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CDR - River City Rocketry

1. 3 s pBweWaxe e J a Nose Cone Centernnda EN NEN 31 Nose Cone Separator Plate Battery Holster 9 Assembly MATER AL Ukir OMMWEr iPCEFD cn See BOM ae Diei AM M ANo ne meer ig 7 Lo university of Louisville PER ATE WIRE v River City Rocketry pam vaa maael 20 iw ony 2013 2014 Design pao CA DEAE ow EHE ILL Deral SwEEL 1 Gt Figure 63 Nose cone altimeter and GPS BOM 2013 2014 RCR CDR Requirement Verification The recovery system electronics shall not The altimeters used in the booster and be adversely affected by any other on lower sustainer are housed in separate board electronic devices during flight from rocket sections and shielded by aluminum launch until landing tape The altimeters housed in the nose cone will have aluminum shielding on half of the sled to shield it from the corresponding GPS unit Each arming switch shall be capable of Key switches will be permanently screwed being locked in the ON position in through threaded holes in the witness ring of the avionics bays Each altimeter shall have a dedicated A dedicated 9 volt battery will be placed on power supply the altimeter sled for each altimeter The recovery system shall contain Each recovery altimeter section will have redundant commercially available two of the same altimeter The nose cone altimete
2. Results of hazard detection are not transmitted to the ground station and web server Overall 4 Inability to use the camera would result in mission failure as no hazard data would be collected Overall 3 Moderate Moderate Data transmission failure would result in the ground station not receiving or recording hazard detection flight event or GPS data from the rocket payload This would result in a mission failure Overall 4 Risk The hardware initialization failure program that runs on device startup will tell the team if the GPS GPRS unit is functional when it is on the launch pad launch checklist to verify the BeagleBone All Moderate Section 1 An entry is present on the pre Black s battery is charged prior to launch 2 The hardware initialization failure program that runs on device startup will tell the team if the camera unit is functional when it is on the launch pad Image processing performance will be tested to verify that hazards can be scanned for in the required time frame on the required hardware The team has verified via T Mobile s online coverage map that the launch field at the Bonneville Salt Flats has wireless coverage An entry has been added to the pre launch checklist to send a test SMS message with the GPRS unit to a cellular phone This will verify that no physical defects are preventing the GPRS unit from functioning prior to launch Entries h
3. am 16 Mission Redesign After SubScale Testing 17 Motor Orders 18 Critical Design Review Submission gt 2 28 19 Critical Design Review Presentation 2 20 Data Analysis and Design Finalilization 21 Manufacturing Hecovery Subsytem Hazard Detection Payload 4 Fairing Subsystem Stability and Propulsion 6 Ful Scale Flights and Final Revisions un 27 Flight Rediness Review QA session Test Flights 1 and 2 9 Third Test Flight 2 I 30 Flight Rediness Review Submission 3 o 4 18 31 Flight Rediness Review Presentation 32 Systems Check and Revisions 33 Travel to Salt Lake City 2 a 34 Flight Hardware and Safety Check E 35 Launch Day o 36 Return to Louisville 37 Launch Analysis and Data Compilation 33 Post Launch Assessment Review Table 63 Team timeline 2013 2014 RCR CDR IN EDUCATIONAL ENGAGEMENT In the past years River City Rocketry benefited from the opportunity to reach out in our local community to bring STEM activities to students parents and educators The team takes pride in the quality of events that we organize and orchestrate With the new season we have new exciting plans to further our educational presence in the community The team acknowledges that the best way to reach the needs of our community Is by receiving feedback on what is effective and what can be improved We are always open for constructive criticism so t
4. Figure 8 2nd Stage ignition logic Apogee Event Apogee Powder Charge 1 Apogee T m DE 7 Powder Charge 2 Figure 9 Apogee recovery logic The apogee event uses two StratoLogger s that deploy at apogee and apogee 1 0 seconds This is a standard dual deployment for high powered rocketry 2013 2014 RCR CDR Lower Sustainer Ejection The lower sustainer will be ejected at 7500 ft and will be under parachute when ejected The same Ravens that powered the motor ignition will power the black powder charges to separate the lower sustainer from the fairing payload Black Powder Charge 1 Maicn d E Match 2 Figure 10 Lower sustainer recovery logic Black Powder Charge 2 Fins The fins used on the rocket s booster and sustainer are constructed out of G 10 fiberglass and have the dimensions listed in the table below Booster Fin Sustainer Fin Number of Fins degrees Fin Cant degrees 0 0 Root Chord in Sweep Angle degrees 63 4 63 43 Thickness in 0 125 0 125 Table 2 Fin dimensions G 10 fiberglass is well known for its use in model rocketry and is renowned for its strength and high factory of safety when under stress Below is a rendered image of one of the booster fins 2013 2014 RCR CDR 19 Figure 11 Booster fin The fin has a tab that is inserted into the body of each stage which will be epoxied using P
5. Yes Has the OS booted up Initialize GPS GPRS unit Initialize hazard detection camera Initialize marker cam Initialize rover motors Initialize rover accelerometer Did the device encounter Yes artup errors Add device to failed hardware list Did any device fail during startup Yes For each failed device blink LED a pre set color for a pre set time Blink LED to indicate no failures s a launch event detected Figure 92 Boot Process Flowchart 2013 2014 RCR CDR Status indication Device LED Status LED a _ Figure 93 Boot Status Indication Setup During the boot process a pair of RGB LEDs is used to indicate the status of the boot process The first LED the Status LED is used to indicate the current stage of the boot process and displays values that indicate devices are currently booting up boot up is complete with non critical errors boot up is complete with critical errors or boot up completed with no errors The second LED the Device LED is used to indicate any specific errors that occurred during boot up Each hardware device is assigned an RGB color and after boot up completes the system will repeatedly cycle through every device in the failed devices list and light Device LED for a short time period This system will allow the team to immediately determine any hardware failures immediat
6. 2 342 20 5 31 90 310 00 Featherweight Raven Power Perch 2 35 00 70 00 MissleWorks RRC3 1 2 6900 138 00 Toa 1 1 766 92 Table 59 Recovery budget 2013 2014 RCR CDR IN 1 25 62 50 3 32 45 2 2 Fairing Payload Budget Unit Bulkhead 3 Centering Ring Bulkhead Hinge Square U bolt Hex Nut Washer 2 8 a 2 1576 3152 _ 8 937 74 96 Socket Cap Screw 6 687 41 22 SplitLockWasher 6 271 16 26 _ Hex Nut 6 792 47 52 __ Aluminum Stock 6 1 9494 94 94 Foam Insert 1 300 00 300 00 Pyro Cap 1 200 00 200 00 O ring 1 809 800 Eye Bolt 1 289 289 Flat Head Socket 4 271 1084 __ Extension Spring 2 1016 2032 Eye Bolt __1__ 228 228 Kevlar String 1 2373 2373 Heat Shrink Tubing Total Table 60 Fairing payload budget 4 1 1 1 1 1 1 1 1 2 1 1 Hazard Detection Payload Budget Quantity Total 2 90 00 XT60 Solid Bullet Connectors 5 50 Heat shrinkable Tubing 04 black 0 40 0 40 LED Program Card For Brushless ESC 1 8 99 8 99 2013 2014 RCR CDR Sky Lipo 1600mAh 14 8V 40C 20 94 41 88 31 99 63 98 4 99 9 98 4 69 9 38 4 99 19 96 7 97 31 88 9 51 9 51 3 96 3 96 1 63 1 63 0 81 0 81 13 60 13 60 4 43 4 43 14 81 14 81 11 88 11 88 1 49 1 49 2 50 2 50 2 61 2 61 5
7. The basic process for the program is outlined above As pictured the program will start by initializing of both OpenCV and the Camera which are integral parts of this process All the error and initialization checking will be done before the program goes forward After it is verified the main program loop will start and the first method takePicFromCam will be run After this method run another verification method called checkPic will be initialized which will check for any blurriness which will have a set threshold of greater than 75 Once this is completed the main hazardCheck algorithm loop will begin which will start populating the list of hazards Once this is completed if at least one hazard has been detected the process will continue onto sending the compressed message to the ground station server Once a successful link is established real time data will be available on the team s web page If no hazards are found and or sending to server completed the program starts back at the main method and starts the process again 2013 2014 RCR CDR M8 The payload shall OpenCV has functions that Tests have been conducted incorporate a camera allow it to have control over to make sure we system that scans the the camera so that it can control the camera through surface during descent in take pictures as necessary OpenCV order to detect potential landing hazards The data from the hazard OpenCV is a
8. MATEHAL ANISH vence E p University of Louisville River City Rocke gt x HO DE Je C4 C 101 10 Mec ce doe uw 2013 2014 Design Ow merit colo WE SLE RES A Figure 103 Rover General Dimensions Electronics Integration All of the electrical components will be placed on top of a 15 5 x 2 5 wood platform that is 74 thick Testing will be conducted once the 3D printed parts arrive to determine if the platform should be converted to aluminum to better handle the stresses upon deployment or landing The camera will be mounted in the front of the rover so that it will be facing downwards during descent The foldable stand that comes with the camera will be cut in half and the remaining part will be attached via screws onto the platform The LiPo batteries will have a sheet metal cover that will hold them in place This cover will have tabs to allow it to screw onto the platform The ESCs will also have a similar sheet metal cover These covers are not shown on the rover as they were not modeled To further insure that the LiPos and ESCs do move small strips of Velcro will be placed in between them and the platform The BeagleBone will be attached to the electronics platform via Nylon male female standoffs The standoffs will screw into the platform and then Nylon screws will hold down the BeagleBone thanks to the through holes it has The reason Nylon was chosen was 2013 2014 RCR CDR IN
9. _____ Install threaded rods into bulkhead ____ Attach sled through threaded rods ____ Attach upper bulkhead Attach GPS sled _____ Check GPS for full charge dl dii CE 2013 2014 RCR CDR 79 Launch day procedures Booster Parachute Assembly BPA Required Equipment e Nomex ____ Verify motor hardware is attached ____ Attach longest length of shock chord to motor hardware ____ Verify motor is installed ____ Attach other end of shock chord to parachute ____ Attach shock chord that attached to parachute to the u bolt ____ Attach pilot parachute to top of deployment bag Remove all rubber bands Wrap deployment bag in Nomex Insert both parachutes into booster gt Lower Sustainer Parachute Assembly LSPA Required Equipment e Nomex ____ Attach parachute to avionics bay Remove all rubber bands 1 2 3 Wrap deployment bag in Nomex 4 Insert parachute into airframe Rover Parachute Assembly RPA 1 Attach rover parachute deployment bag to upper bulk plate 2 all rubber bands 3 Fitparachute into foam insert 4 Attach shroud lines to rover Fairing Parachute Assembly FPA Required Equipment e Nomex X Attach parachute u bolt on upper bulk plate Attach parachute to fairing 1 2 3 Attach pilot parachute to deployment bag 4 Remove all rubber bands 2013 2014 RCR CDR ra 5 Wrap
10. too quickly improperly sized for causing section of the rocket Simulations components of have been performed to validate the rocket to be the design damaged Rocket descends Parachute is The rocket will 3 3 LOW The parachutes have each been too slowly improperly sized drift farther than carefully selected and designed to 2013 2014 RCR CDR Parachute has a tear or ripped seam Parachute or chords become burnt Recovery system separates from the rocket Parachute is less effective or completely ineffective depending on the severity of the damage Parachute is less effective or completely ineffective depending on the severity of the damage 1 Bulkhead becomes dislodged 2 Parachute disconnects from the U bolt intended potentially facing damaging environmental obstacles The rocket falls with a greater kinetic energy than designed for causing components of the rocket to be damaged The rocket falls with a greater kinetic energy than designed for causing components of the rocket to be damaged 1 2 Parachute completely separates from the component causing the rocket to become ballistic safely recover its particular section of the rocket Should this be too large the parachute will have to be resized Through careful inspection prior to packing each parachute this failure mode should be eliminated Through careful packing and the appropriate use of No
