clearly depicted in general well described for the changes o EXP2 not as good strain gauges mentioned but clear positioning is not there need to describe clearly the connections and cabling o Need a better definition and to clearly identify the integration possibility o Can t see from this document how the assembly looks and the connections o Should have some simulations of what you expect to measure identify what the team is focussing on o Describe complete vehicle and complete payload and where you would place them o Need to look at the different options is it possible just from the ADIOS module are there minimum requirements o Itis very important for the payload integration that we have a clear indication of how this would occur number of connectors where the cables are routed o Should have done some basic analysis for determination of location of strain gauges o Team wants to use only a single cable for the strain gauges o Need to ask other teams whether you can pass your line through their modules o Couldn t find scientific justi
69. chen berwiegend aus dem Fachbereich Luft und Raumfahrttechnik Kontakt ADIOS FH Aachen Fachbereich Luft und Raumfahrttechnik FB6 Hohenstaufenallee 6 Raum 02105 CHrexuslat fi aschen de Weitere Infos Wew rexusbexus net Ww eurolaunch ong student programme aspx www dir de rd desktopdefault aspx tabid 2282 3421_read 10516 Newsarchiv FH Aachen vom 10 Januar 2011 Zu den Sternen von Frau Bedbur 4 nach aben By Druckversion Sitemap Suche Impressum EuroLAauncH A DLR and SSC cooperation Source 4 ADIOS Homepage at the FH Aachen website Link http www fb6 fh aachen de lur studienprojekte rexus adios HX11 ADIOS SEDv5 3_07October2013_Final docx Page 108 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation Picture 42 im Fachbereich B Presentation F amp E Research 3 i amp Development Conference Luft amp Raumfahrttechnik 1 E Luft und Raumfahrttechnik Sommersemester 2011 Prof Dr Ing Harald Funke 02 05 SIoBiA Raum 14 00 Biogene Automobilkraftstoffe in der 00201 Allgemeinen Luftfahrt Stefan Kr mer Mo No Vibrations Good Vibrations A Raum 09 05 11 Entwicklung einer passive Schwingungs 5 a 00201 14 00 d mpfungsplattform f r micro g Experimente auf H henforschungsraketen Dipl Ing Katrin Brittner 23 05 11 Karosserieleichtbau 14 00 Multi Material Components contra
70. consumption after lift off 3 2 Wh until T 600s Power OFF 600s after lift off Battery recharging through service module No Experiment signals Signals from service module required Yes SOE Yes at 70s after YoYo Despin RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 80 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation A Table 17 Electrical interfaces applicable to REXUS 6 3 Campaign Preparation For the campaign preparation following topics have to be taken in account The heavy toolboxes and boxes of spare parts should be delivered to DLR MoRaBa for the Bench Test in January to ship these items in the DLR container to Kiruna 6 3 1 List of tools 6 3 2 List of spare parts 6 3 3 List of campaign attending team members For the campaign it is necessary that every subsystem is covered by a responsible person In the case of problems and failures the responsible should be able to find solutions for it Management 1 Stefan Kramer Electronics 1 Dominique Daab 2 Andreas Gierse Structure 1 Joana Hessel 2 Tobias Wagner Software 1 Fabian Baader Outreach 1 Brigitte Muller RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 81 EUROLAUNCH M advanced isolation on sounding rockets no vibrations good vibrations A DLR and SSC cooperation 6 4 Launch Site Requirements The Experiment temperature shall not fall below 20 C because of the calibration of t
71. ctly to the aluminium rings of the locking mechanism The magnetic field strength decreases quadratically with the distance and a contained experiment will not feel stronger magnetic forces than the earth magnetic field strength The optimal damping is reached by a multilevel arrangement of the magnets which is shown in figure 6 By using different field strength in different levels a progressive damping behaviour is realised In order to validate the spring and damper performance as a result of the formerly explained theoretical dimen sioning the ADIOS damping platform is equipped with measuring electronics One three axial accelerometer is mounted to the centre of the FFED a second one is attached to the rocket module as a reference sensor Close to the reference accelerometer an imbalance generator is mounted to the rocket wall During the u gravity phase the imbalance generator is driven in three different excitation frequencies see table 1 to generate a valid signal in far distance to the electric noise of the measuring system The excitation frequencies feast ation give the opportunity to proof the transmissibility for the higher frequencies Page 135 dvanced isolation on sounding rockets a no vibrations good vibrations Figure 6 Multilevel magnet setup in a cross section of the locking mechanism and the counter plate of the FFED Table 1 Excitation Frequencies of Imbalance Generator Phase Frequency
72. cy ESA teil das Studierenden erm glicht wissenschaftliche und technische Experimente auf suborbitalen Raketenfl gen kurzzeitig unter weltraumbedingungen durch zuf hren ADIOS 40vanced Isolation Qn Sounding rockets hei t das Experiment das den Versuch auf der REXLUS 7 aus dem Jahr 2010 fortsetzt vor dem Hintergrund dass manche materialwissenschaftlichen und biologischen Experimente nur in einer weitgehend st rungsfreien Umgebung im Weltraum durchgef hrt werden k nnen bauten Der start dar REXUS 7 im Jahr 2010 die Studierenden eine Experimentiereinheit die entkoppelt von der Raketenstruktur amp DLR Torbj rn Sundberg aussagekr ftige Tests in Schwerelosigkeit erlaubt w hrend der Schwerelosigkeits Phase d mpft das System die St rungen die sich aus dem Raketenantrieb und aerodynamischen Str mungseinfl ssen ergeben Diese Schwingungen werden mithilfe on magnetischen D rmpfern und Federn gr tenteils eliminiert Die Studierenden hatten schon 2010 mit dem Vorg nger WibraDamp Erfolg Sie kannten in ihrem Experiment eine 60 bis 80 prozentige Isolationswirkung erzielen Diese wollen wir beim n chsten Versuch optimieren erkl rt der studentische Projektleiter Stefan Kr mer Daf r werden wir die Magnete neu anordnen und ein anderes D mpfersetup ausprobieren zus tzlich wird parallel ein zweites Experiment durchgef hrt Die Studierenden wollen testen welche Lasten auf die Raketenstruktur wirken und wo gegeben
73. d Raumfahrttechnik zu den f hrenden deutschen Hochschulen Kontakt Stefan Kr mer Fachbereich Luft und Raumfahrttechnik Hohenstaufenallee 6 Raum 02105 52064 Aachen rexus FH aachen de www fb6 FH aachen de lur studienprojekte rexus adios Der Start der REXUS Raketen kann auf der Webcam des Esrange Space Centers mitverfolgt werden Source 9 Press Release by Bedbur Ruth FH Aachen Press Office 08 03 2012 http www fh aachen de topnavi presse pressepressemitteilungen pm details no_cache 148tx_tinews 5Btt_news 5D 3258cHash f5a98b19b24ed8997ec9184e a0218247 HX11 ADIOS SEDv5 3 07October2013 Final docx Page 116 advanced isolation on sounding rockets no vibrations good vibrations Weltraumeinsatz zum Teil erheblich unterscheiden Als wesentliches Ergebnis des Workshops hat DLR beschlossen zun chst kurzfristig ein Instrument f r einen ballistischen Flug zu entwickeln welches bereits einzelne Experimente erm glicht als auch als Entwicklungsmodell f r die orbitale Version dienen soll Die verbleibende Studienaktivit ten sollen sich nun auf dieses Ziel konzentrieren Rainer Treichel 19 3 2012 19 03 2012 TOS Praktikant supports experiment on REXUS 11 Tobias Wagner one of out TOS praktikants is supporting a Sounding Rocket experiment on REXUS 11 Tobias is studying at the University of Applied Research in Aachen Tobis sent us the following status report from Esrange unsere Software hat zwar an
74. denn das DLR bietet dies In seinem neuen Programm STERN Studentische Experimental Rake ten als Fordermogiichkelt f r Hochschulen an die Im Bereich von Tragersystemen ausbilden Wir werden uns auf jeden Fall bewerben sagt Engelbert Plescher Und wer wei vielleicht heben wir dann In drei Jahren so lange wird es dauern bis die Rakete entwickelt und einsatzbereit Ist sogar mit einer eigenen FH Rakete ab RB FH Aachen participates in various programmes that make it possible for teachers as well as students to work in astronautical conditions Some students perform scientific experiments on suborbital rocket flights through the REXUS programme FH Aochen s COMPASS 2 satellite transports new technical components into space Prof Dr Bernd Dochwald explores the technology of solar sail propulsion the use of which will be tested during a space mission The IceMole mission is stil a dream of the future but one day the melting probe wil dig into the thick ice layer of Mars or Jupiter s moon Europa to search for extraterrestrial life Page 112 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation FH AACHEN DIMENSIONEN 01 11 TITELTHEMA TUDIUM NTERNATIONAL FORSCHUNG PERSONE ERVICE 17 RX11 ADIOS SEDv5 3 07October2013 Final docx Page 113 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR
75. dling the financial budget and manpower is another aspect of the management The structure will be improved by using light weight carbon fibre composites Due to this change in the construction new calculations and FE Method simulations have to be made to proof the reliability of the experiment The responsible team members will do the CAD Modelling and the structural analysis In a close relationship to the structure the science branch is developing the simulations on which the experiments will base Important is a good knowledge of structural analysis and design The major part of this workload will be within the framework of at least one master thesis The major part of work in the field of programming will cover the development of the S W for the cRIO with LabVIEW to control the experiment functions as well as the DAQ Electronics will be a complex and comprehensive part of the experiment The power supply and the sensor control needs to be developed and build RX11 ADIOS SEDv5 3 07October2013 Final docx Page 14 EUROLAUNCH advanced isolation on sounding rockets no vibrations good vibrations A DLR and SSC cooperation The outreach program and the link for public relations is covered by Brigitte Muller Due to the parallel work for two other student projects she is in touch with the department of P R of the FH Aachen and to local media The administration of the ADIOS website will also be done by Brigitte Muller The ADIOS
76. e a high level of technology sen sors actuators and complex software solutions Passive systems are usually more cost effective and less complex Both solutions have advantages which are depending on the environment and on the damping requirements Most systems are designed for the International Space station ISS The vibrations and accelerations on the ISS are categorized into three frequency ranges Low fre quencies below 0 001 Hz which are caused by gravity gradients and atmospheric drag less than 10 g The frequencies in the range of 0 001 Hz to 1 Hz are for exam ple caused by motion of the astronauts and attitude con trol maneuvers Higher frequencies above 1Hz can be generated by electric motors pumps compressors fans and also astronaut actions Currently passive vibration isolation systems are only used for the damping of high frequencies above 10 Hz and for payloads which are not sensitive to low frequen cies A practical application for even low frequencies is not far developed yet Active damping solutions are of ten more convenient to low frequency attenuation and are grouped into active rack isolation and active payload iso lation systems 31 Active Vibration Isolation Systems Active systems provide a vibration isolated environment by utilising actuators which are controlled by a feedback control in combination with sensors The overall advan tage is the wide application bandwidth Even low fre quencies ca
77. e is fully integrated the mechanism must be accessible from the outside i e it connects the experimental module located in the rocket with the outer shell of the rocket The unit consists of a machined metal housing to which a total of three D Sub connectors 2 x 9 pin 1 x 15 pin to be arranged opposite each other The front positioned D Sub connector is the interface to the outside The metal hou sing is attached with screws to the outer shell of the rocket RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 64 EUROLAUNCH A DLR and SSC cooperation Lag a17 E A E Flight Plug C p u er ye Motors FFED Power Supply Figure 8 Block diagram Arm plugs 4 6 Thermal Design The requirements for the thermal design are based on the compensating curves and the internal temperature compensation of the ACC sensors The sensors shall not reach a temperature of less than 20 C If this could not be screened out we have to use a heating system or a passive thermal insulation for the pre launch phase The electronics of the ADIOS experiment will dissipate heat during operation The major dissipater will be the cRIO In the former project VibraDamp the experiment had no problems because of heat But this experience is no more valid for ADIOS because of the higher workload onto the cRIO in the operation mode It needs to be tested in the vacuum chamber as far the 3 and 4 NI Module is delivered An assembly of a cooling elemen
78. e module and the ADIOS experiment is a D SUB 15 female connector It will be plugged on a junction box which distributes the several electrical components The Junction box consists of PCB1 and an RS232 PCB1 is implemented with three Traco power DC DC converters Each experiment is supplied by a Traco TEN 20 2423 DC DC converter with a demand of 20W It provides a voltage of 15V at a current of 667mA The DC DC converters are enabled by signals of the REXUS service module SODS SOE That is realised by a FET which distributes the converter with an input voltage of 28V after switching The third DC DC converter is used for power supply of the CompactRIO module The Traco TEN 30 2413 DC DC converter has a demand of 30W and provides an output voltage of 15V at a current of 2A That DC DC converter is directly linked to the input voltage of 28V of the REXUS service module which implies that the CompactRio module is booting before liftoff On PCB1 an optocoupler is used to convert the liftoff HX11 ADIOS SEDv5 3 07October2013 Final docx Page 50 7 advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH ADLR and SSC cooperation signal LO of the REXUS service module to a TTL signal which is linked to the CompactHIO s serial interface Schematic 1 Junction Box PCB1 HX11 ADIOS SEDv5 3 07October2013 Final docx Page 51 EuroLAauncH A DLR and SSC cooperation Picture 27 layout junctio
79. e plier is amounting about 1000 and can be also used for further and parallel space related The Pliers Company student projects Additionally the Knipex Company has conducted a crimping course to the Team ADIOS HX11 ADIOS SEDv5 3 07October2013 Final docx Page 23 EuroLauncH A DLR and SSC cooperatio ee u Picture 5 Four Mandrel Crimping Plier HBM Hottinger Baldwin Messtechnik The HBM sales office in D sseldorf Erkrath has sponsored the whole delivery of strain gauges amounting 691 in total The HB delivery included strain gauges glue temperature sensors and covering silicone ERNI Electronics The ERNI Company confirmed the sponsoring of D Sub connectors for the ADIOS experiment The sponsored amount connectors is about 70 conectors including all needed accessories The delivery is amounting about 200 FCT Electronics ES The FCT Company has sponsored the Team ADIOS by FCT T providing D Sub connectors and pins as well tools for the assembly HARWIN Harwin has provided the connectors for the HAR Wi N acceleration sensors amounting 200 The wre CONNECT DESI GN amp MANUFACTURE crimping plier will be loan for the time of assembly NI NATIONAL INSTRUMENTS The NI Acadmic Relations Office has sponsored the NATIONAL Team with the required NI Modules 2x NI 9205 and instruments 1x NI 9505 including accessories The delivery is amounting 2147 B llhoff
80. e summarized that the measurement prin ciple worked out very well at all phases The level of pink noise was lower than anticipated Eigenforms were not identified in this case study In the future the measurement range of this sys tem could be extended down to static strain if the system was extended by Chopper Amplifiers Page 143 advanced isolation on sounding rockets no vibrations good vibrations T ACKNOWLEDGEMENT The authors would like to thank DLR ESA and SSC who made the KEXUS programm possible which was a huge enrichment for our studies special thanks also to our industrial partners for their support in materials and knowledge Also we like to thank the FH Aachen and our professors for advice and financial support 8 REFERENCES 1 L Pf tzenreuter M Lauruschkat A Gierse and R Vetter VIBRADAMP FH Aachen Tech Rep 2010 2 S Kr mer EVALUATION OF ROCKET FLIGHT LOAD DETERMINATION ME THODS Bachelor Thesis 2012 DLR MORABA 8 L Pf tzenreuter FEM CALCULATIONS ON THE REXUS 11 ROCKET Master The sis 2011 FH Aachen HX11 ADIOS SEDv5 3 07October2013 Final docx EUROLAUNCH ADLR and SSC cooperation Page 144 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation APPENDIX F STRAIN GAUGE REQUIREMENT PROPOSAL 1 SGRP Strain gauge requirement proposal document name RX11_ADIOS_SGRP_v1 6 docx ADIOS Strain Gauge Requirement Proposal
81. e tape 14 Same procedure for strain reliefs 15 Soldering of small cables between strain reliefs and strain gauge 16 Soldering of cable harness to strain relief 17 Cover the whole deanodized area including strain gauges and cable connection with covering agent 18 Merge the cables of all strain gauges of the cross section at the wall to one cable harness to leave the module at 180 19 Connecting the cables to amplifier in ADIOS module The instructions of the manufacturer HBM can be found on the BSCW Server gt 300 Sensors amp DAQ gt Sensorik RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 153 no vibrations good vibrations EUROLAUNCH A DLR and SSC cooperation APPENDIX G ADDITIONAL TECHNICAL INFORMATION RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 154 EuroLAauncH advanced isolation on sounding rockets no vibrations good vibrations A DLR and SSC cooperation ee ore Eka A A incur piini po a 71 D nnd DILE aep run e FA eov n rain cons sc arcani a ncque Acura mac qu rv 4 un rag Fan zer gl Tran Be DET ae Tie re Dc A LLL m LE e IT Tax fr MEXMERGE er Mosa Lom PEDIA OR LARES UD Mirad peer Oe y idas Lus amp erg 7777 ee DE aisi pre OE SL 20 ra md Lnd m cree sn s bam rs ADA sem ort TE NOA AA Hj O eed Du Are rm pi 5 T3 Dd i Pe m Lat 14 Ux Sa DU mate vut Ta TEE ET a ra DR A naco woe pe ff lees Peed A m rr rd o
82. echanism Picture 1 Overview ADIOS Experiment Platform HX11 ADIOS SEDv5 3 07October2013 Final docx Page 7 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation size and mass of the contained experiment by the layout of magnets and springs A single small box of electronics will run the locking mechanism independently from the experiment In the actual status the AD OS platform will be tested on the REXUS 11 flight in March 2012 in Kiruna North Sweden Acceleration sensors mounted on the free flying experiment container and on the rocket structure will measure the residual acceleration onto the elements of the platform Calculations with Fourier transformations can determine the difference of accelerations between the container and the rocket structure To measure the acceleration onto the container a highly accurate measurement system has to be established Usually the noise of the sensors is higher than the measured signal Therefore a complicated compensation of the signal and processing of the data is compulsory to obtain evaluable data The applicability of the principle is already proven by the VibraDamp project on REXUS 7 If the improvements of the AD OS platform design accomplish the goal of 85 90 damping in average the platform can be offered to scientific experiments to use cost effective sounding rockets without a rate control system RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 8
83. ectronic boards will fit into the FFED Therefore the inner volume has been enlarged by changing the position of the walls 4 4 1 Locking Mechanism The LM works on the principle of form fitting Two rings on the upper and lower side of the FFED are holding it during launch and landing The lower Ring is attached directly to the module walls During the reduced gravity phase three geared electric stepped motors are driving the upper ring to enlarge the space in between the LM and the FFED is free flying Bevelled circles on the upper and lower ring are fitting exactly to the bevels on the FFED This assures the perfect position during locking Positioning sticks are mounted on the FFED and are fed through the LM rings If the LM has a malfunction during locking after the reduced gravity phase these positioners avoiding damage to the module and electronics as well as DAQ during landing Due to this the FFED is not able to move further than a few mm away from the x axis of the rocket RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 36 i advanced isolation on sounding rockets E L no vibrations good vibrations EuroLauncH ration A DLR and SSC coope Picture 9 Locking mechanism and FFED A limit switch will assure the optimised position of the LM and hence a defined distance between the LM rings This is necessary to assure the calculated magnetic damping Picture 10 Motor and attachment 4 4 2 FFED Free flying exp
84. ed in November 2011 All ass umptions were actual at that date The positions of the strain gauges were defined as shown and those appliqued in the modules After spin and balancetest the REXUS 11 payload had to be reconfigurated with the result of new unideal positions of the strain gauges and therewith to a loss of information in the data see section 5 RESULTS 4 1 2 Bachelor Thesis by Stefan Kr mer EVALUATION OF ROCKET FLIGHT LOAD DETERMI NATION METHODS 2 NASA and DLR developed several software tools du ring the 1960 s to determine aerodynamic loads on rocket structures This evaluation compared the results of the most sui table programms on the special case of the REXUS 11 rocket The variation range of the results was unexpectedly huge 2 508 04 1 508404 4 FLMD IH 50 104 lli DLR Method we PMC116 FLMD IH Imperial X Position m Figure 2 shows the calculated shear forces using dif ferent software tools on the REXUS 11 rocket at an angle of attack of 4 Based on this calculations no special expectations con cerning excitations or Eigenfrequencies were formulated However these imprecise results showed the necessity of a reliable measurement system Therefore it was deci ded to collect data also while ascent and descent HX11 ADIOS SEDv5 3 07October2013 Final docx EuroLauncH A DLR and SSC cooperation 4 2 Preliminary design on shakertest For the first tests i
85. eering M Sci FH Aachen Luft und Raumfahrttechnik Apprenticeship Precision Mechanic Technician Brigitte S Muller Outreach PR Management Assistance 12 semester Astronautical Engineering B Eng FH Aachen Luft und Raumfahrttechnik Apprenticeship Precision Mechanic Technician Dominique Jonas Nick Daab Electronics 12 semester Astronautical Engineering B Eng FH Aachen Luft und Raumfahrttechnik Apprenticeship Mechatronics Technician Lysan Pfutzenreuter M Eng Science Programming Data Acquisitioning Graduated Astronautical Engineering FH Aachen Luft und Raumfahrttechnik Joana Hessel B Eng Structure 1 semester Astronautical Engineering M Sci FH Aachen Luft und Raumfahrttechnik RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 12 d advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH A DLR and SSC cooperation Fabian Baader B Eng Programming Experiments Controle 1 semester Astronautical Engineering M Sci FH Aachen Luft und Raumfahrttechnik Tobias Wagner B Eng Structure Electronics 1 semester Astronautical Engineering M Sci FH Aachen Luft und Raumfahrttechnik Georg Gdalewitsch B Eng Data Acquisitioning Data Analysis S W 3 semester Astronautical Engineering M Sci FH Aachen Luft und Raumfahrttechnik Dipl Ing Andreas Gierse Science Electronic Development
86. eeseeeeeeeeee 101 Source 2 CDR Minutes by Review Board cccceccccseeeeeeeeeeeeeeeesseeeesaees 104 Source 3 Press release 10 January 2011 9 sn 105 Source 4 ADIOS Homepage at the FH Aachen website 107 Source 5 PeopleMover 2011 occcooccncccccncccccncccncnocononononononanononanncnncnonanenonnns 109 Source 6 Dimensionen 2077 esana EAEE SAE 110 Source 7 ELGRA Symposium Poster S SSION cccsecceceeeeeeeeeeeeaeeeeeaees 113 Source 8 Press Release by Bedbur Ruth FH Aachen Press Office 02 11 2011 Roo yA 114 Source 9 Press Release by Bedbur Ruth FH Aachen Press Office 08 08 LO 1 oocccccccccccocnncoocnnnonnnnonnnnoconnnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnnnnaninonos 115 Source 10 Note ASTRIUM Intranet by Peter Kern ASTRIUM Friedrichshafen and Tobias Wagner ADIOS Team 19 03 2012 116 HX11 ADIOS SEDv5 3 07October2013 Final docx Page 98 EUROLAUNCH A DLR and SSC cooperation Source 11 Press Release by Bedbur Ruth FH Aachen Press Office 23 03 2012 oo ceccccceccccesececeneeeceeeeceeeeceeeeeeeeeseseetseeetseeetsueeetsaeeetseeetaeeetenes 117 Source T2 OUI OSEIT Sa 119 schemsuo 1 Junction BOXTPOBT nennen 50 Schematic 2 RS232 converter PCB4 ooccccccnccccnccccnccocnncnoncconnncnnnncnnnonononos 51 schematic 3 acceleration amplification PCB2 oocccccnnccccnccccnncnonnncnnnnnnnnos 57 Schematic 4 circuit EXP2 PCB
87. en wir eine Tragerrakete finden die unseren Satelliten Huckepack Ins Weltall bef rdert Gr ne Technologle f rs All Normalerwelse sind die Ziele im All durch die Treib stoffmenge begrenzt Raumfahrzeuge dle mithilfe von Sonnensegeln die kostenlose Sonnenstrahlung als Antriebsquelle nutzen haben hingegen Immer einen vollen Tank Dadurch Ist es sogar m glich unser Sonnensystem zu verlassen In der Antriebstechnik des Sonnensegels steckt ein enormes Anwendungspo tenzia schw rmt Prof Dr Bernd Dachwald Schon bald soll die In Deutschland entwickelte Technologie einem Praxistest unterzogen werden Danach planen das DLR und dle ESA eine gemeinsame Weltraummis sion bei der unter anderem die Pole der Sonne mithilfe eines Sonnensegels Oberfiogen werden sollen um unseren Stern aus einer neuen Perspektive zu untersuchen Die Hitze macht dem Sonnensegel nichts aus erkl rt der FH Professor der die Mission In einer Arbeitsgruppe der ESA begleiten wird Es sel ver gleichbar mit Backofenpapler aber wesentlich leichter und feiner Vorstelibar ware auch der Einsatz von Sonnensegeln zur Abwehr von Asterolden Ein Sonnensegel k nnte Asterolden finden die sich so nahe an der Sonne befinden dass man sle von herk mmilchen Raumfahrzeugen oder von der Erde aus nicht entdecken kann sagt Prof Dachwald Dass es sie gibt sagen Computermodelle des Sonnensys tems voraus F r diese ware die Entdeckung solcher K rper ein wichtiger
88. enfalls Material und somit Gewicht eingespart werden kann wenn die Rakete leichter gebaut werden kann k nnte sie h her steigen oder weitere Experimente mit an Bord nehmen so Kr mer Allein die Einsparung von zwei Kilogramm pro Raketenmodul h tte enorme Vorteile Die Ergebnisse dieses Experiments flie en in die Optimierung des Designs von zuk nftigen H henforschungsraketen und deren Modulen ein Die Experimentiereinheit der Studierenden befindet sich momentan in der Fertigungsphase Mitte Dezember nimmt das Team van derzeit zehn Studierenden an der Payload Integration Week teil Alle studentischen Projektteams treffen sich beim DLR um die einzelnen Experimentiermodule zusammen zu setzen und sie gemeinsam mit dem Bordcomputer der Rakete zu testen Sp ter wenn die Rakete fertig montiert ist folgen dann noch Tests um eine stabile Flugbahn zu gew hrleisten Die Rakete wird im Prinzip gewuchtet sagt der FH Student wie beim Autoreifen Danach kann die H henforschungs rakete dann endlich nach Kiruna und in den Nordhimmel abheben lt Zur ck zu News Archiv Druckversion dieser Seite Impressum Letzte Aktualisierung 06 May 2008 Source 8 Press Release by Bedbur Ruth FH Aachen Press Office 02 11 2011 RX11_ADIOS_SEDv5 3_07October2013_Final docx advanced isolation on sounding rockets no vibrations good vibrations STUDIENANGEBOT Startseite Presse Pressemitteilungen Aktuelles Kontakt und Team Kurzpro
89. enfrequency This results in a smaller magnification factor Even more important is the result that at higher frequencies a very good decoupling is achieved 4 2 The Working Principle In order to improve the existing u gravity environment all DOF have to be mechanically decoupled Therefore six three dimensional springs and dampers are necessary The dimensioning eigenfrequency should be as low as possible to achieve a decoupling even at low frequencies Figure 3 obtained from 5 shows the patented decou pling mechanism of the TITUS II experiment The three dimensional springs are realised as bending and torsional beams while magnets are damping the experiment us ing the eddy current effect Working with eddy current dampers the damping depends on the oscillation ampli tudes frequency and the distance between the magnets and the corresponding aluminium board 4 2 1 The Isolation Concept The key elements for the isolation of vibrations in the mechanical decoupling due to the free flying experiment device FFED This principle is not new but it gives the unique base for a nearly disturbance free environment The technical design can be adapted by optimising the space for the FFED in which it can and needs to move without contacting the outer structure Hence the highest amplitude of motion vibration has to be estimated in advance 4 2 2 The Damping Principle Figure 4 indicates the dimensions and influence of the magne
90. ent wird in ein Standard Raketenmodul eingepasst und l sst sich somit einfacher auf H henforschungsraketen integrieren Um die G te der Schwingungsd mpfung zu bestimmen werden w hrend der reduzierten Schwerkraft die Restbeschleunigungen auf die Raketenstruktur und Innerhalb der gedampften Experimentenbox gemessen und anschlie end miteinander verglichen F r die Beschleunigungsmessung wird jeweils ein 3 axtaler Beschleunigungssensar benutzt Schnitt durch das Kaketenmodul Bild ADIOS 331 Bei einer Rakete sollten alle Bauteile so leicht wie m glich sein und trotzdem die Beschleunigungen w hrend des Starts 20g aushalten Aufgrund m glicher Massenreduzlerung z B durch CFK Bautelle Carbon Faser verst rkter Kunststoff sollen die mechantschen und dynamischen wirkenden Lasten auf die Struktur untersucht werden Dies Ist das zweite Ziel des ADIOS Experimentes W hrend des Fluges werden dazu die dynamischen Lasten mittels eines dritten 3 axialen Beschleuntgungssensors im gesamten Beschleunigungsbereich 1503 gemessen Die statischen Strukturlasten sollen mittels DMS Dehnmessstreifen an der Struktur ermittelt werden Hierbei werden jeweils vier DMS in einem Querschnitt der Raketenstruktur angebracht Das daraus gewonnene Wissen wird dazu dienen die Raketenstruktur hinsichtlich Gewicht und Material zu optimieren und somit das Design von H henforschungsraketen zu verbessern Team ADIOS Das Team besteht derzeit aus 8 Studierenden der FH Aa
91. eriment a reliable decoupling mechanism is necessary RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 121 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation The DLR German Aerospace Centre and the FH Aachen University of Applied Science developed a mechanical decoupling system for the TITUS II experiment for usage on the ISS International Space Station The system worked with three dimensional springs and eddy current dampers Today s goal is to improve this decoupling mechanism and make it capable for other ug platforms In the VibraDamp Student Experiment launched with REXUS 7 Rocket Experiments for University Students a decoupling mechanism for sounding rockets based on eddy current dampers including a highly reliable locking device has been tested successfully The ADIOS ADvanced Isolation On Sounding rockets Student Experiment will be launched on REXUS 11 in March 2012 and will verify an improved partly active damping mechanism and locking device Basing on the results of ADIOS a standardised decoupling System for sounding Rockets can be developed The accumulated stock of knowledge can also be used to develop decoupling mechanisms for other ug Platforms 2 Mechanical decoupling A mechanical decoupling system which is the same as a flexible machine bearing naturally consists of springs and dampers Both springs and dampers can be engineered in various designs for different ap
92. eriment device The FFED is the experiment container which could be offered to ug experiments Later on the volume could be easily adapted to the size of an experiment In the ADIOS experiment the FFED contains the ACC Sensor and the amplifying PCB as well as the imbalance generator The FFED is RX11 ADIOS SEDv5 3_07October2013_Final docx Page 37 o advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH A DLR and SSC cooperation secured against damage due to a malfunction of the locking mechanism Pins on top and on the bottom of the FFED are penetrating the locking mechanism and avoid an undesired movement out of the boundaries of the locking mechanism Picture 11 FFED with ACC Sensor 4 4 3 Bulkhead The Bulkhead is a complete new design A Carbon fibre sandwich with an aluminium honeycomb will serve the basic plate Inlets are employed at the places where forces are acting on the structure For example the anchorage of the cRIO as well as the EXP2 PCB Box are tubes which are glued into the structure of the honeycomb between the CFC plates Picture 12 M5 Inlet RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 38 Po N E UROLAUNCH g advanced isolation on sounding rockets no vibrations good vibrations A DLR and SSC cooper To save weight by high stiffness the amount of used inlets is as low as possible The screws for the cRIO and the EXP2 PCB Box are also holdi