11. 2013 2014 RCR CDR Lower Sustainer Ejection The lower sustainer will be ejected at 7500 ft and will be under parachute when ejected The same Ravens that powered the motor ignition will power the black powder charges to separate the lower sustainer from the fairing payload Black Powder Charge 1 7500 ft Black Powder Charge 2 Figure 47 Lower sustainer recovery logic Requirements The launch vehicle shall stage the deployment of its recovery devices where a drogue parachute is deployed at apogee Verification The main parachute for the nose cone will act aS a drogue until the lower sustainer separates under its main parachute The nose cone parachute will also act as the drogue for the hazard detection payload and a main parachute is deployed at a much lower altitude Tumble recovery or streamer recovery from apogee to main parachute deployment is also permissible provided that kinetic energy during drogue stage descent is reasonable as deemed by the Range Safety Officer Table 12 Flight path verification Avionics Bay Each section that will be recovered will have its own custom designed altimeter sled and corresponding avionics bay This section will cover the avionics bays for the booster recover apogee event and lower sustainer ejection the rover ejection event will be covered in the fairing payload section All electronics will be attached to the sled via nylon 4 40 scre
12. NASA STUDENT LAUNCH 2013 2014 CDR FEBRUARY 28 2014 TABLE OF CONTENTS SUMMARY OF CDR REPORT 3 Team Summary 3 Launch Vehicle Summary 3 Payload Summary 3 CHANGES MADE SINCE PDR 7 Changes to vehicle criteria 7 Changes to payload criteria 7 changes made to project plan 7 VEHICLE CRITERIA 8 Design and Verification of Launch Vehicle 8 Subscale Flight Results 24 Recovery Subsystem 29 Mission Performance Predictions 64 DRIFT CALCULATIONS 67 Payload Integration 69 Launch concerns and operation procedures 72 SAFETY AND ENVIRONMENT VEHICLE 93 Safety Plan 93 NAR TRA PROCEDURES 111 HAZARD DETECTION PAYLOAD CRITERIA 116 Testing and Design of Payload Experiment 116 Payload Concept Features and Definition 158 Payload Science Value 160 Safety and Environment Payload 165 PAYLOAD CRITERIA 174 Testing and Design of Payload Experiment 174 Payload Concept Features and Definition 184 science Value 185 Safety and Environment Payload 186 PROJECT PLAN 189 Comprehensive Budget Funding Plan 189 Timeline 194 2013 2014 RCR CDR ae Educational Engagement 195 APPENDIX 1 SUPPLEMENTAL INFORMATION 199 APPENDIX 2 SAFETY DOCUMENTS 200 SUMMARY OF CDR REPORT TEAM SUMMARY School Name University of Louisville Organization River City Rocketry Location J B Speed School of Engineering 132 Eastern Parkway Louisville KY 40292 Project Title Project Phantom Mentor Name Darryl Hankes Certification Level 3 Tripoli Rocketry Ass
13. Note updateAngleEstimates will MODEM be done for x y and z angles Begin updateAngleEstimate Angles n 2 Angles n 1 Angles n 1 Angles n ReadInAngles getEulerAngles Discard the most extreme reading in Angles_n 2 Angles_n 1 Angles_n Y Angles n Average of the not eliminated readings Y End updateAngleEstimate s Angles n Z lt 20 degrees yo a Set IgnitorOut HIGH Set IgnitorOut LOW Figure 38 Angle estimation flowchart 2013 2014 RCR CDR 420 Begin tiltometer actions phase During this phase the tiltometer will wait until the start reset button has been pressed by a team member This ensures that the tiltometer only starts estimating orientation when the rocket is actually on the launch pad Calibrate sensors phase The sensor calibration phase will ensure that the acceleration and gyroscope offsets are properly set on the MPU6050 so that the device s coordinate reference frame is correctly set with respect to the Earth s surface MPU6050 Earth s surface Figure 39 Tiltometer coordinate reference frame First the device waits 80 seconds for the device s readings to stabilize at a near constant level This time value was determined during testing by the team prior to CDR After the 80 seconds have elapsed the tiltometer takes a single reading and sets its current acceleration and angular
14. will not allow smoking open flames nor heat sources within 25 feet of these motors 4 Ignition System will launch my rockets with an electrical launch system and with electrical motor igniters that are installed in the motor only after my rocket is at the launch pad or in a designated prepping area My launch system will have a safety interlock that is in series with the launch switch that is not installed until my rocket is ready for launch and will use a launch switch that returns to the off position when released The function of onboard energetics and firing circuits will be inhibited except when my rocket is in the launching position 5 Misfires If my rocket does not launch when press the button of my electrical launch system wil remove the launcher s safety interlock or disconnect its batter and will wait 60 seconds after the Only Darryl Hankes Gregg and Zak are permitted to handle the rocket motors If during the season an additional team member achieves the required certification he she will be approved to handle the motors after that date The Mechanical Engineering team will be responsible for selecting the appropriate materials for construction of the rocket Motors will be purchased through Wildman Rocketry and will only be handled by certified members of the team who are responsible for understanding how to properly store and handle the motors All launches will be at NAR TRA certified event
15. I nspect canopy and lines for any cuts burns fraying loose stitching and any other visible damage 3 Shroud lines are taut and evenly spaced 4 ___ Fold parachute 5 Place folded chute into deployment bag 6 Secure deployment flaps using shroud line and rubber bands Upper Sustainer Parachute USP Required Equipment e Rubber bands e Hook e Clamp 2013 2014 RCR CDR LEN e Booster parachute deployment bag e Swivels 1 ___ Parachute canopy is laid out flat 2 ____ Inspect canopy and lines for any cuts burns fraying loose stitching and any other visible damage 3 Shroud lines are taut and evenly spaced 4 ___ Fold parachute 5 Place folded chute into deployment bag 6 Secure deployment flaps using shroud line and rubber bands Rover Parachute RP Required Equipment e Rubber bands e Hook e Clamp e Booster parachute deployment bag e Swivels 7 Parachute canopy is laid out flat 8 Inspect canopy and lines for any cuts burns fraying loose stitching and any other visible damage 9 ___ Shroud lines are taut and evenly spaced 10 Fold parachute 11 Place folded chute into deployment bag 12 Secure deployment flaps using shroud line and rubber bands Pilot Parachute 1 PP1 Required Equipment e Rubber bands e Hook e Clamp e Booster parachute deployment bag e Swivels 1 Parachute canopy is laid out flat 2013 2014 RCR CDR UAE 2 ____ Inspect canopy and lines f
16. The rocket should not be launched if a body of water is within the estimated drift radius Should the rocket be submerged in water it should be retrieved immediately and any electrical components salvaged Electrical components are to be tested for complete functionality prior to reuse 2013 2014 RCR CDR 1 Complete 1 Batteries will be checked for Pide y charge prior to launch to ensure will there is enough charge to power cause electrical the flight Should the flight be 1 Batteries failures and fail delayed batteries will should be discharge quicker to set off black and replaced as than normal powder A IUE 2 Shrinking of charges I the temperatures are below beralas naucna Caneel normal launch temperature black cia even 9 powder charges should be tested 2 Rocket will to ensure that the pressurization asics aie ds is enough to separate the rocket easil If this test is successful the rocket y should be safe to launch Extremely cold temperatures Table 27 Environmental Hazards to Rocket Risk Assessment Hazards to Environment Risk Assessment Cause Severity Probability Risk Mitiaation Mechanism Value Value Level g Impure soil and water can have Batteries and other chemicals negative effects should be disposed of properly in Harmful substances Improper disposal on the accordance with the MSDS permeating into the of batteries or environment 4 3 Low sheets Should a
17. can be an issue if launch time is significantly delayed e Inthe PDR the team used an accelerometer to detect launch and landing events The plan was to detect a sudden large force being applied to the rocket and assume that force was coming from the rocket motors This decision has been changed to use a pressure sensor instead The pressure sensor will be used to detect change in altitude which provides a stronger guarantee that the detected event is the rocket launch rather than a sudden jarring of the rocket 2013 2014 RCR CDR Note Tiltometer setup is Begin pre launc preparation initiated by team member pressing the tiltometer s reset button Start tiltometer calibration program l Light calibration status LED to Start pre launch error detection program Did all system initialize properly indicate success or failure failure Report initialization Yes End pre launch preparation Begin image processing activty Take a photograph Has the rocket launched yet Determined by pressure senso Figure 91 Overall flight algorithm flowchart 2013 2014 RCR CDR Er processing activity Add road to hazard Add water to hazard Add crowd of people on 3 to hazard list if list if present in list if present in hotograph photog
18. detection camera shall be format will allow the verified to work with H 264 analyzed in real time bya BeagleBone to better video format process the images 2013 2014 RCR CDR n custom designed on board software package that shall determine if landing hazards are present Table 31 C920 Webcam Requirement Feature and Verification Table GPS GPRS Cape if E Figure 78 GPS GPRS Cape This cape is crucial to the hazard detection payload as it adds GPS and GPRS capabilities to the BeagleBone The cape uses a Telit GE 864 module to obtain GPS coordinates GPRS stands for General Packet Radio Service and is considered to be in between 2G and 3G networks used for cell phones GPRS extends the GSM capabilities of 2G data service to allow internet access SMS messaging and broadcasting MMS transmission and P2P service Since the team has chosen to use SMS for data transmission the features provided by this cape have been very useful To access the GPRS capabilities of this cape a SIM card is required so that it can connect to a cell phone network The SIM card from one of the phones used in last year s payload is being used to connect to the T Mobile network as it allows for prepaid usage of 3 per day for unlimited data which makes it affordable for the team s budget Figure 79 through Figure 82 shows that T Mobile has coverage for each of the team s expected launch sites including the Bonneville Salt F
19. not properly is not large enough to processing activities will detected detect apogee start early having no functional impact on payload performance Apogee is detected late The image processing step of flight is possibly missed completely leading to partial mission failure Thorough testing will be done during 1 4 development to ensure the pressure sensor s readings are accurate Also an entry has 2 4 Moderate been added to the pre launch checklist to take Overall 4 a sample reading from the pressure sensor to Landing detection and rover operations should still verify that it is accurate continue without issue Rocket A temporary change If rocket launch is not 1 5 launch is not in weather causes a detected image processing 2 4 2013 2014 RCR CDR 2013 2014 2013 2014 RCR CDR CDR The time range over which the program will attempt to detect apogee will be made as large as possible so that the odds of the rocket coasting for the entire time period is minimized Mitigations have been added to ensure the detected baseline pressure is accurate properly detected SMS sending hardware Is not functional Rocket landing is not properly detected large pressure change falsely triggering launch detection The baseline pressure is not determined properly Physical electrical pro grammatic error in the SMS sending hardware At apogee the rocket coasts nearly horiz