93. ext to the strain gauge Need to calibrate the sensors with regard to temperature o Investigate shielding of the cable o Is it really sampled at 500 MHz Is most likely a mistake o For telemetry are the baudrates the required telemetry baudrate No is regarding the sensors o Can use a COTS RS 232 to RS 422 converter but need to test it carefully o Have requested multiple signals from RXSM change this as the signals come from the CRio Thermal o Component approach is fine o Need to be careful of temperature sensitivity of sensors o Can use the temperature data of REXUS 8 that is found on the teamsite Software o ls it possible to send commands to the CRio Not planned o Data storage is a problem need to be careful with the arm plug and the data Verification and testing o Verification matrix is ok but not all are done o Need to expand on the testing consider components calibration vibration etc o The calibration of the strain gauges is it being done on the module itself Must use a test with similar setup and loads o Must submit a new test plan for CDR to Delivery o Push you thermal tests Safety and risk analysis o Risk register is not updated and is limited review the risk register and expand o Need to know that FFU does not move inside the payload o Add analysis of this situation to the ADIOS SED and clarify that it is safe for launch and re entry RX11 ADIOS SEDv5 3 07October2013 Final docx Page 104 no vibrations
94. fangs gestreikt konnte aber mittlerweile debuggt werden Am Donnerstag haben wir erfolgreich unser Modul zum ersten Mal testweise mit dem Servicemodul verbunden Am Freitag hat der finale Bench Test stattgefunden Der Hot Countdown f r unsere Rexus 11 ist am kommenden Donnerstag 22 March 2012 angesetzt Heute um 15 Uhr wird bereits Rexus 12 starten sofern das Wetter mitspielt Mit freundlichen Gr en aus Esrange Tobias The REXUS BEXUS programme is realised under a bilateral Agency Agreement between the German Aerospace Center DLE and the Swedish National Space Board SNSB The Swedish share of the payload has been made available to students from other European countries through a collaboration with the European Space Agency ESA Peter Kern 19 03 2012 New Fluid Physics Chemical Lab handed over to Fases Project On Tuesday Feb 28th the setup of the new Fluid Physics Chemical Lab was completed and the lab was handed over to start operations for the FSL EC Fases Sample Filling activities The utilization of the new lab immediately started for the Fases projects with the cleaning assembly and filling process re qualifications During summer this year filling of 44 EM sample cells as ground reference samples is planned It is foreseen to complete the Fases sample cell activities in 1st quarter 2013 with the final filling of 44 FM samples Gerold Picker 02 03 2012 Overview Presentation of Fluid Physcics Chemical Lab
95. fication for a second cross section of measurements looks like it could be done from one justification needs to be given o This experiment would also be very valuable if done with one cross section RX11 ADIOS SEDv5 3_07October2013_Final docx Page 103 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation o Require a significant report on justification of other cross sections and a proposal solution o Is bulkhead electrically conductive Experiment needs to have a good ground can have a simple thin 0 2 0 3 mm aluminium plate o Cable feed through must be at 1800 Have to consider how to secure the cables especially in the case with late cables Arm plug should be an arm plug use a hatch to cover the plug leave this at 240 if possible Good structural analysis Need to make significant assumptions to cover simulations before sci P L week O O O d Electronics and data management o If you turn arm plug 900 this will make it much easier for the mounting of connectors o For the interfaces there is no overall schematic so it is not possible to see all the connections this is not so good as can t help the team by checking the design o Have to change the power supply as they can t operate directly off our signals use an optocoupler o Need to introduce some filtering o Resubmission of electronics schematics for review o How can you be sure that the strain gauges are temperature compensated Are measuring n
96. fil der Hochschule Publikationen Bildmaterial UNIVERSITY OF APPLIED SCIENCES FH AACHEN Corporate Design Page 115 Y EuroLAauncH A DLR and SSC cooperation FACHBEREICHE DIE HOCHSCHULE FORSCHUNG 3 2 1 Zero Studierende begleiten Raketenstart In Nordschweden lt Zur ck zu Aktuelles 8 03 12 Yon Ruth Bedbur Seit Menschengedenken fasziniert der Weltraum die Menschen Auf der Suche nach neuen wissenschaftlichen Erkenntnissen arbeiten Planetologen Astrophysiker Kosmologen und Raumfahrtingenieure intensiv daran in die Tiefen des Weltraums vorzudringen Auch Studierende vom Fachbereich Luft und Raumfahrttechnik der FH amp achen beteiligen sich Am Sonntag machen sie sich auf den Weg zum Raumfahrtzentrum Esrange bei Kiruna in Nordschweden um dort den Raketenstart der REXUS 11 zu begleiten Das Studierendenteam Joana Hessel Mit an Bord der Rakete sind zwei Experimente die von den Fabian Baader Dominique Daab Stefan Studierenden entwickelt wurden Vor dem Hintergrund dass Kramer Andreas Gierse Tobias Wagner manche materialwissenschaftlichen und biologischen und Brigitte M ller v l Experimente nur in einer weitgehend st rungsfreien Foto FH Aachen Ruth Bedbur Umgebung im Weltraum durchgef hrt werden k nnen bauten sie zum einen eine Experimentplattform die entkoppelt von der Raketenstruktur Tests in Schwerelosigkeit erlaubt Das System reduziert die w hrend der Schwerelosigkeitsphase auf die Expe
97. h cover 4 4 5 Position of acceleration Sensors A late change has occurred in changing the position of the verifying acceleration sensor on the bulkhead Therefore a new position is fixed on the inside of the outer rocket structure The reasons for the change are the improved comparability of the measured data There are now no parts with unknown structural behaviour in the way of the vibrations structural analysis of the single carbon fibre bulkhead is complicated and would not assure a detailed knowledge of the isolating behaviour of the bulkhead itself To keep the sensor in an acceptable temperature range it is necessary to use insulating material for the interface between RX Module and acceleration sensor Therefore we need to use ceramic material with a heat transmission factor of 2 W m 2 like Z700 This interface will be supplied by BCE Special Ceramics 4 4 6 Mass reduction Forced by the review board during the PDR the mass of the experiment has to be reduced down to 13 kg The goal will be reached by using light weight CFC including an aluminium honeycomb for the bulkhead For the LM there are two possible options of mass reduction The first option is the milling of cut outs into the existing VibraDamp parts The second option is the redesign by using CFC In the table in APPENDIX D the single parts are shown with the actual weight and the estimation for the new parts RX11_ ADIOS SEDv5 3 07October2013 Final docx Page 42
98. has been assembled to develop an improved layout of the successful VibraDamp concept The new system allows increasing or decreasing of the damping rate by active positioning of the damping magnets while the system is decoupled The optimal position of the damping magnets is calculated as a function of the actual acceleration amplitude This active regulation of the damping rate leads to the following approximated mechanical behaviour as function of different experiment masses RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 126 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation L N N 3 c o D a e amplitude damping dB Amplituden D mpfung 18 20 Key 20 16 Qty A Ton y 30 o M Jo 2 e 1 0 K A 8 Un gu s S Lsp Ne Mas Con Y 4 4 ome en 50 2 Exp Figure 21 Decoupling as function of experimental mass RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 127 EuroLauncH A DLR and SSC cooperation Figure 22 ADIOS Setup Figure 7 shows the improved mechanical design of the ADIOS experiment 5 Conclusion The results of the VibraDamp experiment show that the ug conditions have been improved significantly The ADIOS experiment will show the potential of an actively controlled damping A future project will be the additional detection and damping of high frequency gt 10Hz vibrations produced ins
99. have a minimal sensitivity of 100 ue The sample rate for the strain shall be the same as for the temperature The data volume on the cRIO shall not exceed 0 7 GB measured for all data 10 Each strain gauge shall measure the strain with a sample rate of 4000 Hz and should measure with a sample rate of 16000Hz Strain gauge design The sizes of the train gauges are very small and the required space for the wall application will not exceed 20mm x 20mm for each measuring point The cables will be assembled to one cable harness which leaves the module RX11_ ADIOS SEDv5 3 07October2013 Final docx Page 149 advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH tion A DLR and SSC coopera HBM manufacturer and sponsor of the strain gauges provided us a package of 10 x 120 Q linear strain gauges for testing the application and function of the amplification These strain gauges will be tested at the VibraDamp RX 7 Module The actual size of the strain gauges is shown in the following pictures Picture 3 Linear strain gauge 350 Q Picture 4 T rosettes strain gauges 350 Q RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 150 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation Picture 5 Temperature sensor 350 Q Picture 6 Linear strain gauge for testing 120 Q RX11_ADIOS_SEDv5 3_07October2013_Final docx
100. he acc sensors HX11 ADIOS SEDv5 3 07October2013 Final docx Page 82 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 6 5 Preparation and Test Activities at Esrange 6 5 1 Assembly of spring setup The springs of the passive isolation of EXP1 will be assembled to the module on the launch side to avoid damage due to the transport To assemble the springs minor parts of the structure and the locking mechanism need to be disassembled Numbered parts and locations in the structure will prevent accidental interchange while the assembly The Springs are prepared for assembly One screw will mount the spring to the wall of the RX Module The second end of the spring has to be glued to the FFED 6 5 2 cRIO preparation The cRIO will not be updated unless a failure occurs during testing An Ethernet cable is sufficient for connecting the cRIO with the ground support computer At least two computers will be on the same S W status to connect to the cRIO to assure connectivity 6 5 3 Arm plugs The ADIOS Experiment will use three different types of armed and disarmed plugs The Flight Plug has to be assembled before flight and closes the power connection to the service module The Test Plug is used for ground testing to avoid the opening if the locking mechanism during the bench tests in the final assembled status HX11 ADIOS SEDv5 3 07October2013 Final docx Page 83 no vibrations good vibrations EuroLa
101. he system The Microgravity vibration Isolation Mount MIM developed by the Canadian Space Agency The con trol of the isolated platform is based on six degree of freedom magnetic levitation utilizing eight wide gap Lorentz force actuators The Modular Wideband Active Vibration Absorber MWAVA developed by NASA s Goddard Space Flight Center and University of Massachusetts Low ell The isolation is realized via a two stage mechan ical connector One stage is connected to the other structure and the second stage which is free of vi bration is connected to the device or experiment The GLovebox Integrated Microgravity Isolation Technology g LIMIT developed by NASA Mar shall Space Flight Center MSFC The g LIMIT system is similar to the MIM solution The mentioned systems were all tested and operated on the International Space Station or on Space Shuttle mis sions Hence the damping of vibrations on sounding rockets is relatively new The active Vibration Isolation Platform VIP by Controlled Dynamics Inc has been recently presented at the Next Generation Suborbital Re searchers Conference 2013 Broomfield Colorado This system is designed for different applications and even us able on sounding rockets The realization of an active isolation system on these Page 132 dvanced isolation on sounding rockets no vibrations good vibrations rockets result in a very complex heavy and costly solu ti
102. ide the decoupled experiment using the decoupling eddy current dampers RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 128 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation Cheap passive decoupling mechanism and more advanced active decoupling mechanism can both play a decisive role in future ug research The FH Aachen would be pleased if research groups which are working on experiment using ug Conditions make contact with us References Patent 1 Patent DE 10227968 B4 Lagerungssystem in einem Raumfahrzeug application 06 22 2002 published 03 02 2006 Applicant German Space Center Cologne Inventors N hle R Dipl Ing Troisdorf DE Wahle M Prof Dr Ing Geilenkirchen DE R stel R Dr rer nat Berlin DE Literature 2 Franke M 2001 Diploma Thesis Entwicklung einer ber hrungslosen D mpfung zur Verminderung von Resonanz berh hungen eines Systems zur Schwingungsisolation eines Schmelzofens in der Raumfahrt ADVANCED TITUS Aachen University of Applied Science and German Aerospace Center Cologne 3 Vetter R 2010 Diploma Thesis Entwicklung einer Pr fstruktur mit einem Schwingungsisolationssystem mit magnetischer D mpfung und Test beim Para belflug einer Rexus Rakete Aachen University of Applied Science 4 Rudolf Vetter Andreas Gierse Michael Lauruschkat 2009 Student Experiment Documentation for VibraDamp on Rexus 7 b Stefan Kr mer
103. iel l nger als erwartet technische Daten aus dem Orbit zur Erde Das Studierendenprojekt Ist Testfeld f r verschiedene neue Technikkomponenten deren Haltbarkeit und Leistungsfahigkelt Im Orbit untersucht werden Nach dem erfolgreichen Anlauf des Studierendenpro jekts Dekommt der kleine Satellit nun Dald Gesell schaft Das Team plant und baut derzeit unter studentischer Projektleitung von Matias Bestard Jaume der im M rz Felix K nig abloste den Nachfol ger COMPASS 2 Dieser soll deutlich gr er als sein Vorg nger werden um Industrie und Forschung noch mehr Platz f r Ihre wissenschaftlichen Experimente zur Verf gung stellen zu k nnen erkl rt Jaume gt RX11_ADIOS_SEDv5 3_07October2013_Final docx sammeln in praxisnahen Projekten wertvolle Erfahrungen fur den Berufseinstieg 06 Page 111 advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH ADLR and SSC cooperation 16 TITELTHEMA STUDIUM INTERNATIONAL FORSCHUNG PERSONEN SERVICE FH AACHEN DIMENSIONEN 01 11 Schon Jetzt h tten zahlreiche Firmen und institute Ihr Interesse bekundet Auch die Technologie des Nacnfol gers soll komplexer werden Die Lageregelung wird erneuert das Kommunikatlonssystem verbessert und die Daten bertragungsrate erh ht Wir sind gespannt ob sich COMPASS 2 dort oben genauso gut schlagen wird wie sein Vorg nger sagt der studentische Projektleiter Doch zun chst m ss
104. iment will not have any special requirements belonging to the launch site An Ethernet cable connection to our computer an our own S M Simulator for testing are the only necessary electrical I F before P L assembly The I F to the service module for assembly hot test and flight as well as experimental time are shown in the following in 6 2 6 1 4 Strain gauges RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 79 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation The Strain gauges shall be mounted in three different levels of the rocket Therefore the chosen RX Modules shall have four 20 x 20 mm spaces left on the inner side of the structure The anodization has to be removed at these areas to provide clean surface and an optimized adhesion of the glue There is no space for the mounting of the amplifiers necessary The amplification and data acquisition will take place at the ADIOS Module EXP2 PCB Box Further information about the assembly are given in the document RX11 12_ADIOS_SGRP_vi x pdf 6 2 Electrical interfaces applicable to REXUS REXUS Electrical Interfaces Service module interface required Yes Number of service module interfaces 1 TV channel required no Up Downlink RS 422 required Yes Data rate downlink 38 4 Kbit s Data rate uplink 0 Kbit s Power system Service module power required Yes Peak power consumption 30W Average power consumption 23W Total power
105. in measurement Strain gauges and temperature sensors There will be 8 one axial strain gauges attached to two cross section areas of the REXUS rocket as outlined in Figure 2 They are measuring the strain in flight direction There will be 4 two axial strain gauges located inside the ADIOS experiment First rough estimations show that there will be a maximum deformation of 0 6 mm near the motor adapter Because the orientation of the rocket is not predictable there have to be at least two measurements of the strain at one cross section which are displaced by 90 to each other Because one measurement cannot be used to differentiate between bending and longitudinal excitations a second pair of strain gauges has to be used which are symmetrically with respect to the first two strain gauges attached to the structure To follow the oscillating deformations a second and third measurement cross section are required One will be inside of the ADIOS experiment and one should be near to the nosecone adapter Each strain gauge demands an amplifier The data of the strain gauges has to be temperature compensated Due to the high temperature gradient during launch and landing it is not applicable to use strain gauges in a full bridge configuration Hence the temperature compensation has to be outsourced as post flight activity For that the temperature of the structure has to be measured during flight There will be 2 temperature sensors at each cro
106. in ai Time Figure 8 shows motor separation seen as strain by a strain gauge In Figure 8 also the signal to noise ratio and low fre quent shifts can be seen very well Page 142 00000000000 advanced isolation on sounding rockets no vibrations good vibrations 5 2 Excitations and Eigenfrequencies The measured spectra are fragmented to the three phases ascent ji g phase and descent In all spectra at low frequencies the pink noise of the measurement system and the low frequent shifts due to temperature changes get visible 5 2 1 Ascent S Hr Ascent 100 50 500 1000 1500 Hz Figure 9 shows the spectrum of vibrations while ascent of REXUS 11 Compared to the spectrum at j g phase more energy at low frequencies is noticeable At this time only few experiments were active The electro magnetic pollution and therewith the noise can be considered lower than while u g phase This low frequent energy seems to be related to temperature shifts while ascent At higher frequencies two major responses around 600Hz and around 780Hz can be seen Those are simi lar in kind to the resonances measured during u g phase what leads to the assumtions of structural resonances Many narrow banded peaks are superposing the spec trum between 500Hz and 1000Hz These may be strains caused by aerodynamic loads As the simulation results did not allow any expecta tions all this events can not be related to a theory
107. in m 0 0310 Experiment expected COG t b d asap centre of gravity position Table 4 Experiment summary table 4 4 Mechanical Design The mechanical design is based on the design of the VibraDamp experiment oome aluminium parts will be replaced by CFC components to reduce mass During PDR the team agreed to use a 300mm RX Standard module to save approximately 0 9 kg on the structure additionally The chosen material for the carbon fibre reinforced parts will be a MD55 carbon fibre laminate with an anodized and vented aluminium honeycomb This material is space environment tested and certificated and will be processed in a qualified workshop Bulkhead MD 55 8 layer 1 AL honeycomb Locking mechanism MD 55 8 layer 1 3 AL honeycomb Table 5 Carbon fibre materials All mountings and threads in the laminate will be reinforced by AL Inlets with HeliCoils to avoid deformations of the honeycomb The sponsoring company ADCO is going to support the planning by consulting the structure responsible team members The principle of the locking mechanism as well as the mounting on the outer structure will not be changed because it is tested and worked properly on RX7 RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 35 gt advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH A DLR and SSC cooperation The electronic boxes attached on the FFED are going to be removed and the el
108. ired data shall be sent particularly via telemetry F 10 The control and DAQ shall work autonomously HX11 ADIOS SEDv5 3 07October2013 Final docx Page 16 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 2 2 Performance requirements 2 2 1 Acceleration Sensors EXP1 Verification of damped System FFED P 1 The two tri axial sensors need to measure accelerations with an accuracy up to 10 g P 2 The measuring range should be 2 g P 3 The ACC Sensor shall be resistant against static loads of launch 20 g EXP2 Determination of static loads P 4 The acceleration data shall be acquired with a sample rate of 200 Hz 2 2 2 Strain gauges EXP2 P 5 Each strain gauge shall measure the strain with a sample rate of 4000 Hz and should measure with a sample rate of 16000Hz P 6 The strain gauges shall have a resolution of 100ue P 7 The strain gauges shall be calibrated for usage onto aluminium 2 2 3 Isolation P 8 The Isolation setup by magnets and springs shall reach an isolation of min 90 on the FFED 2 2 4 Electronics P 9 The Power consumption shall be in average beneath 1 A 2 2 5 Imbalance generator P 10 The imbalance generator shall give a defined vibration to the FFED RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 17 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 2 3 Design Requirements 2 3 1 Structure D 1 D 2 D 3 D 4
109. ith eddy current dampers the damping depends on the oscillations amplitude frequency and the distance between the magnets and the corresponding aluminium board A full description provides 2 3 VibraDamp 3 1 Experiment Setup Figure 19 VibraDamp Setup Figure 4 shows the mechanical design of the VibraDamp experiment 3 4 Located at the top of the module are the decoupling System and the free flying experiment Below the measuring and data acquisition system as well as the power supply were placed Three geared motors controlled by a National Instruments Computer actuated the decoupling System RX11 ADIOS SEDv5 3 07October2013 Final docx Page 125 no vibrations good vibrations EUROLAUNCH x DLR and SSC cooperation Six Kistler acceleration sensors measured the residual accelerations at the rockets structure and the inside of the free flying experiment 3 2 Experiment Results FFT x direction amplitude 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 frequency in Hz Figure 20 Fast Fourier Transformation of VibraDamp Data x axis up to 100 Hz Figure 5 shows the achieved reduction of acceleration amplitudes for frequencies up to 100 Hz Frequencies below 1Hz are reproduced faultily because of a used high pass filter This filter was necessary because sounding rockets without a rate control system revolve and overturn slowly during the ug phase A Adios The Team ADIOS
110. ke Elsschicht graben und auf Herz und Nieren gepr ft werden Dieses Mal m chten wir ein U mit dem Elsmaulwurf schmelzen und damit die Ruckf hrbarkelt nachwelserr erkl rt der studentische Projektmanager Clemens Espe der Im M rz Chang sheng Xu abl ste Damit wir zeigen k nnen dass die teuren Messinstrumente die wir f r Wissenschaftler und Unternehmen mitnehmen auch wieder an die Oberfl che kommen Zudem laufen derzeit verschle dene Forschungsantrage Angedacht sind unter anderem Untersuchungen zum Nachwels sogenannter Neutrinos Da die neutralen Elementartelichen nicht zu sehen sondern nur zu h ren sind k nnten mithilfe des IceMole akustische Sensoren tief im Els versenkt werden Eine weitere Mission k nnte In der Arktis stattfinden Staubkorngro amp e Mikrometeoriten regnen permanent auf die Erde Die Untersuchung dieses kosmischen Staubs gibt wertvolle Einblicke In die Entstehung unseres Sonnensystems Da das arktische Els sehr sauber Ist eignet es sich besonders gut um mithiife des IceMole diese Teilchen zu sammeln um sle sp ter zu untersuchen Die FH Aachen hat es mit Ihrer anwendungsorientier ten Forschung und Ihren zahlreichen Studierenden projekten geschafft Immer welter In die Tiefen des Kosmos vorzudringen Ein gr o er Wunsch steht Jedoch noch aus Der Bau einer eigenen Rakete sagt Stefan Kramer studentischer Projektielter Im Projekt REXUS Eln Traum der schon bald In Erf llung gehen k nnte
111. le and shows clearly the difference between the undamped bright blue and the damped deep blue system The strong signal at the end of the timeline is erected by the run of the imbalance simulator RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 87 EuroLauncH A DLR and SSC cooperation ganan 10000 0000 A SUUUU 40000 50000 eu Index Figure 11 Filtered and unfiltered Signal of the X Axis ACC HX11 ADIOS SEDv5 3 07October2013 Final docx Page 88 EUROLAUNCH ADLR and SSC cooperation Mm zu 3 0 03 rnnn 0 025 0 02 0 015 0 01 18 Frequency1 cina 0 15 0 05 f AS o A gt Frequency Figure 12 Fourier Transformation of the filtered Signal 7 3 2 Experiment 2 The following data was determined by a numerical simulation to compare it with the measured flight data After mode superposition Extrema for deformations caused by longitudinal vibrations e Maximum at L 2 3 5 m inside of service module gt Minimum at L 4 8 m nosecone gt Two other extrema inside of rocket motor e Extrema for deformations caused by bending vibrations gt Maximum at L 3 2 m recovery module gt Minimum at L 4 4 m Romulus HX11 ADIOS SEDv5 3 07October2013 Final docx Max Deformation Page 89 EuroLauncH A DLR and SSC cooperation ongitudinal Bending 0 0 75 1 50 2 25 2 99 3 72 4 44 5 18 Length m Figure 1
112. ls EXP1 70s on 320s off start of data acquisition 29 sensors are switched on 80s on 320s off start of experiment unlock locking mechanism Relocking must be finished at least 10sec before parachute opens EXP2 10 seconds before ignition start of experiment 1 seconds after impact end of experiment e Power The ADIOS experiment is completely supplied by the REXUS service module An application of batteries is not necessary e Up and downlink An uplink to the ADIOS experiment is not needed The amount of collected data will be too much to transmit it in total to ground There is no possibility to filter the data in real time to send a preselected data package to ground The ADIOS experiment data will be stored in total on the build in storage of the cRIO Status information of the sensors motors and power supply will be sent and processed in real time on ground to have the actual status of the functions of the experiment during the flight time 4 3 Experiment Components The following table shows a rough estimation of the weights and size In particular the single parts with more accurate information according the weight are shown in APPENDIX D RX11 ADIOS SEDv5 3 07October2013 Final docx Page 34 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation Experiment mass in kg ca 14 kg Experiment dimensions in m 0 3120 Experiment footprint area in m 0 0995 Experiment volume
113. m has to be tested project management must be discussed with your project manager and a proper solution must be found PDR Result conditional pass Pass is given upon the condition that an SED is resubmitted including all PDR information required taking into account the PDR comments and developing a proper project plan Next SED version due 30 March 2011 Source 1 PDR Minutes by the Review Board HX11 ADIOS SEDv5 3 07October2013 Final docx Page 102 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation REXUS BEXUS Experiment Critical Design Review Flight REXUS 1 1 Payload Manager Mark Fittock Experiment ADIOS Location DLR Oberpfaffenhofen Germany Date 10 06 201 1 1 Review Board members Adam Lambert ESA Paul Stevens ESA Marcus Hoerschgen DLR Markus Pinzer DLR Frank Hassenpflug DLR Frank Scheurpflug DLR Andreas Stamminger Chair DLR Tobias Ruhe DLR Mark Uitendaal SSC Nils Hoeger DLR Mark Fittock MoM DLR 2 Experiment Team members Dominique Daab Vladimir Klassen Stefan Kraemer 3 General Comments SED o Filename and mission should refer to RX 11 Change Record should be updated When referring to EuroLaunch this is only DLR and SSC DLR Space Agency has changed name to DLR Space Administration Need to include overall schematic in the appendices just include all schematics o Need to be very careful in the documentation that you can clarify whi
114. n box Motors The three motors of the VibraDamp experiment have worked very well that we decided to use this type again These motors are supplied by one of the 9505 modules of the CompactRIO The used motors are provided by Maxon Motors The details are listed below A max 26 12V max 4W Model 110173 GP26B Planetary gear Model 144044 An additional motor which is supplied by the second NI 9505 module of the CompactRIO drives the imbalance generator RX11 ADIOS SEDv5 3 07October2013 Final docx Page 53 7 advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH ADLR and SSC cooperation Picture 28 Motor FFED Limit switch To switch off the motors which drive the locking mechanism a limit switch is mounted on the structure An Omron D2F 01D3 ultra sub miniature basic switch is used To verify the surviving of the switch during the liftoff it will be tested on the shaker and in the vacuum chamber During the liftoff phase the limit switch doesn t have any function Thus there is no effect on the experiments when it switches while launching of the rocket This type of switch is recommended for the use in CUBE SAT s Picture 29 Limit Switch Circuit board components For the VibraDamp experiment several electronic components were already tested in a vacuum chamber Those components will be used on the ADIOS experiment as well Components which are different to the VibraDamp expe
115. n University of Applied Sciences invented a platform as free flying experiment container This platform is theoretically able to decrease the influences of the residual forces onto the contained experiment down to five percent The technical design of the VibraDamp project working on the eddy current principle achieved a damping of up to 85 for peaks and 65 on average The major goal of AD OS is to increase the average damping and hence to increase the quality of the u gravity by design improvements of the platform During the reduced gravity flight phase the experiment container is uncoupled and free flying The container is damped by small neodymium magnets The first eigenfrequency of the container is given by the adjustment of small beam springs During launch and landing the container is securely locked to avoid damage onto the experiment The secondary goal is to decrease the mass of the platform by using carbon fibre reinforced materials A lower mass of the platform yields in a longer reduced gravity phase due to a higher altitude of the ballistic flight Additionally the mass of the contained experiment could be extended The big advantage of the AD OS platform is the easy adaption to a broad range of different types of experiments with demanding requirements to the quality of u gravity The damping system can be easily adjusted to the Experiment Container i a 2 a Bulkhead with power supply and Data Acquisition Locking M
116. n a REXUS modul it was decided to test strain gauges in a constant current design due to the advantages of e small size of sensors and PCBs e insensitivity against electromagnetic pollution and long cables e cheap prize The tests showed that already the warming up of the mo dul structure due to vibrational energy was sufficient to drift the sensors signals out of the chosen measurement range within 10 seconds The design was extended by a DC decoupling and temperatur sensors in all three levels and therewith tested sucessfully U to strain gauge Figure 3 shows the circuits principle of a constant current source filtering and amplification Lis 4 3 Flight hardware All electrical parts were manually assembled The measurement system consisted of 20 channels on four PCBs and a NI cRIO computer system For wiring shiel ded twisted pair signal cables were used which were grounded on both ends of the cable to the rocket struc ture Figure 4 channels shows one PCB containing five measuring Page 141 advanced isolation on sounding rockets no vibrations good vibrations Figure 5 shows the bulkhead of the ADIOS ezperi ment with cRIO computer and all PCBs of the modal analysis measurement system Figure 6 shows strain gauges and a temperature sen sor to the right appliqued to a modul Also the electrical grounding of the cable shield can be seen 4 4 FEM recalculation of new flight c
117. n be isolated typically Active systems often require much space and power 3 1 1 Active Rack Isolation Rack isolation systems can provide an nearly undisturbed environment for a whole experiment rack This leads RX11 ADIOS SEDv5 3 07October2013 Final docx EuroLauncH A DLR and SSC cooperation to a voluminous design on the one hand and gives the opportunity to change the experiments and further use of the isolation system on the other hand The Active Rack Isolation System ARIS developed by the Boeing Corporation was already tested on the ISS These ARIS racks are dynamically controlled by closed feedback loops around inertial sensors and voice coil rotary actuator pushrods which connect the rack and the space station structure 2 The motions of the ISS and of the rack are measured by accelerometers That data is used for the ARIS control algorithms 3 1 2 Active Payload Isolation Payload isolation systems increase the 1 2 level for a sin gle experiment hence the system have fixed optimised de sign parameters e The Suppression of Transient Accelerations By Lev itation STABLE developed jointly by NASA Mar shall Space Flight Center MSFC and McDonnell Douglas Aerospace Corporation MDAC now the Boeing Corporation The system consists of three actuator assemblies nine acceleration sensors three position sensors and the associated electronics and control boards Control algorithms are used to oper ate t