20. oignature Date 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e violate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events 7 mi 2124 2014 Signature Date 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e violate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events ZZ Signature Date 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply
21. using 41 3 where T is the motor thrust and g is the gravitational constant 9 81 m s Equations 1 2 and 3 are then used to compute the burnout velocity decay coefficient 1 s using 2k X1 4 Equations 3 and 4 are used to calculate the burnout velocity m s using 1t 5 where t is motor burnout time s The altitude at burnout can then be computed by y In ai 6 2k T mag Once the burnout altitude is calculated the coasting distance must be determined beginning with the calculation of the coasting mass using Mc Me 7 The coasting mass replaces the average mass in equations and 4 resulting in equations 8 and 9 for the coasting velocity coefficient and coasting velocity decay coefficient respectively T mcg dec 8 2013 2014 RCR CDR rmm 9 Equations 8 and 9 can then be utilized to determine the coasting velocity m s using 1 e ct Vc 10 de Ty e xct The coasting distance can then be computed using cg kv ye ZE In Met 11 The peak altitude is then determined using PA Ve 12 The center of gravity location is calculated using W cg 13 where W is the total weight d is the distance between the denoted rocket section center of gravity nose rocket body engine and fins respectively and the aft end The center of pressure measured from the nose tip is calculat
22. 1 and 4 has been assigned to each hazard with a value of 1 being the most severe In order to determine the severity of each hazard the outcome of the mishap was compared to an established set of criteria based on the severity of personal injury environmental impact damage to the rocket and or damage to equipment A probability value between 1 and 5 has been assigned to each hazard with a value of 1 being most likely Material Safety Data Sheets for payload components can be found in the Appendix 2013 2014 RCR CDR 165 GPS GPRS Cape is not functional Hazard detection camera is not functional Data transmission from the GPHRS unit is not functional Ground The ground station is Failure of the ground station does not turned on when station to receive data from 1 Cause s of Hazard Programming error Electrical issues battery failure etc Physical defect device is physically compromised during launch Programming error causes a crash of the camera code Electrical error in the camera subsystem power outage connection problem Hazard scanning performance is too slow for the required time frame Poor network reception Physical malfunction of the GPRS transmission device The GPS or GPRS antenna is not properly secured to the BeagleBone Black A programming error causes the GPRS unit not to transmit data Hazard Detection Payload Risk Assessment Severity Hazard Outcome
23. 4 Stage termina Separation ets Black P Powder C Charge 1 Apogee 2 0s Figure 7 Booster recovery logic The booster will be the first section to be recovered at motor burnout two MissleWorks RRC3 s will be used to separate the booster from the sustainer These altimeters were chosen for being both able to separate the booster and provide redundant recovery events at apogee at half of the price of the Raven There are two black powder charges at apogee 1 0 seconds this is due to the combination of one altimeter being in backup mode and the other being in apogee only mode 2 Stage Motor Ignition Using OpenRocket and taking an iterative approach with the new larger vehicle it was determined that to achieve the highest altitude that the 2nd stage motor will have to provide thrust 3 0 seconds after burnout In the following flowchart it shows the ejection 2013 2014 RCR CDR oe charge as being 3 0 and 3 5 seconds those values are placeholders until we are able to Statically test the motor The motor will be tested on a static thrust stand and the time taken from sending the ignition signal until the motor produces thrust will be documented and then subtracted from the 3 0 second delay Two igniters will be used with one from each Raven for redundancy Second Stage Motor Ignitor 1 First Stage Burnout 3 05 First Stage Burrjout 3 55 Second Stage Motor Ignitor 2
24. CDR 7 27 Length in Em Field paces Desoription A 1 Begin transmission control character used to signal beginning of the current transmission Message header Message body NEN used to signal end of the message characters Table 39 SMS Message Structure Length Descipion Packet mE Rm specifies ifthisis H hazard detection type a routine hazard detection message message or a special event E event notification launch apogee landing message notification message otart time The time when GPS 090446 000 coordinates were retrieved which converts to Roughly equivalent to the time 09 04 46 000 UTC when the scanned image was taken Recorded in UTC GPS 1 Indicates if the GPS unit had a A data is ok Status reliable connection when V data is invalid coordinates were read in for this message Latitude lt 10 specifies the latitude of the 3816 1785 payload at the time of reading which converts to Encoded in Decimal Degrees 38 9 42 426 and Minutes modifier if it points North or South S South Longitude lt 10 Specifies the longitude of the 08541 9846 payload at the time of reading which converts to Encoded in Decimal Degrees 85 25 11 4456 and Minutes modifier indicate if it points East W West characters 2013 2014 RCR CDR Table 40 SMS Header Structure Length in
25. Material specifications for nose cone design U Bolt x1 Sustainer Stage Ignition Bay The sustainer stage ignition bay will serve three purposes 1 Connect the booster stage to sustainer stage during booster burn phase 2 House black powder charges for booster stage separation 3 House and protect the ignition system for the sustainer stage 2013 2014 RCR CDR The bay will be composed of a 6 0 fiberglass body tube measuring 6 0 in length The read centering ring will be placed 3 5 from the rear of the sustainer This will allow the forward coupler of the booster stage to seamlessly couple with the sustainer stage as seen in the figure below Figure 6 Sustainer stage propulsion bay connection Located inside of the first centering ring of the sustainer stage propulsion bay will be the ignition control system for the sustainer stage This system will be run using a Featherweight Raven altimeter The system will have two outputs the first being for the ignition of the black powder for sustainer stage separation The second output will be for the ignition of the booster stage following the burn out and separation of the booster stage The two outputs will be programmed using the Featherweight interface The planned programming is given in the next section To promote safety calculations have been done to find the range of altitudes the rocket must reach for the ignition of the sustainer stage to take place This rang
26. Springs are to be removed when not launching in order to prevent stretching Springs do not Springs become provide enough Rover will fatigued force to open fairing Airframe for fairing has a vertical cut Rocket will through the entire become airframe Due to unstable the nature of unsafe during wound fiberglass flight this could deform Airframe will have ribbed supports and internal components such as bulk plates to support the structure Airframe becomes deformed Coupling and airframe will be sanded to provide smooth surface allowing the two parts to easily separate The springs that force the fairing apart were carefully selected to provide enough force to open the fairing upon separation but not so much force that the rocket cannot separate Friction between coupling and airframe is too high for pressurization from black power charge to overcome Rover will not deploy and will not be able to perform intended Fairing does not separate from the sustainer Table 56 Fairing Risk Assessment 2013 2014 RCR CDR Rss PROJECT PLAN COMPREHENSIVE BUDGET FUNDING PLAN Vehicle Budget Quantity 1 Unit G12 Filament Von Karman Nose Cone G12 Filament Airframe Tubing 1 ft G12 Filament Coupler Tubing 1 ft G12 Filament 75 mm Tubing 1 ft Acrylic Sheet 1 8 x 12 x 12 1 4 20 Hex Nut Aluminum 1 4 20 Washer Aluminum 1 4 20 U Bolt Aluminum 1 4 20 Thr
27. Verification Table 2013 2014 RCR CDR I Tacon 1200KV Brushless Motors Figure 84 Tacon 1200KV Brushless Motor The motors that will be used were mainly chosen for the torque they provide These motors have a 1200KV rating which means they will rotate 1200 times a minute per voltage applied with no load The motors also have 23 turns each which is another indicator of their higher torque Their maximum voltage is 12 6V and the maximum current draw is 20A These motors weigh 213 8 grams are 36mm in diameter and 60mm in length The D shaft on the motors will allow a coupler to be used to attach a longer shaft The reason that brushless type motors were chosen was because they require little to no maintenance offer more torque have better heat dissipation and experience no power loss across brushes which means better efficiency These motors cost 23 each which is within the team s budget Requirements Features Verification Testing he rover must travel at The 1200KV rating and Once the rover is built the least 20 feet once it has high torque will allow the motors will be tested to landed rover to go over most make sure they can safely terrain in a short amount of drive the rover The motors time have been verified to operate with the ESCs Table 35 Motor Requirement Feature and Verification Table 2013 2014 RCR CDR I Lithium Polymer Batteries Figure 85 Turnigy LiPo Batteries
28. and the launch vehicle was ready for launch After booster burnout the sustainer stage ignited and successfully separated from the booster The sustainer climbed to its estimated altitude while the booster s main parachute was deployed at its apogee The sustainer continued to climb to its apogee and successfully deployed both its drogue and main parachutes and their appropriate altitudes Both booster and sustainer sections landed within 200 yards of the launch pad 2013 2014 RCR CDR I RECOVERY SUBSYSTEM Overview The purpose of any vehicle is to deliver a payload so that the payloads mission can be completed successfully Because this vehicle has multiple payloads the requirements for each payload were factored in to determine the recovery method Payload Requirements the recovery system must satisfy Hazard Detection Be able to land and perform surface maneuvers Stage Separation Land independently of the launch vehicle Fairing Be able to eject a payload during descent Table 3 Payload specific recovery requirements For the hazard detection payload to be able to perform surface maneuvers it must either be able to leave the vehicle after landing or be ejected during descent the fairing must be able to eject a payload during descent To reduce complexity it was decided to merge these two requirements and recover each rocket section independently under its own parachute The sections that will be recovered will be the boost
29. first American to orbit the Earth The lesson will cover founding NASA and the beginnings of space exploration in the United States and U S S H Several core concepts will be taught throughout the lesson including e Rocket stability e Principles of aerodynamics e Newton s Laws e Basic rocket building techniques Paper rocket activity Day Two Apollo Program History This lesson will examine in detail the most monumental program in the history of manned spaceflight The students will learn about the 17 Apollo missions the fatal fire of Apollo 1 mankind s giant leap of Apollo 11 the successful failure of Apollo 13 and the rest of the historic moon landings Core concepts taught during this lesson will be e Thrust to weight ratio e Improved rocket building techniques Advanced paper rocket activity Day Three Shuttle Program 155 and Curiosity Rover History This lesson will examine in detail the movement of NASA from making deep space missions to mastering low earth orbital techniques The space shuitle will also be analyzed in terms of reusability The International Space Station will follow with a look into what it takes to sustain life in low earth orbit Finally a brief look at the Curiosity Rover 2013 2014 RCR CDR 197 mission will demonstrate how we land a probe on another planet Students will have the opportunity to do the following e Understand the use of composites vs metals in aerospace applications e