118. n box PCB1 RS232 converter PCB4 A RS232 module is used to provide the communication between the REXUS service module and the CompactRlO s serial interface The circuit of the converter was found on http www amateurfunkbasteln de rs485 rs485 html Power 5 25 3 4 9V RS232 to RS485 Konverter x3 halbduplex by DL1DMW un 12V L GND TU 4 5 G Ew B CS C10 x1 Q E tu 1 003 c GND A 14 s T2 AN ZOUT MAXASICPA R2OUT RAN 74H MAX232 A ICAA GND Sub D Suchse GND GND Schematic 2 RS232 converter PCB4 RX11_ ADIOS SEDv5 3 07October2013 Final docx Page 52 e advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation CompactRIO The CompactRIO has several modules Module NI 9505 drives the motors for the locking mechanism A second Module 9505 drives the motor for the imbalance generaior The two modules NI 9206 are the interfaces between the CompactRIO and the acceleration sensors as well the strain gauges 2g tri axial sensors Every sensor needs its own circuit board PCB2 To provide short ways for the unamplified signals the circuit board is situated next to the acceleration sensor The sensor measures in three axes Every axis has its own data channel Therefore the circuit board is realised with three measured data amplifiers The two sensors are powered by one Traco TEN 20 2423 DC DC converter which is located in the junctio
119. n sounding rockets no vibrations good vibrations EUROLAUNCH A DLR and SSC cooperatio 3 2 4 External Support The TEAM ADIOS is deeply grateful for the support given by the following companies A realisation of the ADIOS project would not be possible without their soonsoring Thank you all FH Aachen The application for the FH Aachen internal commission for education and studies was successful and the team ADIOS will be supported with an amount of 5000 for the year 2011 Additionally the FH Aachen will partially finance the participation fees and travel cost for the ELRGA Symposium European Low Gravity Research Association in Antwerp Belgium in September 2011 for three students FH AACHEN FH Aachen Lehrwerkstatt opecial thanks goes to the Lehrwerkstatt for the fast and uncomplicated cooperation by building structural parts for the ADIOS experiment ADCO Advanced Composites The directors of ADCO assured ADIOS to provide the carbon fibre composite parts for the experiment under ACC C the condition of practical support by the team For the ADCO sponsor it is important that the team gains experience with the material TRACO Electronic TRACO TRACO supports the team ADIOS with two free POWER TRACO s amounting to 90 for the power supply unit POWER KNIPEX Pliers The Knipex Company is providing a Four Mandrel gt Crimping Plier for turned D Sub connector pins as a KNIPEX permanent loan Th
120. ng the interfaces for the ACC PCB and the junction box The EXP2 PCB Box contains the four PCB s for the amplification of the strain and temeperature measurements The design will assure the easy access to the PCB s for calibration and test It is mounted to the bulkhead by six M5 screws in Picture 13 EXP2 PCB Box Picture 14 Bottom view of the Bulkhead with PCB Dummies HX11 ADIOS SEDv5 3 07October2013 Final docx Page 39 d advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH A DLR and SSC cooperation Picture 15 Bulkhead with cRIO and EXP2 PCB Box The cRIO is mounted to the EXP2 PCB Box and reinforced by a aluminium belt which is fixed on the bulkhead The Belt also avoids a loosening of the NI Modules of the cRIO 4 4 4 Arm plugs For the Arm plugs the RX Module needs to be processed for a hole of 40 mm x 24 mm The connector will be mounted from the inside to the wall and closes the hole A 9 Pin D Sub will be used as an Arm plug which can easily assembled and disassembled to the experiment HX11 ADIOS SEDv5 3 07October2013 Final docx Page 40 advanced isolation on sounding rockets no vibrations good vibrations EuroLAuncH A DLR and SSC cooperation Picture 16 Arm plug interface Picture 17 Arm plug interface front view HX11 ADIOS SEDv5 3 07October2013 Final docx Page 41 EuroLAauncH A DLR and SSC cooperation Picture 18 Arm Plug interface wit
121. nlocking 4 sec after Tscobe deployment for reduction of oscillation 21 T 105 TV Channel Tscobe gt Caru 22 T 105 ADIOS untocking complete 15 secs after SOE 2371 117 CaRu SOE 2 secs after ADIOS unlocking complete 24 T 139 81 11 Apogee 25T 170 ADIOS imbalance generator on TBC 40 secs before locking for imbalance generator min 30 s 26T 210 ADIOS SOE deactivate locks FFED must be done with less than 1g 27 T 220 2f 1 220 TV Channel Caru gt Tscobe O O 281 25 amp xTsobeExpSOE Tscobe Exp SOE jettison 23T Tscobe hatch closing 30 T Tscobe pyro hatch power off Safely before reentry 31 T 247 TV Channel Tscobe gt Recov 32T 247 26 Maximum Decelleration IRTE 251 16 Start of subsonic flight 34 T 4 6 Heatshield stab chute activation amp beacon activation 35 T 3 9 Stab chute dereefing 36 T 3 0 Main chute activation 37 T 1 7 Main chute dereefing 38 T 600 0 6 Experiments Power Off not incl ADIOS 39 T 1000 0 6 TM TV Power Off 40 T 1000 0 6 ADIOS power off If experiments are powered off without completing launch sequence RAIN must reset status with uplink Table 19 RXS 11 Timeline RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 86 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation 7 2 Launch Campaign For the ADIOS Team the Launch Campaign was very successful For the Launch five students were able to attend the campaign sponsored by DLR and FH Aachen
122. ns E UROLAUNCH A DLR and SSC cooperation 14 Team Details 1 4 1 Contact Point The Team ADIOS can be contacted REXUS fh aachen de ADIOS on REXUSOqmx de advanced isolation on sounding rockets no vibrations good vibrations Phone 49 0 1 6 61261739 Picture 2 ADIOS Logo FH Aachen Fachbereich 6 Luft und Raumfahrttechnik Studierendenprojekt ADIOS Hohenstaufenallee 6 Room 02105 Aachen Picture 3 URL 92064 Aacne Link to ADIOS NRW Germany Website Name E Mail Phone Stefan Kr mer Stefan Kraemer alumni fh aachen de 49 176 61261739 Brigitte S M ller Brigitte Mueller alumni fh aachen de Dominique Jonas Daab Dominique Jonas Daab alumni fh aachen de Lysan Pf tzenreuter Lysan Pfuetzenreuter alumni fh aachen de Vladimir Klassen Vladimir Klassen alumni fh aachen de Joana Hessel Joana Hessel alumni fh aachen de Fabian Baader Fabian Baader alumni fh aachen de Tobias Wagner Tobias Wagner alumni fh aachen de Georg Gdalewitsch Georg Gdalewitsch alumni fh aachen de Johannes Stahl Stahl johannes alumni fh aachen de Andreas Gierse Andreas Gierse dialup fh aachen de Table 1 Contact details of the Team members RX11 ADIOS SEDv5 3_07October2013_Final docx Page 11 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation 1 4 2 Team Members Stefan Kramer B Eng Project management Structure Science 1 Semester Astronautical Engin
123. nuar 2011 10 25 Zu den Sternen Rubrik News Von Ruth Bedbur FH Stud ierende e di ERE mit Raketen unter Raumfahrtbedingungen Im M rz 2010 st die REXUS 7 bei Kiruna in Nordschweden gestartet DLR Torbj rn Sundberg Einmal bei einem echten Raketenstart dabei und direkt daran beteiligt zu sein das ist der Traum von vielen Luft und Raumfahrtstudierenden F r Stefan Kr mer Lysan Pf tzenreuter Nick Daab und Brigitte M ller von der FH Aachen geht dieser Traum bald in Erf llung Sie d rfen am REXUS Programm teilnehmen das Studierenden aus dem Luft und Raumfahrtbereich erm glicht wissenschaftliche und technische Experimente auf suborbitalen Raketenfl gen unter kurzzeitigen Weltraumbedingungen durchzuf hren REXUS Raketen Experimente f r Universit ts Studenten ist ein deutsch schwedisches Studierendenprogramm das von der European Space Agency ESA und dem Deutschen Zentrum f r Luft und Raumfahrt DLR erm glicht wird Die REXUS Raketentreibs tze wurden fr her zu milit rischen Zwecken am Boden und in der Luft eingesetzt erkl rt Diplom Ingenieur Engelbert Plescher vom Fachbereich Luft und Raumfahrttechnik der FH Aachen der die Studierenden bei diesem Projekt betreut und selbst schon gemeinsam mit dem DLR eine Messplattform entwickelt und auf Raketenmission geschickt hat Da die Entsorgung dieser Raketentreibs tze sehr teuer ist hat man sich f r diese alternative und sinnvolle Weiterverwendung entschieden D
124. o say where those maxima and minima are located To consider the different behaviour in different positions in one stage there shall be four strain gages applied equally distributed and displaced by 90 onto the structure In addition to the location of each measurement stage the position of the strain gauges in comparison to the zero degree mark has to be termed This will be based on the assembly of the ADIOS module Since mountings and bore holes in the structure falsifies strain measurement the strain gauges shall not be positioned at 0 120 and 240 There are the mountings of the bulkhead the free flying experiment device FFED and the motors Since the strain gauges are displaced by 90 the positions of 40 80 160 200 280 and 320 are no possible application position too To have the lowest possible perturbations the strain gauges shall be positioned at 20 110 200 and 290 Figure 3 shows the positioning of the strain gauges in one stage schematically Since strain measurement is always depending on the temperature of structure either the strain gauges has to be temperature compensated or the temperature has to be measured during flight to compensate the strain data afterwards It is not possible to compensate the strain gauges itself with the planned ICP measurement setup Hence the temperature at each stage has to be measured For that temperature sensors are applied to the structure next to the
125. ocncocnconcnnnononanooncnnnnncnanonnnnnnnos 64 Data Inte kac DO Based ee ede edi dde dd ee 68 Figure 10 Functional flow of ADIOS S W Fehler Textmarke nicht definiert RX11_ ADIOS SEDv5 3 07October2013 Final docx Page 96 EUROLAUNCH A DLR and SSC cooperation Figure 11 Mode superposition for REXUS 11 Maximum deformations over length Of the rocket ccccceccceecceeeeseeeceeeceeeeseeeceueceueeseeesaueeeueeseeeseeeseueeaeeesaess 89 Figure 12 Figure 13 Figure 14 Picture 1 Picture 2 Picture 3 Picture 4 Picture 5 Picture 6 Picture 7 Picture 8 Picture 9 Picture 10 Picture 11 Picture 12 Picture 13 Picture 14 Picture 15 Picture 16 Picture 17 Picture 18 Picture 19 Picture 20 Picture 21 Picture 22 Picture 23 Picture 24 Picture 25 Picture 26 Picture 27 Estimated resulting strain in flight direction during launch phase 89 Estimated resulting strain in flight direction during landing phase 90 Estimated resulting strain in flight direction during launch phase 144 Overview ADIOS Experiment Platform 6 PIO SOO eee eos eones 10 URL Link t0 ADIOS WebSite 10 Team ADIOS 2002240022400 0220 nennn nenne nenne nenne nenne nenne nenne nenne nennen 12 Four Mandrel Crimping Plier 20022200224002000nnnn nenn nennen 23 Overview of the Experiment 00222000222000nenne nennen nenne nennen 30 Canle Feed TMoU al T90 tesi
126. on Especially the highly sensitive acceleration sensors and the required complex software solutions are an un economic factor Also the weights of the payload and of the payload supply systems are limited Hence a pas sive lightweight and simple vibration isolation system for sounding rockets which is also damping low frequen cies would be eligible 3 2 Passive Vibration Isolation Systems Passive systems often use the mass of an experiment plat form as the key element for the isolation of higher fre quencies Elements made of rubber or viscous materials are often used for damping purpose In view of a pas sive isolation system the advantages are obvious high reliability with no power consumption and usually less complexity Nevertheless the status after Whorton 3 and Grodinsky 2 assumes a high system mass and no pos sibility of decoupling lower frequencies and high ampli tudes without the problem of meeting the natural frequen cies of the damping system Additionally it is assumed that the decoupling by a passive system only works in one direction from the excited structure to the experiment The ADIOS platform mitigates all these constraints It works in both ways it decouples an experiment from an excited structure and it can also save the structure and other experiments from the influences by a vibrating sys tem A practical solution of a passive vibration reduction sys tem has been developed for the Advanced X Ray A
127. onducted test are stored in a folder on the BSCW server A list of the conducted tests and a protocol example is shown in APPENDIX C EXP1 The ACC Data will be processed by a data processing s w which calculates the total damping of the FFED in relation to the frequency The comparison of the data of the two ACC sensors is the basic of the calculations EXP2 The data determined by the strain gauges will be processed again ina special data processing s w Here the ACC data of the service module and the strains will be put into relation and finally compared with the ANSYS structural analysis RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 78 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation 6 LAUNCH CAMPAIGN PREPARATION 6 1 Input for the Campaign Flight Requirement Plans 6 1 1 Dimensions and mass Experiment mass k Estimation regarding carbon fibre parts ca 13 kg g Experiment dimensions m 0 3120 Experiment footprint area m 0 0995 3 m Experiment volume 0 0310 Experiment expected COG t b d asap centre of gravity position Table 16 Experiment mass and volume 6 1 2 Safety risks There are no safety risks known for the moment The experiment will not require liquids explosive batteries pyrotechnical devices or poisonous Or hazardous parts The moving parts are not accessible when the experiment is fully assembled 6 1 3 Electrical interfaces The ADIOS Exper
128. onfigura tion After spin and balancetest of the RExus 11 rocket it was decided that some experiment modules of the REXUS 11 and 12 had to be switched This reconfiguration changed the positions of the strain gauges Even more important was the effect on the Eigenforms Those changed mainly due to the recon figuration that the nosecone was not ejected Again the bending and longitudinal Eigenforms were calculated longitudinal 176 Hz 494 Hz 364 Hz 956 Hz Table 1 shows the calculated Eigenfrequencies RX11_ADIOS_SEDv5 3_07October2013_Final docx EuroLAauncH A DLR and SSC cooperation Figure 7 shows the final configuration of the RE XUS 11 payload and the first two bending Eigenforms of the new configuration and the new positions of the three strain gauge levels In the new configuration the second level is close to the third level Therewith the strain amplitude ratio is at all bending Eigenforms close to 1 It was clear before flight that with this configuration the verification of the Eigenforms was going to be very difficult if possible at all 5 RESULTS The system worked during the hole flight and recorded about 75 10 datapoints Short after the end of microgravity time the cRIO system changed channels for no known reason Still all data was relatable 5 1 Events Several events like motor separation and deployments of payload parts were measured qualitatively by the strain gauges a ye Stra
129. ons inside the FFED The first 20 seconds of experimenting time are superposed by the capacitor influence of the amplification board and are ne glected here Nevertheless it is obvious that the red graph reveals the slow movements Hz of the rocket Page 136 dvanced isolation on sounding rockets a no vibrations good vibrations gl 1 2x10 1 0x10 I 0 8x10 0 6x10 0 4x10 0 2x10 0 l W i 0 2x10 10 20 30 40 50 60 70 80 0 4x 107 0 6 x 10 Figure 8 Unfiltered acceleration signals of the flight axis as a result of REXUS 11 test flight RED undamped rocket structure GREEN decoupled experiment con tainment payload during the phase of reduced gravity This has been triggered due to the motor separation and the ab sence of a rate control system The higher amplitude of the high frequency vibration at the end of the graph indi cates the run of the second stage fercitationrr 34 Hz of the imbalance generator The first and third stage are just recognisable after Fourier transformation of the data In the time after about 60 s the movements of the rocket payload section became stronger and the FFED followed the higher amplitude of low frequent agitation At these amplitudes a contact between the FFED and the structure of the locking mechanism could not be ruled out Figure 9 exhibit the processed data by Fourier transfor mation which point out that the forced excitations
130. ooncnanonncnnnanonnnonnnnnnanonnnoss DO Thermal operating ranges of electrical and structural components 65 Power consumption ADIOS experiment eeesssee 66 Verification table oooccconccccnicocncocnoconococononnononononnnnonononnnonnnnanenanoss 73 O ee ii A 74 BWC IN aaa 74 Thermal Environmental TesSt coocccoccccccocncccnconocononononnnnncnnanonos 75 Fonciona Sensor Test ae 76 Functional Electronic Test ooccconcconcccncccnconnconocanocanononcnnonanenano 76 Functional Test Assembled Mode 77 Experiment mass and volume uu2240220002000nnnn nenn anne nnnn nenn nenn 78 Electrical interfaces applicable to REXUS 80 Timeline for countdown and flight cocooccccocnccocncconnccnonnnnanoss 83 SMASSTEALCUON NS nennen 154 SAN SUF CUM RTT 13 Application of the strain gauges onto the structure 18 Work breakdown structure of ADIOS status 23 November 2011 19 preliminary time schedule cooccccocnccccncoccnncocnccnnncnnnnccnnncononoss 28 Structural levels ooccconcconncconncocnconnccornnonnconrncnrnonnnocnronornconnnnnnnos 44 Block diagram ADIOS experiment ooccccoccncccccncccccnccnncnnonacnncnacnnnnns 48 Overall schematic ADIOS experiment electronics 49 Block diagram Arm plugs ccoocccocncccccc
131. opment of the VibraDamp Project launched on RX7 in March 2010 The goal is to measure the performance of the developed passive isolation by the comparison of the accelerations on the damped system and the rocket structure The secondary part EXP2 is the practical verification of a numerical analysis of the loads and forces acting onto the rocket structure during the whole flight time Due to the loads tensions shall be measured at different interesting points on the structure like motor separation level nose cone and centre of mass RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 9 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 1 3 Experiment Overview The ADIOS experiment is divided in two parts EXP 1 and EXP 2 EXP 1 contains following hardware e FFED including magnets and springs e Locking mechanism including three servo motors clamping rings and limit switches e wotri axial acceleration sensors EXP 2 contains following hardware e 12 strain gauges and amplifiers 8 one axial and 4 two axial strain gauges e 6 temperature sensors for temperature compensation of the measured strain Both experimental parts will fit into a 300 mm REXUS module The data acquisition DAQ the control of the locking mechanism and the communication with ground are going to be handled by a real time controller HX11 ADIOS SEDv5 3 07October2013 Final docx Page 10 no vibrations go od vibratio
132. out EXP2 PCB3 4 5 4 Arm plugs To ensure a soundly active experimental procedure during flight it is necessary to pass some passive test runs on ground before It is therefore of crucial importance that the ADIOS experimental module can be placed safely into an armed und disarmed mode This determination will be implemented by using three different types of arming and disarming plugs HX11 ADIOS SEDv5 3 07October2013 Final docx XX Page 63 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation 1 The flight plug has to be assembled before flight and closes the power connection to the service module All dynamic systems are set to active The defined experimental procedure can be actually performed 2 The test plug is used for ground testing in horizontal condition All dynamic systems are set to inactive In this way the free flight experimental device FFED will be still fixed by the closed locking mechanism and take no damage during the bench test in the final assembled status under gravity The defined experimental procedure will be performed in virtual simulation 3 The transport plug will be used for the transport to Kiruna as well as after landing to open all power lines to the cRIO and to avoid an accidental reboot which results in a deletion of memory and loss of all data The technical implementation is carried out by a manual plug in mechanism with D Sub ports As the rocket during the test phas
133. overed by the rate control system of the sounding rocket system A combination with the ADIOS platform can reach g levels up to 107 g Transient events shocks are damped in the range of amplitude in which the FFED does not hit the surrounding locking structure 7 OUTLOOK The principle has been proofed and a practical applica tion would show the real worthiness of this system Nev ertheless the ADIOS system works well even for lower frequencies Now technologies of combined systems are in work to further improve the quality of j gravity for any kind of system ACKNOWLEDGMENT The authors would like to thank all responsible persons at DLR ESA and SSC concerning the REXUS Program A special thank goes to our industrial partners who pro vided material sponsoring and skills to realise the tech nical experimental hardware Also we like to thank our Professors and lecturers for mental assistance and advice and the FH Aachen for financial support REFERENCES l Lysan Pf tzenreuter Michael Lauruschkat Andreas Gierse and Rudolf Vetter Vibradamp Technical re port FH Aachen 2010 2 Carlos M Grodinsky and Mark S Whorton A Survey of Active Vibration Isolation Systems for Micrograv Page 137 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation ity Applications Technical report Bicron Corporation Newbury OH 44065 3 Mark S Whorton Microgravi
134. pares the dynamic mechanical behaviour of this system using viscous dampers green and active eddy current dampers blue A System with one degree of freedom has one eigenfrequency This eigenfrequency is characterized by a high magnification factor At frequencies higher than the eigenfrequency the amplitude of the Experiment decreases and finally is much smaller than the excitation amplitude This phenomenon is called decoupling Obviously the active eddy current damper allows an increased damping close to the eigenfrequency This results in a smaller magnification factor Even more important is the result that at higher frequencies a very good decoupling is achieved 2 1 Decoupling all axis To improve the existing ug environment all axes have to be mechanically decoupled Therefore three dimensional springs and dampers are necessary The dimensioning eigenfrequency should be as low as possible to achieve a decoupling even at low frequencies HX11 ADIOS SEDv5 3 07October2013 Final docx Page 124 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH n A DLR and SSC cooperatio Figure 18 Schematic of Eddy current damping system 1 Figure 3 obtained from 1 shows the patented decoupling mechanism of the TITUS II experiment The three dimensional springs are realised as bending and torsional beams while magnets are damping the experiment using the eddy current effect Working w
135. plications Here the decoupled experiment which can be an experiment of any kind itself is considered to be a single mass without own eigenfrequencies The eigenfrequencies of a real experiment set up are usually of much higher frequency than the eigenfrequencies of the decoupling mechanism what makes it possible to separate these two cases The decoupling mechanism restrains the energy from the outer structure to affect the experiment If the experiment itself includes sources of RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 122 no vibrations go od vibrations E UROLAUNCH A DLR and SSC cooperation mechanical vibrations these sources or the most sensitive parts of the experiment have to be decoupled separately Figure 16 Single mass system incl spring and damper Figure 1 shows a one dimensional decoupling mechanism one degree of freedom x consisting of a one dimensional spring a one dimensional damper and the experiment as a single mass The movements of the outer structure s are the excitation of the spring and the damper Spe n 2 5 Visco damping Visco D mpfung eddy current damping Wirbelstrom D mpfung transmissibility Durchl ssigkeit 0 5 10 10 10 frequency Frequenz Hz Figure 17 Estimated damping behaviour RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 123 no vibrations go od vibrations E UROLAUNCH A DLR and SSC cooperation Figure 2 com
136. prohibit any movements of the FFED during launch and landing D 4 There shall be easy access to electronic boards for maintenance and calibration D 5 Electronic access via Ethernet connector at assembled status The Experiment shall fit into a REXUS 300mm RT CAD Model Module ling D 7 To economise weight the locking mechanism Design shall be build from carbon fibre composites change The strain gauges should be mounted on the HX11 ADIOS SEDv5 3 07October2013 Final docx Page 73 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation inside of the outer structure application tests completed D 10 The Strain gauge setup shall be temperature Test Plan 5 compensated 1 EXP1 and EXP2 shall work independent from each other If one fails the other one shall not reviewed be affected seriously The Electronics shall be as simple as possible D 13 The electronic setup should be as light weight reviewed as possible 14 The Electronics shall cope with 28 V RTA Breadboard tests finished D 15 Power consumption needs to stay beneath3 A RT Test Plan 5 peak D 16 The sensors shall be temperature Test Plan 3 compensated The ACC Sensors shall be Shock resistant up BEEN O 1 The temperature of the structure shall not Passive under run 20 C thermal insulation O 2 The Esrange recovery crew should disarm the experiment with a transport plug Table 9 Verification table RT RT RT 5
137. r2013_Final docx Page 45 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation 4 4 7 Structural Analysis In the following pictures the results of the modal analysis of the critical parts and assemblies are shown The excitation is simulated by a random vibration with 20 Hz 20 000 Hz The pictures show the deformation The material is aluminium 1 0736e 6 Max 9 5435e 7 8 3506e 7 7 1577e 7 5 9647e 7 4 7718e 7 3 5788e 7 2 3859e 7 1 1929e 7 0 Min Picture 22 deformations of the FFED 0 200 m 0 050 0 150 Picture 23 Deformations of the LM bottom plate HX11 ADIOS SEDv5 3 07October2013 Final docx Page 46 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation 6 eb 5 0453e 6 3 3636e 6 1 6818e 6 0 Min 0 100 m 0 025 0 075 Picture 24 Deformations of the LM top plate 0 0 01 0 02 m 0 005 0 015 Picture 25 Deformations of the Motor mounting 0 000 0 020 0 040 m aS 0 010 0 090 Picture 26 Deformations of the Brackets RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 47 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation The results show that there will not be any critical deformations of the structural parts 4 4 8 Drawing Number System To keep an overview over the CAD parts and drawings a numbering system was invented The CAD parts and a
138. ramm REXUS LJ Die Rakete 3 Das Startgebset zur ck zu Luft und Raumfahrttechnik Alssolventenehrung Jahrgang 2010 11 Freitag 07 10 2011 ab 18h CHE Hochschulranking 2011 4012 Forschung amp Entwicklung im FB6 Montag 23 05 2011 14 Kaum 00201 FH Aachen international infoveranrtaltang am 18 Maschinenbau u Mechatronte 97 38 05 2011 FBG Masterstudium nformatioruweranstaltung 13 05 13 00 14 00h H rsaal 04114 Newsarchiv Suchbsgonff eingeben Page 107 advanced isolation on sounding rockets no vibrations good vibrations REXUS Rocket borne EXperiments for University Students Ist ein deutsch schwedisches Studlerendenprogramm das von der ESA European Space Agency und der OLR Raumfahrt Agentur des Deutschen Zentrums f r Luft und Raumfahrt erm glicht wird ADIOS ADvanced Isolation On Sounding rockets ist die weiterentwickelte Version des VibraDamp Experimentes welches erfolgreich auf der REXUS 7 2010 bereits geflogen ist In erster Linte handelt es sich dabel um eine passiv ged mpfte Experimententox Diese bietet Platz f r ein Mikrogravitationsexperiment welches gegen u ere St reinfl sse isoliert wird Die passive Isolierung basiert auf einer ber hrungslosen D mpfung nach dem Wirbelstromprinzip und einer Federeinspannung Das ADIOS Experiment ist f r den Betrieb unter reduzierter Schwerkraft wie sie beim Flug einer Hohenforschungsrakete auftritt ausgelegt Das Experim
139. rations good vibrations E UROLAUNCH A DLR and SSC cooperation Requirements and constraints O O expand on requirements number them full sentences expand on operational requirements there are many misclassifications Mechanics O O Qu X x O O difficult to judge there is not much description show the components in the pictures Single components should also be depicted Also a picture of the complete payload has to go into the SED detail how many boxes there will be in the E box and what are you going to place where Describe position and size of strain gauges hard to understand where the measurements shall be taken Suggest position for the strain gauges how big are they what are the electrical interfaces what do you expect to see on the strain gauges Simulations required what is the movement of the box 2 cm in radial direction feed through other experiment cables next to your module implement it already now bring your mass down not just say but act set a level for mass and make sure it will be below this level Provide a mass budget lots of good points where weight could be reduced holes in plates for example proposal of EXP2 sensor locations must be given to your project manager together with the SED resubmission consider possibility of using a 300 mm module Electronics and data management O O O OOO Thermal O Software O O O O O O QD x main part is comp
140. ri m Er d ert AA SA 1 Lc luii ETH rt emn an ee E eT D en f ccs one 17r RE FH 5 pl E prs mon sari B e DEN ERE a PA r ri md eve pog vanae 1 i nu I7 aes TE 3 REUS Guam DE Drg SUS e pc RT Pami p nmi suco n ttt Taa DAA dera 0 EEE wen DET EFE DT bam FE Bi m ma cere degna gt E HO AAA tag pa tar qu rc IT Lain mpeg FT Tr m wer Ar I Arg pele CT rr u m EE tite praa 1 17 ar ITE pm ee jus 17 EN nm IB cc ger En TFIT Saa D iz ee ER Ed miem w Hioc 12 wig rient per m ne eilt mm gell ete vera fl ret soma sona mn ni ere i CT KETTE a mL v Banana beu pins e C T2 F AT TE u 3 rri on ST Ge TT Arr EA sn all m ERE drum wire sed Y i Vaart wien rri auper E arpg E ri GER Erie re ae POTITI WEM rH tee Te Pd PA PE wate pb nn El rr OE st wer M ocr tomate A vay Seed pw T r 1 ra DEI cm e erg ol Substructure of WBS RX11_ADIOS SEDv5 3_07October2013_Final docx Page 155 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation 1 1 1 1 PDR Brackets 4 2 1 1 2 Sub D feed through mounting 1 1 1 1 1 V Post PDR 1 1 1 5 Launch Campaign 1 1 1 1 6 Final with results 1 2 8 was 11 3 Time Schedule 1 4 Budget 2122 m Interface to Electronics 2 1 3 Locking mechanism BEI atm res 2 1 3 4 B Limit S
141. riment were also tested in the vacuum chamber RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 54 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation Picture 30 Circuit board components during VibraDamp thermal vacuum test Circuit boards Printed circuit boards PCB The circuits are drawn in TARGET 3001 That program allows also a derivation of the electrical circuit to the layout of the PCB The PCBs will be produced and drilled Otto Junker GmbH in Simmerath Lammersdorf The assembly and the soldering of the PCBs will be at FH Aachen Circuit boards will have a 35um copper layer Connectors To link the several electronic components D Sub 9 Pin 15 Pin and 25 Pin connectors are used Turned pins which are crimped with the Knipex Four Mandrel Crimping Pliers will provide a secure connection To realise the connection from the acceleration sensors to the belonging PCB Harwin Datamate connectors Vertical PC Tail Reverse Fix are used The connectors are screwed directly on the PCB The Pin configuration of the connectors is specified at special documents Each connector has its own document which shows the gender the location and the function of the pins HX11 ADIOS SEDv5 3 07October2013 Final docx Page 55 s advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH ADLR and SSC cooperation D Sub 9 Pins Name gender location S female plug C Rio gt
142. rimente einwirkenden Ersch tterungen der Rakete mithilfe von magnetischer D mpfung und Federn le besser diese St rungen abgefangen werden desto genauer sind die sp teren Experimente sagt Stefan Kr mer studentischer Leiter des Projekts Zum anderen wird das Team die mechanischen und dynamischen Lasten die auf die Raketenstruktur wirken mithilfe von Sensoren untersuchen Mit den Ergebnissen soll die Raketenstruktur hinsichtlich Gewicht und Material optimiert und damit das Design von H henforschungsraketen verbessert werden Insgesamt zwei Wochen wird das siebenk pfige Team im Raumfahrtzentrum Esrange verbringen Dort treffen sie auf die anderen sieben Studierenden Teams um gemeinsam ihre Experimente flugtauglich zu machen und sie dann in der zweiten Woche auf insgesamt zwei REXUS Raketen zu testen Es ist toll Studierende aus anderen L ndern zu treffen die dasselbe studieren wie wir sagt Student Dominique Daab Und wer kann schon behaupten mal bei einem echten Raketenstart muss nur noch alles so klappen wie wir uns das vorstellen REXUS Raketen Experimente f r Universit ts Studenten ist ein deutsch schwedisches Studierendenprogramm der European Space Agency ESA und des Deutschen Zentrums f r Luft und Raumfahrt DLR das Studierenden erm glicht wissenschaftliche und technische Experimente auf suborbitalen Raketenfl gen kurzzeitig unter Weltraumbedingungen durchzuf hren Die Praxisbezugs im Bereich der Luft un