30. in Table 49 and the volume one step higher was chosen as guidance A safety factor of 1 5 was chosen to influence the size of the final port hole size Altimeter Housing Volume in 78 91 single Port Hole Size in oafety Factor Final Port Hole Size in 0 255 Table 50 Altimeter housing port hole analysis Table 50 shows the data used to determine the final port hole size for the altimeter housing With the safety factor applied it was determined that the 1 4 inch hole used for the screw switch was adequate enough to act as a proper port hole for the StratoLogger Fairing Pyro Cap The primary objective of the fairing is to safely deploy a specific payload at a predetermined altitude The fairing is designed in such a way that the two halves of the fairing want to remain open in its equilibrium state In order for the fairing to stay closed thus encapsulating the payload an aluminum pyro cap and shell will be used to securely 2013 2014 RCR CDR 176 constrain the fairing shut The shell that secures around the pyro cap is comprised of two sections Shell A and Shell With the fairing being primarily completely symmetric in shape and split in halves each bulkplate is a half moon in shape Each shell is securely mounted to its own half moon bulkplate on one half of the fairing In the design of the pyro cap system tolerances were a key item of concern The shells had to be able to snuggly fit together but coul
31. in launching If there is no activity after 60 seconds have the safety officer check the ignition system for a lost connection or a bad igniter If this does not fix the failure mode be prepared to remove the ignition system from the rocket motor retrieve the motor from the launch pad and replace the motor with a spare Confirm that all personnel are at a distance allowed by the Minimum Distance Table as established by NAR in order to ensure that no one is hurt by flying debris Extinguish any fires that may have been started when it is safe to approach Collect all debris to eliminate any hazards created due to explosion 2013 2014 RCR CDR 100 Rocket doesn t reach high enough velocity before leaving the launch pad Booster does not separate from rocket Sustainer ignites early 1 Rocket is too heavy 2 Motor impulse is too low 3 High friction coefficient between rocket and launch tower 1 High angle of flight 2 Too tight of fit between the booster and sustainer False reading from the altimeter 1 2 Unstable launch 1 Booster motor will not fire 2 Damage to interior components of the booster section Significant damage to the booster section particularly in the case of burns to the booster recovery system Would also result in loss of overall Low Low Low Too low of a velocity will result in an unstable launch Simulations are run to ver
32. it a success These tests are based off of the success criteria mentioned earlier Success Qualification Run motors at full throttle until they stop ESCs and motors do not overheat or fail DUE aa mustum for atleast hour o Run BeagleBone and attached peripherals Electronics are still powered after an hour Gather amp Send GPS data to webserver GPS coordinates must be received and match expected location by using Google Maps without much latency Run image processing software Each of the tested hazards are able to be detected and identified correctly 90 of the time Run image processing software and Data is received correctly 90 of the time different altitudes the time at altitudes yet to be determined Drop rover with parachute attached from Accelerometer is able to detect landing at least 50 feet rover doesn t land upside down and no components are damaged or detached Drive rover over several different terrains Must go at least 20 feet without problems Activate Marker Cam to release the Rover doesn t get tangled with parachute FM multiple times sensor must be similar to those obtained via an altimeter Rocket Launch Tests All systems operate correctly and rover Table 46 Hazard Detection Payload Tests Variables Since the rover will be ejected from the fairing in the air there are many variables that could affect this payload The main variable that could affect this payload is weather conditions The r
33. kd rover body to stabilize release sequence Y N Send PWM signalto __ specified pin 1 An exception is LL thrown from any function Wait 4 seconds for rotation to complete Stop sending PWM LE _ signal di se neun ERROR release sequence Was ERROR Veturia ReleaseAttempts 1 ReleaseAttempts No Y Continue to start rover engine and begin rover movement 4 Yes Figure 108 Parachute release algorithm The parachute release algorithm first waits for the landing event to occur to prevent detaching the parachute midair or before launch Once the payload has landed it will wait a period of 10 seconds before proceeding further This is done to increase the probability that the body of the rover is physically stable IE not rolling down a slope After the rover has waited 10 seconds the parachute release sequence begins The parachute release sequence simply consists of sending a PWM signal with a specified duty cycle 85 was used for testing to a designated pin for a given time period 4 seconds was used during testing that is attached to the parachute release servo This action will cause the servo to rotate 180 degrees and thus release the parachute from the rover body Finally the payload will stop sending PWM signals to the servo If during this process any soft
34. made for the BBB so it is guaranteed to work and it attaches to the pins on the BBB via headers Two antennas attach to the cape to allow it to receive GPS and transmit GPRS data The data from the surface hazard detection camera and software system shall be transmitted in real time Verification Testing Data has been sent using this cape via SMS to a cell phone This cape features a GPRS module capable of transmitting data over SMS by using a cell phone SIM to a ground station An electronic tracking device shall be installed in the launch vehicle and shall transmit the position of the tethered vehicle or any independent section to a ground receiver 2013 2014 RCR CDR Er card A Telit GE 864 GPS module is included on the cape This module is accurate to less than 2 5 meters Google Maps has verified that the GPS co ordinates match our location The electronic tracking This cape is compatible Tests will be conducted to device shall be fully with the BeagleBone which insure the cape does not functional during the official will be in charge experience any problems flight at the competition operating the cape launch site Table 33 GPS GPRS Cape Requirement Feature and Verification Table HobbyWing 35A EZRUN ESC Figure 83 HobbyWing 35A EZRUN ESC To interface the motors on the rover with the BeagleBone an off the shelf electronic speed controller ESC will be used with o
35. of the maximum altitude to which rockets are allowed to be flown at that site or 1500 feet whichever is greater or 1000 feet for rockets with a combined total impulse of less than 160 N sec a total liftoff weight of less than 1500 grams and a maximum expected altitude of less than 610 meters 2000 feet 10 Launcher Location My launcher will be 1500 feet from any occupied building or from any public highway on which traffic flow exceeds 10 vehicles per hour not including traffic flow related to the launch It wil also be no closer than the appropriate Minimum Personnel Distance from the accompanying table from any boundary of the launch site 11 Recovery System will use a recovery system such as a parachute in my rocket so that all parts of my rocket return safely and undamaged and can be flown again and will use only flame resistant or fireproof recovery system wadding in my rocket 12 Recovery Safety will not attempt to recover my rocket from power lines tall trees or other dangerous places fly it under conditions where it is likely to recover in spectator areas or outside the launch site nor attempt to catch it as it approaches the ground All team launches will be at NAR TRA certified events The Range Safety Officer will have the final say over any rocketry safety issues The team will comply with this rule and any determination the Range safety Officer makes on launch day The Recovery team will be r
36. opens about In order to ensure a smooth motion of the fairing opening the team has implemented an aluminum hinge with 304 stainless steel pin The main draw of the hinge are the polyacetal bushings These bushings prevent metal to metal contact that could possibly induce undesirable friction 2013 2014 RCR CDR 185 SAFETY AND ENVIRONMENT PAYLOAD Fairing Risk Assessment The hazards outlined in Table 56 are risks that are related to the fairing This includes potential risks during assembly launch recovery and operation of the fairing 2013 2014 RCR CDR 486 Fairing Risk Assessment Cause Severity Probability Risk Mitiaation Mechanism Value Value Level 9 Sustainer does not eject from the rocket Fairing gets tangled in parachute Battery in altimeter housing dies E match fails 1 Nylon shear pins do not fully shear 2 Friction between sustainer and booster is too high Improper packing of parachute 1 Use past the normal life of the battery 2 Extremely cold weather 1 E match become dislodged 2 Faulty e match 1 2 Ejection charges will not fire preventing the rocket from Splitting and the rover being deployed 1 2 Ejection charges will not fire preventing the rocket from Splitting and the 2013 2014 RCR CDR Rocket will not achieve goal altitude Rover will be unable to deploy Rocket GAELA will still completely recover Rover will no
37. other measures seen fit to reduce risk Risk levels will also be reduced through verification of systems Risk Assessment Matrix Probability Value every valle Catastrophic 1 Critical 2 Marginal 3 Almost Certain 1 Lug TONS 4 Moderate Table 21 Risk Assessment Matrix Lab and Machine Shop Risk Assessment Construction and manufacturing of parts for the rocket will be performed in both on campus and off campus labs The hazards assessed in Table 22 are risks present from working with machinery tools and chemicals in the lab 2013 2014 RCR CDR ra Launch Pad Risk Assessment The hazards outlined in Table 23 are risks linked to the launch pad that the team has previously designed and built Since the launch pad was used throughout the entirety of last season without any problems we are confident in the safety of its design Stability and Propulsion Risk Assessment The hazards outlined in Table 24 are risks associated with stability and propulsion There are particular risks involved when staging a rocket This year is the team s first experience attempting a complex rocket The risks were initially higher than would be considered acceptable for the competition launch Sub scale tests have verified that the team can successfully launch a dual stage rocket successfully The risks will be reduced at a later date to reflect our confidence in the system when it can be validated that the full scale rocket can be staged
38. our LiPo batteries As mentioned in Table 48 all personnel will be asked to stand away and the range safety officer will immediately be contacted If the fire cannot be contained immediately local authorities will be contacted about the situation Other than a fire this payload poses no foreseeable environmental concerns On the other hand the environmental concerns towards the payload could be slightly problematic The main concern is loss of communication data due to altitude or being in locations where there is no network signal This could result in partial mission failure due to loss of real time data transmission The payload will be tested several times at different altitudes to insure it is not a problem and network maps will be consulted to insure signal is available at all launch locations Another concern for the payload is drift due to the wind once it has been deployed from the fairing If the payload drifts for too long it could go into areas without network coverage Besides losing connectivity the payload could drift past the launch field into private property which could make retrieval a problem The payload s parachute will be sized to reduce the amount of drift while still making sure the payload is able to survive the landing impact Risk Assessment Table 48 shows the current payload risk assessment table for the hazard detection payload The risk matrix is similar to the one described for the vehicle A severity value between
39. prevent water damage 1 Have to 1 2 3 When planning test launch at high launches the forecast should be High winds N A angle reducing 1 4 Moderate monitored in order to launch ona altitude day where weather does not achieved prohibit launching or testing the 2013 2014 RCR CDR Trees Swampy ground N A Ponds creeks and other bodies of water N A N A 2 Increased drifting 3 Unable to launch 1 Damage to rocket or parachutes 2 Irretrievable rocket components Irretrievable rocket components 1 Loss of rocket components 2 Damaged electronics Moderate Moderate Moderate entire system If high winds are present but allowable for launch the time of launch should be planned for the time of day with the lowest winds Launching with high winds should be avoided in order to avoid drifting long distances Drift calculations have been computed SO we can estimate how far each component of the rocket will drift with a particular wind velocity The rocket should not be launched if trees are within the estimated drift radius With the potential of the salt flats being extremely soft as well as local launch sites the rocket should not be launched if there is swampy ground within the predicted drift radius that would prevent the team from retrieving a component of the rocket Launching with high winds should be avoided in order to avoid drifting long distances
40. prior to use to Faulty igniter or p igniter becomes significantly ensure it allows the signal to ignite dislodged below the goal the motor within the allowable Rocket will still range The tiltometer will be fully recover zeroed on the launch pad prior to each use 3 There will be 2 igniters used for redundancy If the delay allows for the rocket to fall past parallel to 1 Test altimeters to make sure the ground they are fully operable prior to significant flight Altimeters have special 1 Altimeter damage would bays designed to ensure secure Sustainer ignition malfunction be done to the mounting throughout the flight delayed 2 Bad connection rocket and 1 4 Moderate Raven diagnostic codes will alert between ignition personnel could personnel if there is an error control systems be at risk If it is 2 All connections are to be a short delay inspected prior to flight This causing the inspection is included as a part of rocket to fall launch day procedures less than 90 there will be a loss in altitude 2013 2014 RCR CDR H Fins shear during flight Airframe buckles during flight Internal bulkheads fail during flight Insufficient adhesion during Installation resulting ina failure in the Airframe encounters stresses higher than the material can support Forces encountered are greater than the bulkheads can support Unstable rocket causing the flight
41. proceed or not Then the program will continuously poll the pressure sensor to determine if the launch event has occurred When launch is detected the rocket will proceed to the in air activities phase of operation In air activities As soon as the in air activities phase begins the payload will send an SMS to the ground station indicating that the launch event occurred Then the program will continuously wait to detect apogee from the pressure sensor Once apogee is detected another SMS message will be sent to the ground station indicating this event Image processing activities After apogee is detected the payload enters its image processing phase In the image processing phase an image is taken from the onboard camera Then the image is scanned for evidence of water roads and crowds of people and the presence or absence of these hazards is recorded After the image is scanned for hazards an SMS is sent to the ground station with hazard detection results Finally the program will check for landing through the pressure sensor and if landing is detected the post landing activity phase will begin If landing is not detected the program will continue extra image processing steps Post landing activities After the rover lands it will first send an SMS to the ground station indicating that landing has occurred Then the rover will wait 10 seconds to stabilize before releasing the attached parachute Once the parachute is release
42. requires interdisciplinary work between computer electrical and mechanical engineering students Due to this the main challenge the team faces is having good communication skills between all majors to keep development running smoothly as there are many systems aboard the rover that have to co operate to make this payload a success Good communication skills are not just required for this project but in the real world which therefore makes this project a good learning experience The main technical challenge the team faces is coding the software package so that all systems operate as intended his requires the hazard detection algorithms to be as accurate as possible Fortunately image processing is a topic covered at the 2013 2014 RCR CDR undergraduate level The second obstacle will be transmitting the data to our ground Station via SMS Since last year s payload used SMS to transmit data via a cell phone the coding for this payload will be easier thanks to the amount of documentation available since the payload is getting centralized around a rover concept the rover must be able to secure all the components and survive landing independently of the rocket Fortunately the team has full control over the rover s design and is able to 3D print parts as necessary to insure that everything is structurally safe Overall this payload has several challenges that will need to be overcome to make it a success but the level of difficu
43. saws drills etc Sanding or grinding materials Working with chemical components resulting in mild to severe chemical burns on skin or eyes lung damage due to inhalation of toxic fumes or chemical spills 1 Improper training on power tools and other lab equipment 1 Improper use of PPE 2 Improper training on the use of a Dremel tool 1 Chemical splash 2 Chemical fumes 1a Mild to severe cuts or burns to personnel 1b Damage to rocket or components of the rocket 1c Damage to equipment 1a Mild to severe rash 1b Irritated eyes nose or throat with the potential to aggravate asthma 2 Mild to severe cuts or burns from a Dremel tool and sanding wheel 1 Mild to severe burns on skin or eyes 2 Lung damage or asthma aggravation due to inhalation of fumes 1 Individuals must be trained on the tool being used Those not trained should not attempt to learn on their own and should find a trained individual to instruct them 1 Safety glasses must be worn at all times 1 Sweep or vacuum up shavings to avoid cuts from debris 1a Long sleeves should be worn at all times when sanding or grinding materials 1b Proper PPE should be utilized such as safety glasses and dust masks with the appropriate filtration required 2 Individuals must be trained on the tool being used Those not trained should not attempt to learn on their own and should find a trained individua
44. sleds that will both reside in the nose cone The forward most sled houses a Garmin Astro DC 40 GPS dog collar which will be used to track the vehicle section This sled will be held in place via aluminum threaded rods similar to all other avionics bays Beneath the GPS sled will be a wooden bulkplate which will be covered with aluminum tape to shield the altimeters from the GPS signal Nose Cone MATEMAL ABS Avionics Bay ANISH University of Louisville River City Rocketry 2013 2014 Design N A g SwEEIL 1 Gt Figure 61 Nose Cone GPS sled 2013 2014 RCR CDR All dimensions symmetric around centerline B SECTION B B SCALE 1 1 DETAIL A SCALE 2 1 D WEHS IONS ATE IN os 6 srt TOLERANCE ARE Cae areas abe University of Louisville DISC ION ROTI re rali arar 1 Boirain DEC AS AC GE ott ver City Rocketry XI 401 98 acu os CAT 12 o ed UC C 4 ae re MUNRO CIEE Mab a 2013 2014 Design Sot ti 65 XIE 2905 eh Foi CHEE WHO VE 4 85000 fueris wr ot ease SHEET OF POC Oft neret PROPRIETARY NOTE M 5 PAPI Figure 62 Nose Stratologger sled ITEM NO PART NUMBER QTY Nose Cone Stratologger Sled 2 Nose Cone GPS Sled 3 Mosecone Tp Assem bly
45. spill occur ground or water chemicals that in turn proper measure are to be followed work their way in accordance with the MSDS into humans sheets and any OSHA standards causing illness Due to the nature of the location Holes will have of the competition launch holes Staki to be drilled in will have to be drilled into the salt Destruction of salt ening ol me the salt flats in flats in order to stake the launch launch tower in 4 1 Moderate flats order to proper ad This has been discussed hard ground pp Stake the launch with personnel at the site and they tower have verified that this is acceptable to do 2013 2014 RCR CDR Table 28 Hazards to Environment Risk Assessment 2013 2014 RCR CDR n NAR TRA PROCEDURES NAR Safety Code The below table describes each component of the NAR High Power Rocket Safety Code effective August 2012 and how the team will comply with each component NAR Code 1 Certification will only fly high power rockets or possess high power rocket motors that are within the scope of my user certification and required licensing 2 Materials will use only lightweight materials such as paper wood rubber plastic fiberglass or when necessary ductile metal for the construction of my rocket 3 Motors will use only certified commercially made rocket motors and will not tamper with these motors or use them for any purposes except those recommended by the manufacturer
46. subscale was where the team first discovered it had underestimated the rocket s recovery system s sizes The design for the subscale originally called out for a 5 foot and 6 inch rocket After the recovery system s sizes were re evaluated and corrected the team s subscale was just shy of 7 feet and 9 inches The team flew the rocket twice and noticed a few key design flaws that would transfer over into a redesign into the full scale Figure 17 View of the staging coupler overhang The primary design challenge for the team was to determine how to properly couple the two stages together The team decided to have a piece of coupler tubing epoxied into the bottom of the sustainer s lower airframe This coupler tubing had a 3 inch overhang below the sustainer in order to allow the booster s upper airframe to securely couple with the sustainer In order for the coupler tubing to be properly inserted and not interfere with the fins precisions cut fin slots were cut into the tubing 2013 2014 RCR CDR 4 2 7 8 A z Figure 18 Sustainer stage motor tube assembly with centering rings and staging coupler With this design finalized the team was pleased with the form and fit of the two stage launch vehicle The first flight of the subscale was more eventful than the team prepared for After the electronics were wired in and double checked the rocket stages were coupled together In order to make sure the coupling of the
47. successfully The planned full scale testing will reassure that the designed system is safe and operates as intended Recovery Risk Assessment The hazards outlined in Table 25 are risks associated with the recovery Since there are four recovery systems onboard many of the failure modes and results will apply to all of the systems but will be stated only once for conciseness Vehicle Assembly Risk Assessment The hazards outlined in Table 26 are risks that could potentially be encountered throughout the assembly phase and during launch preparation Environmental Hazards to Rocket Risk Assessment The hazards outlined in Table 27 are risks from the environment that could affect the rocket or a component of the rocket Several of these hazards resulted in a moderate risk level and will remain that way for the remainder of the season These hazards are the exception for needing to achieve a low risk level This is because several of these hazards are out of the team s control such as the weather The hazards that the team can control will be mitigated to attain a low risk level Hazards to Environment Risk Assessment The hazards outlined in Table 28 are risks that construction testing or launching of the rocket can pose to the environment 2013 2014 RCR CDR ra Lab and Machine Shop Risk Assessment Cause Severity Probability Risk Mitiaation Mechanism Value Value Level g Using power tools and hand tools such as blades
48. that dry grass is cleared around each launch pad in accordance with the accompanying Minimum Distance table and will increase this distance by a factor of 1 5 and clear that area of all combustible material if the rocket motor being launched uses titanium sponge in the propellant 8 Flight Safety will not launch my rocket at targets into clouds near airplanes nor on trajectories that take it directly over the heads of spectators or beyond the boundaries of the launch site and will not out any flammable or explosive payload in my rocket will not launch my rockets if wind speeds exceed 20 miles per hour The team will comply with this rule and any determination the Range Safety Officer makes on launch day The team will ensure that the launch pad meets these requirements using any additional tools necessary on launch day to ensure compliance and a safe launch The team will comply with this rule and any determination the Range Safety Officer makes on launch day 2013 2014 RCR CDR 112 will comply with Federal Aviation Administration airspace regulations when flying and will ensure that my rocket will not exceed any applicable altitude limit in effect at that launch site 9 Launch Site will launch my rocket outdoors in an open area where trees power lines occupied buildings and persons not involved in the launch do not present a hazard and that is at least as large on its smallest dimension as one half