143. rings An effective stiffness of a spring is approximated by implicating the bending and torsion of the spring wire A spring design shown in figure 5 gives a similar stiff ness in all directions of freedom Using the stiffness cal culated as follows AF Ea 1 leads to the overall spring constant The single Az are calculated with the parameters Jp as moment of inertia in bending direction and p as mo ment of inertia in torsion direction and G represent Page 134 Figure 5 Three dimensional spring design the Young s modulus as well as the modulus of shear de formation X Ar 2 gt Dari P 1 gt N 2 AF L A in ee 3 and for small angles AF L Attonston uXcfs 4 Assuming a force acting in the direction of leg IIT the leg II reacts as a bending beam and leg I as a torsion spring Leg III is assumed to be rigid in force direction If the spring length is determined this way a practical length must be chosen The effective spring constant kapp is calculated with the set length 1 kef 9 18 5 Im op o SER REM Gs With the reduced mass of the FFED the natural frequency of the damping platform can be determined Bert TT Fa Yu e ON 6 f 2 T7T 2 7 6 4 3 2 Dimensionmg of magnets First the Lehr s damping coefficient need to be deter mined with 1 IV 7 using the maximal assumed magnification factor V HX11 ADIOS SEDv5 3 07October2013 Final docx EURO
144. rockets no vibrations good vibrations EuroLAuncH ration A DLR and SSC coope Strain and Temp 1 272 ms Strains 1 2 Temperatures PE fe Ae A Bee A A A A A EUER ini HL E E O PE EES D E HTB AA SI PARSIN K 4440 44 0 6 oat N rk bz sb Fu 0 4 3 EE AME HE E A 0 4 lij AT 0 2 411 Ht 024 FL m AI ARE B LIMIT 0 4 3 Y HAHN 0 444 FID H P FIN p Y AH os IL oe HAMA EU AI 0 8 44 1 H 0 8 T HESS Heec m Umum o eciam d Um 1 E Accelerations 1 3 Accelerations 4 6 Picture 40 Telemetry Software screenshot HX11 ADIOS SEDv5 3 07October2013 Final docx Page 71 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation 5 EXPERIMENT VERIFICATION AND TESTING 5 1 Verification Matrix Requirement text Veri fication EXP1 The experiment shall measure the ATR Test plan accelerations on the damped FFED during 1 4 reduced gravity phase using a tri axial acceleration sensor EXP1 The experiment shall measure the ATR Test plan accelerations on the undamped structure 1 4 during reduced gravity phase using a tri axial acceleration sensor F 3 EXP1 The damping system shall isolate the FFED from influences due to the rocket EXP1 The locking mechanism shall prohibit TA Test plan 1 any movements of the FFED during launch and landing EXP1 For verification the FFED shall be ATR Test plan excited by a defined imbalance in a broad 15 bandwidth of frequencies EXP2
145. routine is following shown as a block diagram Initialisation SOE ON received Open Locking Mechanism Power on de ech alc tc T Start acceleration DAQ Start timer for Start Sending acceleration imbalance generator boot sequence Run FPGA VI Configure serial port Stop Sending acceleration Close Locking Mechanism Configure FIFOs open files Wait for LO The LO signal is required for starting the Strain Temp measurement and calibrating the internal clock Acceleration DAQ starts with SOE ON after unlocking the FFED When the Test Plug is installed the software will simply skip the unlock lock action so nothing will get stuck in the final tests in horizontal orientation after assembly For a simulation time of 1000 s the data volume is approximately 0 66 GB 16000 Hz strain measurement 800 Hz acceleration measurement The data volume for the planned experimental setup for 1000 s measurement of strain and temperature and approximately 160s measurement of acceleration will be as follows e 16 strain gauges 0 4768 GB e 6 temperature sensors 0 1788 GB e 6 acceleration sensors 0 0003 GB RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 69 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation Sum 0 6559 GB Since the data volume of the cRIO memory is about 2 GB it is necessary to replace files during flight It is not necessary to have manual access to the
146. rts soldered on the electronic boards The second one is to proof the function under the changing circumstances from ambient pressure down to vacuum 5 2 3 Thermal Environmental Test Test type Thermal test Test facility Laboratory for space technology FH Aachen 1 Tested item Electronic boards Strain gauge amplification Acceleration amplification Power supply cRio Motors COTS RS 232 to RS 422 Test level Qualification 30 C up to 60 C Test campaign duration Table 12 Thermal Environmental Test Regarding the very small expected signals it is very important to Know the behaviour of the amplification boards as well the power supply under changing environmental conditions 5 2 4 Functional Sensor Test Test type Functional test Acceleration Sensors Test facility Laboratory for fluid dynamics FH Aachen Tested item Test of ACC sensors on a pendulum for calibrating Filters and Amplifiers Test level 1g 2g Test campaign 5 h duration RX11 ADIOS SEDv5 3 07October2013 Final docx Page 76 no vibrations good vibrations EuroLauncH A DLR and SSC cooperation Table 13 Functional Sensor Test To test the function of the ACC Sensors they will be mounted to a pendulum The acceleration can be measured in the single axis The sensors will be calibrated by the manufacturer For the calibration and test of the strain gauges the first test items have been placed on the VibraDamp RX7 Module
147. s 31 o ee 31 Locking mechanism and FFED ccccsececeeeceeeeneeeceeeeeueeneeenees 36 Motor and attachment ccccccecceseeeeceeeeseeeeeeeeseseeseeeeseeeseeeas 36 SF WAU AC C CI SON nennen nenne 37 MO a HO 37 DAA o A o 0 O 38 Bottom view of the Bulkhead with PCB Dumnmies 38 Bulkhead with cRIO and EXP2 PCB BOX ccccooccccccoccccccocccnocononnnos 39 SARA DIO WUT AC siria 40 Arm plug interface front view ooccoccccccncccnconcccncnnnnnonanonnnonnnnonanonos 40 Arm Plug interface with cover ccccscccsecceeeeceeeseeeceeeeeeeeseeesees 41 Old and new design of the LM aluminium rings 42 tAltemanve S POLES AA een 43 Mounting of locking MECHANISM ccccceeeceeeeceeeseeceeeeneeeseeeeees 43 deformations of the FFED cccccccseccceeeeeeeeeeeeeseeeeseeeeeaeeeeas 45 Deformations of the LM bottom plate 45 Deformations of the LM top plate sssseeuesesssessss 46 Deformations of the Motor mounting seessssuussss 46 Deformations of the Brackets ccccscccsscceseeceeeceeeseeeeeseeseeesees 46 layout junction box PCB1 occoccccnccnccccncnccnconcncnncncnacncnncncnncnnnnoos 51 RX11 ADIOS SEDv5 3 07October2013 Final docx Page 97 EuroLaunch 53 A E q 53 Pic
148. scher himself has participated the MAPHEUS 01 Program of the DLR providing the RAMS experiment He also was responsible for several parabolic flight experiments 3 2 2 Workload The following table shows the possible workload which can be done in a week by each team member Team member Field of work Estimated workload h week Stefan Kramer Management Structure Brigitte Miller Outreach Website 104 Management assistance Lysan Pf tzenreuter Science Programming 25h from 1th June 2011 Table 2 Possible workload of each team member HX11 ADIOS SEDv5 3 07October2013 Final docx Page 21 no vibrations good vibrations EUROLAUNCH peration A DLR and SSC coo 3 2 3 Budget Following an estimation of the budget needed for the successful realization of the ADIOS experiments Phase On Stock RX 7 VibraDamp 2000 Provided by External RX Module Internal Carbon fibre composite parts Locking 800 Mechanism Magnet 200 holders Acceleration 6x Kistler On Stock 2x out of RX 7 order VibraDamp 2x ASC tri 3500 DLR axial 29 ordered Strain 691 Sponsored gauges by HBM Dao wem Storage c Rio Modules 1300 Amplifiers Filters 1500 Office Outreach PR Print paper 500 supplies Posters Stickers costs Table 3 Budget list of parts C C D C D A E RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 22 advanced isolation o
149. ss section The sizes of the train gauges are very small and the required space for the wall application will not exceed 20mm x 20mm for each measuring point The cables will be assembled to one cable harness which leaves the module HBM manufacturer and sponsor of the strain gauges provided us a package of 10 x 120 Q linear strain gauges for testing the application and function of the amplification These strain gauges will be tested at the VibraDamp REXUS 7 Module The actual size of the strain gauges is shown in the following pictures HX11 ADIOS SEDv5 3 07October2013 Final docx Page 59 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation Picture 34 linear strain gauge 350 O Picture 35 T rosettes strain gauges 350 Q RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 60 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation Picture 36 Temperature sensor 350 Q Picture 37 linear strain gauge for testing 120 Q RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 61 N advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation Picture 38 strain relief for cabling A detailed introduction to the assembly is explicitly shown in APPENDIX C in the document RX11 ADIOS _SGRP_v1 6 paf 14 Schem
150. ssemblies will be archived in folders of levels of the structure The single parts will have version numbers to easily identify status of progress and changes Because of the evaluation of weight the materials of the different parts are named in the system RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 48 o advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation 4 5 Electronics Design The ADIOS experiment consists of two different experiments The first experiment EXP1 verifies the quality of the damping system EXP 2 will measure the loads and forces which affect the structure of the rocket during the whole flight 4 5 1 Block diagram of the ADIOS experiment Bulkhead FFED damped system Figure 6 Block diagram ADIOS experiment RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 49 EUROLAUNCH A DLR and SSC cooperation Figure 7 Overall schematic ADIOS experiment electronics 4 5 2 EXP1 The accelerations are measured by a tri axial acceleration sensor on the FFED and by an identical sensor on the structure The measured data are stored in a CompactRIO module To drive the locking mechanism three motors are required An additional motor will be mounted on the FFED to drive a defined imbalance The motors are driven by the CompactRIO module NI 9505 Electrical Components Junction box The interface between the REXUS servic
151. stro physics Facility AXAF 4 The goal was to decrease the influence by g jitter induced by the reaction wheels of the space craft 4 TECHNICAL REALISATION In order to achieve the goals of a high sensitive decou pling without the use of active devices which consume energy during action the principle of the eddy current damping was first developed to damp the TITUS II Ex periment on the MIR space station The working princi ple has been patented by the DLR in 2002 5 4 1 Fundamentals of Mechanical Decoupling A mechanical decoupling system which is the same as a flexible machine bearing consists naturally of springs and dampers Both springs and dampers can be en gineered in various designs for different applications Here the decoupled experiment which can be an ex periment of any kind itself is considered to be a single mass without own eigenfrequencies The eigenfrequen cies of a real experiment setup are usually of much higher frequency than the eigenfrequencies of the decoupling mechanism which makes it possible to separate these two RX11 ADIOS SEDv5 3 07October2013 Final docx T Ly EuroLruncH A DLR and SSC cooperation 3 TTT TTTT Try T 25 4 Visco damping Fi Visco D mpfung 2 c 203 3 j a gt 15 4 L eddy current damping un SAA P BG 4 er a 1 mM Wirbelstrom D mpfung q Z un ci E 05 10 10 10 frequency Frequenz Hz Figure 1 The magnifica
152. t could solve the problem if the cRIO operation temperature increases above 50 C Furthermore there are the working temperature ranges of the major components as well as the critical temperatures shown in the following table RX11 ADIOS SEDv5 3 07October2013 Final docx Page 65 no vi brations good vibrations E UROLAUNCH A DLR and SSC cooperation Component Operating range Critical temperature 40 C to 70 C High temp due to Needs to be operation tested possibly critical Strain gauges Up to 200 C Higher than 250 C Temp Sensors Sensors 50 50 C to 180 C to 180 Cl Rate gauges Ei to 280 glue ACC Sensor 20 C to 85 C Temp below Ambient temp 20 C during Flight phase not critical no contact to hot outer structure Table 7 Thermal operating ranges of electrical and structural components 4 7 Power System All single terms are approximated with a safety factor of minimum 30 The average of the power consumption is approximately 23W The total power consumption is 3 2Wh 130mAh RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 66 advanced isolation on sounding rockets no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation Timeline Single power Number of Power Power Timespan s Power consuption mA Parts consuption mA consumption W consuption mAh E 600 sec Before ignition Compactkio 100 af too 2
153. t stages to cover all flight phases are 1 Recovery module and service module during launch 2 ADIOS and CaRu during landing phase NC is neglected For that the largest strain at each stage is expected to be in the middle between two perturbations of structure Perturbations are connections between the modules mountings and bore holes in the structure Hence first stage is located 92 mm from bottom inside the ADIOS module The second stage shall be located at 120 mm from bottom inside the CaRu module It would have been good to have a third stage located at 200 mm from bottom of the recovery module Next the number of strain gauges in each cross section has to be termed For that the different kind of structural loads have to be considered During flight there are longitudinal and bending vibrations Physically a longitudinal vibration on a symmetric structure causes equal strain magnitude and algebraic sign on opposite sides of the structure A bending vibration leads to strain with equal magnitude but different algebraic sign To decide which kind of vibration is acting on the rocket and to measure its magnitude two strain gauges has to be applied to the structure positioned on opposite sides of the rocket structure that means displaced by 180 As Figures 1 and 2 show the strain maxima in a stage will be displaced by 180 followed by strain minima displaced by 90 to the maxima Previous to flight it is not possible t
154. tic fields due to the permanent magnets attached to the locking mechanism The blue and the red graphs rep resent the magnetic field strength of the magnets on the HX11 ADIOS SEDv5 3 07October2013 Final docx EuroLauncH A DLR and SSC cooperation 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150lmm Figure 4 Magnetic field strength in dependence of the distance to the magnet upper as well on the lower side of the locking mechanism in relation to the distance Due to this certain position of the magnets above and below the FFED the non mag netic counter plate of the FFED has its initial distance at 8 mm for the current design The yellow graph shows the superposition of the magnetic fields If the FFED trav els towards one direction away from the initial position the influence by the magnetic field become immediately stronger In concern of the eddy current principle the ve locity hence the frequency of the movement is a driver of the resulting damping As higher the frequency as stronger the damping takes affect 4 3 Design Parameter This section deals with a brief explanation of the physi cal background to determine the design parameters of the presented isolation platform The framework of this pa per is not sufficient to include all considerations for the calculation It can only give an overview of the basic ap proach 4 3 1 Dimensioning of Springs We regard in the first step the dimensioning of the sp
155. tion box 6 8 1 3 lew Layout circuit 6 8 1 4 design circuit diagram j 6 5 lew test box fuse box 6 6 size positioning circuit boards 6 7 Experiment 1 6 7 1 DAQ Hardware 6 8 1 6 3 circuit board assembly J 16 8 1 6 4 soldering 6 8 1 7 testing of circuit 6 10 2 transport plug 6 10 3 flight plug HX11 ADIOS SEDv5 3 07October2013 Final docx Page 158 advanced isolation on sounding rockets no vibrations good vibrations EuroLAauncH A DLR and SSC cooperation Legende HI priority 1 7 Outreach e priority 2 7 1 Webpage prioriky 3 m priority 4 nae Q 5 12 Content motye 1 7 2 Team acquisition e started 9 in progress 17 2 1 Handouts CB har iristea 7211 Design ae vi finished 7 2 2 Posters L 7 2 2 1 Layout PR office m good progress m critical progress 7 2 2 1 1 w Recruitment minor progress 17 2 2 1 2 Ger Information mw 7 2 3 Lectures Roadshows m ES po 7 7 2 3 1 resentation Layout 7 2 3 2 c at FH Aachen 17 2 3 2 1 FRE Symposium 7 2 3 3 external 7 2 3 3 1 ELGRA Symposium 7 3 Newspaper articles 7 3 1 own projects 7 3 2 press office FH Aachen 117321 at FH Aachen Website 1 7 3 2 2 m external FH Aachen 7 3 3 external papers RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 159 EuroLAauncH adv