49. that run the length of the rover Success of locomotion for the rover would be an incremental qualifying procedure for this variety of movement By meeting the criteria listed below the payload will have met all the requirements in the Statement of Work 1 The GPS coordinates sent to webserver must match the expected the location 2 Each of the tested hazards must be able to be detected and identified correctly 90 of the time 3 Data is sent to webserver correctly 90 of the time 4 Rover is able to detach parachute and drive off safely for at least 20 feet 5 All electronics must be operational after 1 hour with the same power supply Table 45 Payload Success Criteria Experimental Logic Approach and Method of Investigation Due to the nature of the hazard detection payload most of the experiments to be performed by the payload will be evaluated on a pass or fail basis To verify that our software package is correctly registering and identifying a hazard we will have to visually compare that the object identified in an image is the hazard that we were looking for The visual detection of the payload will be based algorithmically on OpenCV framework The image processing program will be tested to insure that it can identify any of the hazards we tell it to This will happen by comparing filtered and unfiltered images These images will then give the image processing part of the payload a pass or fail grade The experimentation o
50. the payload s hardware requirements are simplified which will also make integration easier Figure 75 shows the layout of the payload s electrical hardware excluding any power sources Camera _GPS GPRS Cape 0 Custom BeagleBone Black ESCs Motors Parachute Cam Figure 75 Electronic Hardware Layout 2013 2014 RCR CDR 116 One of the main lessons learned from last year s competition was that cell phones were excellent for transmitting data Therefore this year the team plans to keep using similar cell phone technology by using an off the shelf circuit board that contains a GPRS module for data transmission as well as a GPS sensor This PCB will be mounted onto a BeagleBone Black BBB microprocessor which will be used as the brains that will control all of the payload components One of the many features of the BBB is its USB slot which will be used for connecting a Logitech C920 webcam directly This allows the team to eliminate the need for additional circuitry to interface both of these components Added to the BBB will be a custom made PCB that will contain any needed sensors to determine crucial events such as launch apogee and landing This PCB will also be used for attaching the circuitry required for powering the BeagleBone the Electronic Speed Controllers ESC for the rover s motors and for the servo controlling the Marker Cam Each component shown in Figure 75 is described in more detail below BeagleB
51. us to use a cape with transmitting capabilities Low power consumption in standby mode will allow us to keep critical components active until launch is detected The BeagleBone is capable of having 4 capes stacked upon it allowing us to use a cape with GPS capabilities The BeagleBone is a standalone computer that can function without any external circuits The webcam has been verified to work with the BeagleBone and we are able to obtain images via the BeagleBone simple image processing has been run via the BeagleBone and data was able to be processed in a few seconds Data has been sent from the BeagleBone to a cell phone via SMS Data has also been sent to a webserver Tests will be conducted to insure all components are active for at least 1 hour The GPS coordinates from the GPS GPRS cape have been verified to match our expected location The payload is completely separate from any components relating to the recovery system Table 30 BeagleBone Requirement Feature and Verification Table 2013 2014 RCR CDR 118 B Logitech C920 HD Pro Webcam Figure 77 Logitech C920 HD Pro Webcam After the BeagleBone this camera is be the most important payload component since it will be responsible for obtaining images with as high resolution possible while still being able to be processed at a decent rate The C920 webcam is capable of taking 15 megapixel photos as well as recording in full HD 1080
52. was chosen due to its capabilities for handling the software s expected demands To control the payload s brain the software package the team is developing will be responsible for controlling everything aboard the hazard detection payload from the time its activated until it is retrieved The part of the program that will use most of the BeagleBone s resources is the image processing algorithms To reduce the strain on the BeagleBone the software will be optimized as much as possible An overview of how the different parts of the payload software package will operate is described below Changes Since PDH A few changes have been made to the overall flight algorithm since PDR These are mostly minor logical tweaks to fix errors Issues addressed e Inthe PDR the device failure reporting step resulted in stopping the entire launch process even if a non critical error occurred This has been modified to make the launch process continue if hardware setup errors occur and give the team the option of continuing to launch depending on the device s that failed e n the PDR GPS coordinates were sent continuously from the payload to the ground station prior to launch detection This step has been removed because 1 the GPS coordinates of the launch pad can be closely approximated by the coordinates of the first packet sent to the ground station 2 Continuously sending text messages to the ground station will cause unneeded battery drainage which
53. will also be properly tapped to allow for the StratoLogger screw switch and the acrylic glass front plate to be securely mounted to the altimeter housing 2013 2014 RCR CDR LN Figure 110 Exploded view of the altimeter housing Furthermore there is a hole in the back of the altimeter housing which can be seen in more detail below in Figure 111 Once assembled this hole will line up with a hole that will be drilled into the coupler tubing the altimeter housing rests in This hole will allow access to the screw switch so that the altimeter can be armed on the launch pad SECTIOM B 3 ALTIMETER HRCAUSIPAZS PERE df E E HTH lou TES F 3 XE EN Cily Rocher 4 Figure 111 Altimeter housing basic dimensional drawing 2013 2014 RCR CDR ETC Utilizing information from StratoLogger s website the port hole size for the altimeter housing was determined Table 49 shows the information gathered and calculated from StratoLogger s website Avionics Bay Single Diameter Length Volume Port inches inches in Hole Size in 60 1206 0032 60 2078 0 048 80 5655 0113 80 9557 0202 5 5 7 5 Table 49 StratoLogger s volume to port hole size comparison In order to decide on the appropriate port hole size the volume of the altimeter housing was calculated This value was cross referenced against the information
54. with all local state and federal laws e Ensure compliance with all NAR regulations e Provide a written team safety manual that includes hazards safety plans and procedures PPE requirements MSDS sheets operator manuals FAA laws and NAR regulations e Confirm that all team members have red and comply with all regulations set forth by the team safety manual e Ensure the safety of all participants in educational outreach activities providing PPE as necessary Emily has written a team safety manual that each team member was required to review and sign indicating compliance The document includes hazards proper safety plans and procedures PPE requirements MSDS sheets FAA laws and NAR regulations The manual will be revised throughout the year as a need arises Emily has confirmed that each team member has read and acknowledged the safety manual and will continue to enforce all statements in the safety manual The manual can be found on the team website along with a signed document of compliance from each team member 2013 2014 RCR CDR ra Hazard Analysis Risk Assessment Matrix By methodically examining each human interaction environment rocket system and component hazards have been identified and will continue to be brought to the team s attention Each hazard has been assigned a risk level through the use of a risk assessment matrix found in Table 21 by evaluating the severity of the hazard and the probability that the
55. with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e violate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events 14 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e violate these regulations realize that may not be able to participate construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events 1m 2 24 20 Sy oignature Date 2013 2014 RCR CDR 200 RIVER CITY ROCKETRY UNIVERSITY OF LOUISVILLE SAFETY COMPLIANCE FORM By signing this form agree to comply with all safety rules and regulations set forth by the safety manual have read and am familiar with the entire document u
56. 15 Tie the nylon cord from the deployment bag to the appropriate eyebolt 16 Insert and tape electronic matches into proper ports in pyro cap 17 l nstall O ring into O ring groove around the pyro cap 18 Fill both black powder chambers with black powder 19 Close the fairing 20 Carefully install the pyro cap so that no black powder spills 21 Install 4 40 shear pins into the pyro cap assembly 22 Tie nylon cord from the pyro cap s eyebolt to the appropriate eyebolt in the adjacent bulkplate 2013 2014 RCR CDR ra Safety Checklist Launch Pad Launch Pad Assembly Checklist LPA To be checked and initialed by Launch Pad Safety representative Launch Pad Safety Representative Signatures 1 2 Required Equipment e Allen Wrench Set Standard e Upper and Lower Launch Pad sections e Launch Pad legs e 9 16 Wrench e Leg quick release pins e 3 4 wrench e Hammer e Stakes e Clamp e Drill 1 ____ Inspect launch pad for any cracked welds 2 ___ Attach legs to Launch pad using quick release pins Polish mounting pins on lower launch pad section 4 Slide Upper Launch Pad section onto corresponding mounting pins in the Lower Launch Pad section 5 X Secure brackets to upper and lower launch pad 6 Position lower Launch Pad enclosure so that it is fastened to both upper and lower sections of the launch pad 7 Secure lower launch pad enclosure to guide rails using existing ha
57. 2014 RCR CDR ra MISSION PERFORMANCE PREDICTIONS Mission Performance Criteria The following criteria must be satisfied for the mission to be considered a success 1 The vehicle and hazard detection payload must be reusable 2 The apogee altitude be at 10 000 feet or less 3 A horizontal drift must be less than 1 5 miles if the alternate launch site is to be used 4 The vehicle must have a stability margin greater than 1 75 while the booster is active and a stability margin greater than 1 3 for the sustainer Vehicle Characteristics A combination of OpenRocket solid modeling and weighing of component parts a simulation has been made and shown in Figure 65 o ey ey Stability 2 6 cal v CG 116 in 132 at 0 30 Length 198 max diameter 6 2 in Mass with motors 74 5 Ib Apogee 9939 ft Max velocity 827 11 5 Mach 0 75 Max acceleration 330 ft s Figure 65 OpenRocket simulation Overall Length inches Overall Mass Ibs Stability Margin Both 26 otages Stability Margin Single 4 36 Stage Figure 66 Vehicle dimensions 2013 2014 RCR CDR Motor Thrust Curves Motor thrust curves 3 Za 3 200 3 220 Time s Figure 67 Thrust curve of the M3100 motor to be used in the booster Motor thrust curves 2 000 1 200 1 250 1 000 Thrust g 0 00 0 50 1 00 1 25 Time s Cesaroni Technology Inc L1720 W
58. 4 RCR CDR ra Figure 72 Top View of Rocket retained in Guide Tower Another added benefit of the guide tower design is the leveling adjustment This allows for the team to accurately level the rocket before launch as well as tilt the launch pad based on local windage Orientation of the pad is adjusted using four adjustment screws surrounding a swiveling head below the base of the guide tower as seen in Figure 37 These adjustment screws are also used to distribute the load transferred to the base during launch Figure 73 Leveling adjustment screws Also aS you can see in Figure 37 the Launch Pad Assembly can be broken apart for transport It is designed to break down into 3 sections for transport as shown in Figure 38 These sections are assembled before launch using quick release pins and screws 2013 2014 RCR CDR La Upper Section Figure 74 Break down of Launch Pad 2013 2014 RCR CDR LAUNCH CONCERNS AND OPERATION PROCEDURES Safety Checklist Stability and Propulsion To be checked and initialed by S amp P Safety representative Stability and Propulsion Representative Signatures 1 2 Booster Propulsion Bay Assembly Checklist PBA Required Equipment e 5 Casing e Cesaroni M3100 WT e Aeropack 75mm flanged e Propulsion Bay Stand ____ The team mentor will be responsible for preparing motor within casing ____ Slide motor casing fully into the motor mount tube ____ Attach mo
59. 71 5 71 12 24 12 24 5 23 5 23 18 80 18 80 51 97 103 94 HobbyWing eZRun 35A Brushless ESC 6 32 3 32 Height Hex Nuts sciGrip Plastic Cement 4 40 Male Female Nylon Standoffs 5 40 7 64 Height LockNut 4 40 1 4in Length Nylon Screws 12in x 24in Black Acrylic Sheet 3in x 12in MultiPurpose 6061 Aluminum Rod Logitech C920 HD Pro Webcam 69 99 69 99 T Mobile Mobile Plan 30 3 00 90 00 749 43 Table 61 Hazard detection payload budget Travel Budget 1 730 65 2 000 00 5 906 65 Table 62 Travel budget 2013 2014 RCR CDR I Total Tentative Budget Vehicle Recovery Fairing Payload d t 1 500 0 2 000 0 Travel Expenses 5 906 65 18 319 81 Subscale 1 075 68 Educational Engagement Promotional Materials Vehicle Recovery Fairing Payload Hazard Detection Payload v Nu Subscale Travel Expenses Figure 117 Total tentative budget COMMUNITY SUPPORT Kickstarter For the past two competition years River City Rocketry launched a Kickstarter site to connect with the community and gain support Kickstarter is a fundraising KICK platform that allows creative projects to find support from people near and far River City Rocketry offered various STARTER rewards to its supporters such as custom science boards team t shirts and even advertisement or logo space on the rocket so that sponsors have a personal connection to the team and project The si
60. Check that the airframe is not deformed 2 ___ Check the structural integrity of all bulk plates 3 ____ Inspect the foam inserts and ensure there is no play or deformations in them 4 ___ Ensure that the fairing can smoothly open and close Launch day procedures Fairing Payload Assembly FPA Required Equipment 2013 2014 RCR CDR e Black powder e StratoLoggers 9V Batteries e Screw switches e Electronic matches e Springs e Hinge e Square U Bolts e Rover payload e 4 40 Shear Pins e Duct tape 1 ____ Lay out the two halves of the fairing and ensure that all permanent components are still intact and flight ready Install both StratoLoggers Install both screw switches Secure both 9V batteries Wire up both altimeter housing assemblies Ensure the screw switch is not activated and wire in all electronic matches ___ Install acrylic faceplates to altimeter housings ___ Install hinge to one half of the fairing ____ Place springs and one section of shock cord on one square U bolt 10 __ Install square U bolt with springs attached 17 ___ Join the two halves together by installing the other half of the hinge to the second half of the fairing WH 12 ___ other end of springs on secondary square U bolt along with the other section of shock cord 13 Install secondary U bolt 14 Securely place rover payload and rover recovery system into the foam inserts
61. Design a payload that would fit inside the space shuttle cargo bay e Design a space station with the fundamental elements for sustaining life e See simulations of extra terrestrial landing techniques for unmanned missions Day Four OoenRocket Simulation The class will have the opportunity to model a rocket using OpenRocket software The model rocket will later be constructed and launched This simulation software will allow students to see how flight trajectories and altitudes are accurately predicted Concepts that will be reinforced are as follows e Software proficiency e Understanding how math is applied through software solutions e The importance of measurement accuracy e Mass balance e Stability margin acceptability Day Five Rocket Construction Each student will have the opportunity to construct and launch their own rocket Rockets will be small Estes model rockets using black powder motors and each student will be carefully supervised The students will be led through a visual walkthrough of rocket assembly The following concepts will be taught e Proper measurement e Construction techniques e Fin installation e Launch lug mounting e Shock cable and parachute organization Day Six Final Construction Rocket Launch Summation The students will be taught how to properly and safely setup launch pads Any remaining construction work on the rockets will be completed during this session The students will be taught how to pack
62. Lithium Polymer batteries LiPo will power the electronics for this payload The reason LiPo batteries were chosen was due to their excellent track record in previous competitions Only two LiPo batteries will be required for the payload one for the motors and one for the BeagleBone and its attached peripheries Since each cell on a LiPo has a nominal voltage of 3 4V a cell LiPo will be used for the motors and a 2 cell LiPo for the BeagleBone Each LiPo also has a mAh rating which measures the storage capacity for that battery The mAh value tells you how much current the battery is able to deliver per hour Each of the batteries will have a 2200mAh rating as this will allow the BeagleBone to run for around 4 hours thus the payload has enough power to remain on the launch pad for an hour Further testing will qualify this theory Turnigy LiPo batteries were chosen as they contain a fire retardant material in case of fire Table 36 shows the requirements the LiPo batteries satisfy what features will help meet that requirement and how they are expected to be verified Requirements Features X Verification Testing The launch vehicle shall be The 2200mAh rating will The payload will be run with capable of remaining in allow the BeagleBone and the batteries for at least an launch ready configuration all its peripheries to be hour to make sure the mAh at the pad for a minimum of active beyond the 1 hour rating is appropr
63. N that it is non conductive to electricity To attach the Parachute Cam screws will be used to attach it and the servo onto the platform These screws will go through tabs built into the Parachute Cam To attach the motors clamps will be used that go around the motors and hold them in place These clamps will then screw into the end plate of the rover Figure 104 Motor Clamp Most of the wires for the electrical components will be routed underneath the electronics platform The wires will be held in place with zip ties Some of the wires on the components will have to be cut due to their length such as the USB cable from the webcam which is 6 feet long Special attention will be used when doing this as it could impact the payload s performance After the wires are soldered together tests will be conducted to insure that the components still function as intended The electronics platform will have holes in it to allow the wires to go to their respective components Power Screw Design The main feature of this rover is the power screws which will be used for movement Each of the power screws will be 3D printed out of ABS plastic since their complex shape would be difficult to machine ourselves and expensive to contract out They are currently being printed by the rapid prototyping lab at the university The screw slope angle was chosen as 16 degrees due to information from a previous study Terramechanics based Propulsive Characteristics
64. Ped characters _ Delon Example _ _ Evidence Indicates whether or not 1 crowd detected of crowd crowd of people was detected 0 crowd not detected of in the most recently scanned people image ide Indicates whether or not a road 1 road detected was detected in the most 0 road not detected road recently scanned image of a body of water was detected in the 0 body of water not of water most recently scanned image detected characters Table 41 SMS Body Structure Hazard Detection Message Length in EO characters Dein _ Event The type of event that was L Launch type detected Can be a launch A Apogee event apogee event landing N Landing or mission ending event Mission end Total m in m Table 42 SMS Body Structure Event Notification Message Message content 4H083512000A3816 1785N08541 9846W101 A hazard detection packet was sent at 8 35 12 UTC at coordinates 438 9 42 426 85 25 11 4456 which detected a crowd of people and a body of water E083512000A3816 1785N08541 9846WE An event notification packet was sent at 8 35 12 UTC at coordinates 438 9 42 426 85 25 11 4456 indicating that the mission has ended Table 43 Message Examples SMS messages start with a header section contains metadata about the packet The header contains the type of packet that is being sent and the GP
65. S coordinates at the time of transmission There are two types of packets that the payload will send which are noted in the packet type field Hazard detection messages are meant to indicate that an 2013 2014 RCR CDR 140 image was scanned for hazards and the presence or absence of all hazards that were scanned for Event notification messages notify the ground station that a special event has just occurred in the launch sequence For our purposes event notifications will be limited to notification of rocket launch apogee and landing A body section immediately follows the header section with the results of either hazard detection or event notification Begin ground station program received from he payload Parse SMS into relevant data structures Upload SMS data to web server via FTP Note Program ends when terminated by the user Figure 95 Ground station flowchart SMS messages are transmitted from the payload to the ground station a cellular phone from one of the team members The ground station s program logic is simple The ground station contains a program that will continuously listen for incoming SMS messages from the payload When a message arrives the message will be parsed and transformed into a formatted text file to be uploaded to the web server From there the team s web server will notice that a new text file has been uploaded The server will updat
66. T Figure 68 L1720 Thrust Curve 2013 2014 RCR CDR ra stability Margin Stability margin calibers o 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 Time s Figure 69 Stability margin Drag Characteristics 300 000 290 000 280 000 270 000 260 000 250 000 240 000 230 000 J 220 000 210 000 200 000 190 000 180 000 170 000 160 000 150 000 140 000 130 000 120 000 110 000 ji 100 000 90 000 80 000 70 000 60 000 50 000 40 000 30 000 20 000 10 000 Drag coefficient 2210 D a _ _ _ 0 10 20 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 Time s Figure 70 Drag force and drag coefficient 2013 2014 RCR CDR C Drift Calculations The total drift is calculated using by Drift D D 28 where Da is the ascent drift and Dp is the descent drift Ascent drift is determined using the OpenRocket simulation and shown in Table 16 upwind drift is defined to be negative and downwind is defined to be positive Wind Speed mph Booster Drift ft ift ft 40 Sustainer Drift ft 1242 718 Table 16 Ascent drift Descent drift was calculated using D Vwt 29 where t is the descent time
67. Wire strippers e Wire cutters e Screwdrivers e Extra wiring e Extra batteries e Extra hardware Required PPE e Safety glasses 1 ____ Inspect that all hardware components have duplicates in their own labeled bags 2 ___ Ensure all proper wrenches and screwdrivers needed for hardware secured into toolbox Altimeter Housing Required Equipment e Altimeter box e StratoLogger e 9V battery e Screw switch e Multimeter 1 Ensure the black powder is properly sealed from moisture and secured in the team s explosives box 2 ___ Test StratoLogger s to ensure functionality is nominal 3 _ Test screw switch to ensure connections are nominal 4 ____ Verify batteries have a voltage of at least 5V 2013 2014 RCR CDR ra Pyro Cap Assembly PCA Required Equipment e Hardware e O ring e Black powder e Electronic matches Required PPE e Nitrile gloves Check O ring for deformities or cracks ____ Inspect shells for bends or wear that would cause clearance conflicts ____ Inspect electronic matches for burnt out matches ____ Check that black powder is sealed and has no exposure to moisture oS Fairing Deployment Mechanism FDM Required Equipment e Hardware e Excess shock cord 1 ___ Inspect that springs have not been warped and still retain their proper spring rate 2 ___ Ensure that the hinge is free of debris and opens smoothly Fairing Assembly FA 1 ____