156. tion curve of the eddy current damping in comparison to visco damping Figure 2 Single mass with spring and damper cases The decoupling mechanism restrains the energy from the outer structure to affect the experiment If the experiment itself includes sources of mechanical vibra tions these sources or at least the most sensitive parts of the experiment should be decoupled separately Figure 2 shows a one dimensional decoupling mechanism one DOF degree of freedom x consisting of a one dimen sional spring a one dimensional damper and the experi ment as a single mass The movements of the outer struc ture s are the excitation of the spring and the damper Figure compares the dynamic mechanical behaviour of this system using viscous dampers green and passive eddy current dampers blue with the same isolation qual ity at higher frequencies A System with one degree of freedom has one eigenfrequency This eigenfrequency is characterized by a high magnification factor At frequen cies higher than the eigenfrequency the amplitude of the experiment motion decreases and is finally much smaller than the excitation amplitude This phenomenon is called decoupling Obviously the active eddy current damper Page 133 on sounding roc advanced isolation on rockets no vibrations good vibrations Figure 3 The magnet setup of Eddy current damping taken from 5 allows an increased damping close to the eig
157. to the classification 6 of the Technology Readiness Levels TRL for the current design of the ADIOS platform adapted to the application on sounding RX11 ADIOS SEDv5 3 07October2013 Final docx EuroLAauncH A DLR and SSC cooperation Locking FFED Mechanism Signal proces sing and DAQ Figure 7 CAD cross section model of the ADIOS ex periment setup with FFED locking mechanism and data acquisition unit rockets a TRL 7 is reached This level implements the system prototype demonstration in an operational envi ronment For the application on other types of reduced gravity platforms like space stations and satellites the TRL 4 proven principle can be assumed Even short term experiment applications at drop tower facilities or parabolic flight aircrafts can be considered 5 RESULTS The in flight test on REXUS 11 provided good process able data Although the conditions of the REXUS 11 flight was not as good as usually the ADIOS system could show its performance for this case Even the very low frequent tumbling at Hz of the rocket payload was smoothed for the free flying experiment container The presented graphs in figures 8 and 9 are the measured data of the flight axis of the vehicle Both other directions y and z show very similar results and are mitigated in this discussion Regarding the unprocessed data of figure 8 the red graph represent the excited rocket structure while the green graph show the accelerati
158. ture 30 Circuit board components during VibraDamp thermal vacuum i 94 ol A 55 Picture 32 Traco Power DC DC converter occconccccccnccccnccocnconcnconnnccnnncnanoconons 56 Picture 33 ASC 2g acceleration sensor ooccccoccncccocnnccncncnoncnononenononenononenoss 57 Picture 34 linear strain gauge 350 Q oocccoccncnncnccncnccncncnnnnnoncnonnnncnnnncnnnnnnnons 59 Picture 35 T rosettes strain gauges 350 Q oocooncccconononononononononoanononanenononenos 59 Picture 36 Temperature sensor 350 Q ooccocccccncococococonocononononcnnnconanonanonanes 60 Picture 37 linear strain gauge for testing 120 O ooonccconiccnonccconacnconncncnnncnnns 60 Picture 38 strain relief for CabliNg ccooccconccocncoonccncnnnononanocanononncnanonnnonos 61 FICUS SI2 lay OUN EAP PO I N 9 62 Picture 40 Telemetry Software screenshot 4u40444440nenne nennen enn een 70 Picture 41 First and second recruitment poster sseeeuesssus 106 Picture 42 Presentation F amp E Research amp Development Conference FH Aachen Fachbereich Luft und Raumfahrttechnik 108 Picture 43 Presentation F amp E Research amp Development Conference FH Aachen No Vibrations Good Vibrations S Kr mer 108 Source 1 PDR Minutes by the Review Board
159. ty vibration isolation for the international space station Technical re port TD55 Vehicle Control Systems NASA Marshall Space Flight Center Huntsville AL 35812 4 Karl J Pendergast and Christopher J Schauwecker Use of a Passive Reaction Wheel Jitter Isolation Sys tem to Meet the Advanced X Ray Astrophysics Facil ity Imaging Performance Requirements Technical re port TRW Inc One Space Park Redondo Beach CA 90278 1998 5 Rainer N hle Michael Wahle and Reinhard R stel Lagersystem in einem Raumfahrzeug Patentschrift Technical Report DE 102 27 968 B4 2006 03 02 DLR 2002 6 James R Wertz David F Everett and Jeffery J Puschell editors Space Mission Engineering The New SMAD Microcosm Press 1 edition 2011 RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 138 EuroLauncH A DLR and SSC cooperation advanced isolation on sounding rockets no vibrations good vibrations APPENDIX E RESULTS EXP 2 Paper on Experiment 2 21 ESA Symposium on Rocket and Balloon Related Research EXPERIMENTAL IN FLIGHT MODAL ANALYSIS OF A SOUNDING ROCKET STRUCTURE Andreas Gierse Stefan Kr mer Dominique J Daab Joana Hessel Fabian Baader Brigitte S M ller Tobias Wagner Georg Gdalewitsch Engelbert Plescher and Lysan Pf tzenreuter 1 ZARM Fallturm Betriebsgesellschaft mbH am Fallturm 28359 Bremen Germany andreas gierse zarm unt bremen de FH Aachen FB6 Hohenstaufen
160. umfahrtstation Esrange bei Kiruna in Nordschweden starten k nnen Aus bisher ungekl rten Gr nden hat sich der Fallschirm der REXUS 12 mit dem die Rakete nach dem Start wieder sanft auf der Erde h tte landen sollen nicht ge ffnet Die Folge war eine Bruchlandung bei der alle Hardwareteile und auch die Software gr tenteils zerst rt wurden Trotzdem konnten zumindest die Daten noch geborgen werden so dass sie nun im Anschluss von den Studierenden Teams susgewertet werden k nnen Die REXUS 11 darf nun vorerst nicht an den Start solange der Fehler der REXUS 12 nicht ausfindig gemacht wurde Alle Teile der Rakete und die Experimente der Studierenden wurden daher wieder ausgebaut eingepackt und werden jetzt auf dem Esrange Gel nde gelagert Die Studierenden sind nat rlich entt uscht Aber das FH Team darf wiederkommen und bei der n chsten Kampagne ihre Experimente testen Die Hochschule dr ckt die Daumen dass sie dann ihren Traum bei einem echten Raketenstart dabei zu sein verwirklichen k nnen REXUS Raketen Experimente f r Universit ts Studenten ist ein deutsch schwedisches Studierendenprogramm der European Space Agency ESA und des Deutschen Zentrums f r Luft und Raumfahrt DLR das Studierenden erm glicht wissenschaftliche und technische Experimente auf suborbitalen Raketenfl gen kurzzeitig unter Weltraumbedingungen durchzuf hren Die FH Aachen beteiligt sich an zahlreichen Programmen und geh rt vor allem
161. uncH A DLR and SSC cooperation 6 6 Timeline for countdown and flight Time Event Second LO Signal EXP2 measurement starts LO Yo Yo Release Start EXP1 DAQ Drive LM unlock SOE on 250s Drive Imbalance Generator via internal Timeline Drive LM lock Stop EXP1 DAQ Start EXP2 DAQ SOE off 500 S Stop of EXP2 DAQ 530 S Shutdown cRIO 600 S POWER OFF Service Module or 1 minute after landing Table 18 Timeline for countdown and flight 320 S Regarding the RX11 Timeline the ADIOS Experiment is quiet flexible to handle The LM needs to unlock after YoYo Despin and to lock before re entry The use of the Imbalance Generator can be pushed to the end of the ug phase to avoid disturbances to other experiments A time slot of 45s to 60s for the excitation would be appreciated 6 7 Post Flight Activities e The Recovery Crew shall remove the Flight Plug before recovery to the Esrange base The change is not compulsory if the S M will not be switched on again before the cRIO has been switched to hardware save mode e The FFED needs to be disassembled to access the cRIO before reboot and data backup to avoid a accidently deletion of the memory hardware safe mode e Data backup via Computer access to cRIO RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 84 no vibrati ons good vibrations E UROLAUNCH ADLR and SSC cooperation e Data analysis e g temperature compensation of strain etc
162. und e g in high frequency resonances of parts induced by the random excitation of the rocket motor Weakly damped structures can store vibrational energy like a bell Additionally the high frequency excitations are usually superimposed with low frequency structural oscillations and vehicle Presented at the 21st ESA Symposium on Rocket and Balloon Pro grammes and Related Research 9 13th of June 2013 Thun Switzer land RX11 ADIOS SEDv5 3 07October2013 Final docx Page 131 d isolation on sounding ro id advanced isolatio g rockets no vibrations good vibrations movements For most experiments the low frequency excitations are often a limiting factor High amplitude low frequency movements even can completely disable the function of e g physical science experiments For some cases interferences between the experiments must not be neglected Due to the short experimenting time sometimes several experiments have to run in parallel Currently if one experiment disturbs the performance of another one the time needs to be apportioned A practical solution for this problem is to decouple the sensitive or the disturbing experiment from the rocket structure Limited power and the need of high reliability leads to a passive lightweight and straightforward solution 3 STATE OF TECHNOLOGY Vibration damping for microgravity experiments can be realized with active or passive isolation systems Active isolation systems requir
163. ure as shown in Figure 2 HX11 ADIOS SEDv5 3 07October2013 Final docx Page 18 no vibrations go od vibrations E UROLAUNCH A DLR and SSC cooperation Rexus Structure Strain Gages Figure 2 Application of the strain gauges onto the structure Additional Requirements to the performance of the strain gauges The strain gauges shall be calibrated for aluminium The strain gauges shall have a minimal sensitivity of 100 ue The sample rate for the strain shall be the same as for the temperature The data volume on the cRIO shall not exceed 0 7 GB measured for all data oe A 5 Each strain gauge shall measure the strain with a sample rate of 4000 Hz and should measure with a sample rate of 16000Hz 2 4 Operational Requirements O 1 The temperature of the structure shall not under run 20 C O 2 The Esrange recovery crew should disarm the experiment with a transport plug RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 19 no vibrations go od vibrations E UROLAUNCH A DLR and SSC cooperation 3 PROJECT PLANNING 3 1 Work Breakdown Structure WBS The following work breakdown structure shows the preliminary work packages for the single subsystems Regarding the readability the subsystems are showed in particular in Appendix D cpu ADIOS o ee EE 1 777 9 Li Malaia A m A g P m Br E ames s ag Je Tae i dec mo a ill g RU ixi El M EEE ae a iui MA B
164. wegen ihres hohen Praxisbezugs im Bereich der Luft und Raumfahrttechnik zu den f hrenden deutschen Hochschulen Kontakt Stefan Kr mer Fachbereich Luft und Raumfahrttechnik Hohenstaufenallee 6 Raum 02105 52064 Aachen rexus FH aachen de www fb6 FH aachen def lurf studienprojekte rexus adios Source 11 Press Release by Bedbur Ruth FH Aachen Press Office 23 03 2012 http www fh aachen de topnavi presse presseaktuelles aktuelles details tx_ttnews 5Btt_news 5D 354 amp cHash 9201c875b5a47fd1a278713 7e0ec3364 RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 118 no vibrations good vibrations EUROLAUNCH ADLR and SSC cooperation RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 119 EuroLAauncH g rockets advanced isolation on soundin no vibrations good vibrations A DLR and SSC cooperation v9 2909 1872 pjZ ve SOSZ89LOZG YSEHOSPSE GQS SMSU PIS SMEUN XYZ s ejep Sej enpye sejenjieesseud esseud i eudoyep usyoee uy WWWyr dyu cLoc o ec TLOZ 0 6L LvC8ICO89v81629 668P9v2Q6 09689 YSEHISSTE GS SMSU NISASMOUN xygrzeuoeo oudg siejep C0 0 80 udjueBunjegiuesseudessaud esseud ieudoyep usyoee uy Mw dyy ZL02 20 vo ep ueuoee uy mww dyy LLOZ ZL ZO LLOZLL ZL ep ueuoee uj bp mww dyy LLOZ LL vL LOGHELVE yseHo91ez pigyoeq smauy pese ce smau y smauy xpgz LLOZ LL zo Layuiod smauy gg oJelsmauy 19666165Z 1d smauy xy90 00Z0L0zZ
165. weltestm glich eindam men Im Marz 2012 soll die n chste REXUS Generation an den Start gehen PRESSESTELLE RUTH BEDBUR DV 35 Source 5 PeopleMover 2011 RX11_ADIOS_SEDv5 3_07October2013_Final docx Page 110 advanced isolation on sounding rockets EuroLAauncH A DLR and SSC cooperation no vibrations good vibrations 0112011 Magarin ver Pi Aacnen Urrwerzw of Appeed Soences Dimensione STUOIUM INTERNATIONAL FORSCHUNG Ein echter Volitreffuwr Graswurzeiarbent inAtmopien Vollst ndig vernetzt Stucerence des Facbereicns Hilfe die ankommt Prot Or Thomas Ritz entwerten Prakat Prot Or Michael Frings baut Utx die Bedeutung modtier Informationssysteme 48 UNIVERSITY OF APPLIED SCENCT S FH AACHEN Adama Untwersity auf 38 FH AACHEN DIMENSIONEN 01 11 ZU den Sternen Raumfahrtprojekte sorgen an der FH f r einen ho Praxisbezug in Studium und Forschung Ob SpacestuttE Rakete oder Satelit Fur Forscher und Studierende ist die Raumfahrt ein reizuolies Aufgabengetiet Auf der Suche nach neuen wissenschaftlichen Erkenntnissen arbeiten Planetologen Astrophysiker Kosmologen und Raumfahrtingenieure intensiv daran In die Tiefen des Weltraums vorzudringen Auch die FH Aachen beteiligt sich an zahlreichen Programmen die Lehrenden wie Studierenden erm glichen unter Raumfanrtbedingungen zu arbeiten und Schritt f r Schritt den Kosmos und seine Planeten mit Raketen Satelliten Sonnensegeln und sogar einer
166. were the estimation of Eigenforms and Eigenfrequencies of the REXUS 11 rocket Therefore several models of the rocket were designed and calculated using ANSYS One model considered the launch configuration of the rocket another model con sidered the configuration during u g phase and so forth The different Eigenforms were calculated to find the ideal positions for strain gauges in the payload where Eigen forms of all configurations could be verified The main focus was on the Eigenforms while u g phase Based on this calculations three levels in three dif ferent payload modules were defined Each level should contain four strain gauges 90 apart of each other at the circumference of the modul Figure 1 shows the calculated first three bending Ei genforms of the REXUS 11 payload in u g condition and the located ideal levels 1 2 3 for the strain gauges The verification of Eigenforms is based on different strain amplitude ratios between the levels at different Eigenforms As can be seen in Figure 1 at the first Ei genform the strain amplitude is very similar in all levels free free bending At the second Eigenform the strain Page 140 dvanced isolation on sounding rockets no vibrations good vibrations amplitudes at level 1 and 3 are similar but the strain amplitude in level 2 is considerably lower Therewith it is possible to accomplish the measured Eigenfrequencies to the calculated Eigenforms This thesis was finish
167. winterer Str 522 524 53227 Bonn Germany ABSTRACT LOW FREQUENCY VIBRATIONS are a limiting factor for many experiments in microgravity environ ment Accelerations due to excited structure parts of the experiments can cause strong influences on the quality of the experiments Especially on sounding rocket flights the time of reduced gravity is very valu able and shall be used efficiently Constraints due to the interferences between different disturbing experi ment events often force to apportion the experiment ing time By the mechanical decoupling of an experi ment the induced perturbations can be minimized in both directions Protecting the experiment from the influences by the vehicle and shielding all other exper iments from the self induced disturbances is the goal of the ADIOS platform Key words Vibration Isolation Damping Sounding Rockets REXUS 1 INTRODUCTION The ADIOS platform is a passive and contactless isolation system based on magnetical damping which has been designed for experiments on sounding rockets Driven by the motivation to increase the quality of p gravity for experiments on sounding rockets in a easy and cost effective way in 2008 a student team at the FH Aachen University of Applied Science started to develop a system in the framework of the REXUS programme Rocket borne EXperiments for University students of DLR SNSB SSC and ESA Already the second design study of the system called Vibra
168. witch 2 1 4 Springs amp Dampers 2 1 5 Bulkhead 42 1 5 2 1 Inlets 2 1 5 3 lass Interface to Electronics 1 4 1 1 7 mu ERNI 1 4 1 3 FH Aachen 412154 B erio mounting 2 1 6 Rocket Adapter 2 1 7 armed plugs 11 41 31 V Ki Antrag 22 1 f FEM Analysis of Parts 1 4 2 Manpower 7 1 4 2 1 Structure and Fields of work 1222 Evaluation of weights 1 4 2 2 Workload 1 4 3 1 a Estimation of weights 1 4 3 2 validation of concepts 2 3 Construction 11 5 Organisation Usa Interfaces 1 5 1 1 DLR Bremen PROJECT MANAGEMENT REXUS 1 5 1 2 DLR MORABA z 1 5 1 3 Companies 2 4 2 1 CFC Parts 2 4 2 2 9 Motors 2 4 2 Vacuum s 2 4 2 3 Start electronic parts 1 5 1 3 2 HOM 1 5 1 3 3 ASC 2 4 3 Thermal 2 5 Integration HX11 ADIOS SEDv5 3 07October2013 Final docx Page 156 B i advanced isolation on sounding rockets E L no vibrations good vibrations UROLAUNCH ADLR and SSC cooperation 3 Science 4 Sensors amp DAQ 5 Programming 3 1 EXP 1 4 1 Selection of Sensors 5 1 Software determination of magnet setup 4 1 1 g Acceleration 5 1 1 Star LabVIEW 2010 n 5 2 DAQ 3 1 2 ms determination of spring setup 4 1 2
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