68. Works RRC3 altimeters and the two battery holsters Standoffs for the altimeters 2013 2014 RCR CDR ra will be built into the sled and be tapped so the altimeters and the battery holsters screw directly into the sled This reduces the chance that a small piece can be lost or damaged DETAIL B SCALE 1 DETAIL SCALE1 1 Booster Altimeter en MATERNAL ABS Plastic OTerPWEr SPEE 1 TEES E Sled See BOM AMISH DP FRAMES AE University of Louisville e f River City Rocketry Model DO MO IE JP C4 4 7 2 Math ans 2013 2014 Design Deral ow mari lt a LRL DEI SMEEI1 C 1 Figure 52 Booster altimeter sled ITEM NO PART NUMB ER Booster Sled 2 Battery Holster 2 Assembly MATERNAL Ukris Onerww r sPrCFFo on See BOM BCT xiu university of Louisville TOMTPAPCTS s River City Rocketry pee ver mea came 1 wo 4 2013 2014 Design Derol ow cove 1 wee tT Oe nt S EELT C 1 Figure 53 Booster altimeter sled BOM 2013 2014 RCR CDR 54 The sled will be held in place between two sets of bulkplates via two inch aluminum threaded rods The rods had to be placed far enough apart 4 5 inches to avoid contact with the sustainer motor retainer To not waste the space between the threaded rods the altimeters will be mounted perpendicular to the vehicles direction of tra
69. a for input output voltages to the regulator heat dissipation will not be a concern for powering the brain of the rocket rover for the duration of the competition The 7805 uses a maximum quiescent current of 8mA to regulate the voltage a negligible load when compared to the lt 1A needed for the cape micro combination 3V Reg to BB 7805 Figure 86 LM7805 Voltage Regulation Circuit Per the BeagleBone website it is recommended to run the BeagleBone at 5V 2A supply when using any peripherals 1A otherwise Depending on the processing speed the microcontroller alone can draw up to 465mA With our milliamp hour rating the setup will allow us to run at least the BeagleBone for 4 hours with margin enough for other peripherals For standby power and the 1 hour launch standby potential we will be at an idle mode for the controller The datasheet for the BeagleBone states that idle current draw will be around 170mA At 1 hour the standby for the board would potentially use less than 10 of our battery life this allows us a safe margin to power the launch with or without a delay Once the system design is matured we will be able to perform system level power testing Kernel Booting Peak Kernel Idling 305 19 20 Figure 87 BeagleBone Black Power Consumption Our testing will first be concerned with the measurement of standby power with the added power draw of the custom PCB GPRS cape and camera The camera i
70. activate The pressure sensor physically electrically programmatically fails The library documentation for the used function Python s time sleep asserts that the requested wait time can be longer than requested due to signals being caught in Python The sleep function that is used encounters an failure of this mission objective The parachute will be completely detached from the rover during descent leading to probable destruction of the payload The code that ejects the parachute from the rover and drives the rover forward is never executed causing partial mission failure The parachute is not cleared from the body of the rover leading to a chance that the rover cannot move forward causing partial mission failure Overall 3 Moderate Low Low 2013 2014 RCR CDR threat and considers it an acceptable risk considering the time and cost of implementing a system to compensate for this problem The team has verified that the parachute release mechanism will eject the parachute lines from the body of the rover barring mechanical failure or extraordinary environmental conditions An entry was added to the pre launch checklist to verify that the servo is rotated in the proper position before launch This check verifies that this problem did not occur before placement on the launch pad The sensor will be tested multiple times to insure it does not give incorrect readings Whe
71. and Vw is the wind speed The descent time was calculated using 30 where AH is the net altitude difference Vi is the steady state velocity under parachute The steady state velocity was calculated using 2 9 V 31 Due to the nature of the recovery scheme the steady state velocity will be different not only for each section but for different altitudes because the values for A and m will be different To account for this the process was repeated with the different sections over different altitudes to determine the total descent time The resulting total descent drifts are shown in Table 17 Wind Speed mph Booster Drift ft 1531 2297 3063 Lower Sustainer Drift ft 2072 4144 6216 8288 Upper Sustainer Drift ft 1827 3653 5480 7 306 Rover Drift ft 1772 3543 5315 7086 Table 17 Total descent drift The total drift is then calculated using equation 28 the results are shown in Table 18 2013 2014 RCR CDR 67 Wind Speed Drift ft mph 1692 1392 1447 1457 3402 2801 2911 2231 4974 4073 4238 3014 7570 6368 6588 Table 18 Total vehicle drift The highest drift would still be within the 1 5 mile radius of the alternate launch site 2013 2014 RCR CDR ra PAYLOAD INTEGRATION One of the primary objectives of the team was to develop a system that would complement the hazard detection payload By designing a rover that would integrate the haz
72. ard detection payload on it the team will be able to further simulate a real life application of the overall systems While utilizing the hazard detection system to detect and plot out hazards in the environment the rover would be able to interpret that data and move about an autonomous course of action while avoiding all hazards A primary function of the launch vehicle is to safely deliver its payload A custom fairing system has been developed to safely house the components of the payload all while shielding them from the environments The team has taken caution in designing how the payload will be secured within the fairing By utilizing custom machined semi firm foam boards the team has developed a housing for the rover This housing fully encompasses the payload and provides shock absorption from the harsh stresses seen during launch Launch Pad Design and Integration In order to reduce friction between the launch pad and rocket during launch a guide tower launch pad is being utilized The idea behind the guide tower design is to eliminate the interference between the rocket and the launch pad therefore allowing us to launch more consistently and control our altitude more effectively Rather than using mounting lugs to attach the rocket to a guide rail as we have in the past the guide tower design guides the rocket between four rails which do not contact the body as seen in Figure 35 Figure 71 Launch Pad with Rocket 2013 201
73. as chosen as the material of choice to house the rover and its recovery system Table 54Error Reference source not found details the general material properties of the selected material General Plastics FR 7107 Rigid Polyurethan Foam Density pct Compressive Strength 18 psi Compressive Modulus psi Tensile Strength 23 psi shear Strength psi Shear Modulus 16 psi Flexural Strength DSI Flexural Modulus DSI Water Absorbtion 0 01 Ibs ft Table 54 General data information of FR 7107 foam material Due to the nature of high powered rocketry the design form and function of the foam inserts had to be able to stand up to the rigerous requirements called for in this field of rocketry In order to determine the proper material analysis was completed to ensure that the maximum pressure the foam inserts would see in it s smallest cross section would not exceed the structural limits of the selected foam 2013 2014 RCR CDR IN Foam Material Selection Analysis Max Acceleration Force on Rocket Pressure on Foam Safety a ft s ft lb s Factor ft s ft Ib s psi 24722 5 49 97 149 91 Table 55 Analysis to determine proper foam material A safety factor of 3 was used in determining the appropriate foam material The primary reasoning behind this was due to the fact that while this material is not necessarily untested the application for its use is Table 55 lays out how the
74. atoLogger can be configured to provide a constant serial UART stream 9600 baud rate ASCII characters of the device s current altitude over ground The device can be safely powered by a 4V 16V source and requires 1 5 mA typical 10A maximum when activating e matches 2013 2014 RCR CDR ET Featherweight Raven Altimeter 8 85 LII gt n Raven mys gt BND gt 4 4c A JF f nni cx BE LL s0900 gt iaar e 22 Be os a e eu Hino Figure 32 Featherweight Raven he Featherweight Raven altimeter records its altitude at a rate of 200Hz via accelerometers and at 20Hz using a pressure transducer with a 0 3 accuracy The Raven will be powered by its own Featherweight Power Perch which also features a magnetic switch which will be used to lock the altimeter in the on position externally The device is rated at 30 amps for air start applications MissleWorks Altimeter Figure 33 MissleWorks RRC3 Altimeter The MissleWorks RRC3 altimeter records data at a rate of 20Hz using a pressure transducer It will be powered via an external 9 Volt Duracell battery This altimeter has three outputs an apogee event descent altitude event and an auxiliary event Garmin Astro DC 40 Figure 34 Garmin Astro DC 40 GPS Tracker 2013 2014 RCR CDR A Garmin Astro DC 40 will be used to track the booster lower sustainer and nose cone rocket sections The system consists
75. ave been added to the team s pre launch procedures checklist to verify that the GPS and GPRS antennae are screwed in securely and held in place with electrical tape The GPRS unit has been and will continue to be tested to verify that the SMS sending code functions without error Moderate An item has been added to the team s pre launch checklist to verify that the 2013 2014 2013 2014 USLI Proposal ES 2013 2014 USLI Proposal ES not receive data from BeagleBone Black Web server does not receive data from ground station BeagleBone Black fails to boot up or run code LiPo battery fails Payload Components fall off during descent the data is transmitted The ground station does not have network reception when the data Is transmitted The web server host experiences internal issues when data is transmitted from the ground station IE a DOS attack scheduled or unscheduled maintenance The FTP credentials used to upload to the web server are not correct The Linux OS could have been corrupted during previous use BeagleBone has suffered physical damage Battery catches fire due to low or high voltage Battery is punctured during transportation or landing Components are not attached securely onto electronics platform the payload would result in not recording hazard detection flight event or GPS data from the rocket payload Such an error would constitute a complete
76. azard Detection Payload Risk Assessment 2013 2014 RCR CDR DO PAYLOAD CRITERIA TESTING AND DESIGN OF PAYLOAD EXPERIMENT The fairing can be divided into three main sections the altimeter housing payload housing and fairing retention bay Each section has its own primary role in ensuring the safe deployment and recovery of the specific payload The main components that make up the fairing including airframe and bulk plates can be visualized as equally divided into separate halves Altimeter Housing In order to save space within the confinements of the fairing the team wanted to have a standalone altimeter within the fairing This called for no separate altimeter bay The team designed an altimeter housing shown in Figure 109 that would be 3D printed from ABS plastic The enclosure would incorporate a StratoLogger a 9V battery an acrylic glass face plate and a screw switch that would be used to activate the altimeter Figure 109 Altimeter housing assembly The decision to use 3D printing of this component allowed for a unique design The outer body of the housing has an outer diameter that matches the inner diameter of the coupler tubing where it sits in the fairing assembly The housing hosts a body extrusion that will safely house a standard 9V battery A vented lid was 3D printed separately The lid is screwed in place and properly constrains the battery in place Included in the 3D printed design are raised extrusions that
77. azards during descent A webcam will be used to obtain images which will be analyzed via a BeagleBone Black microprocessor An off the shelve Printed Circuit Board PCB will be mounted onto it which contains a GPS unit to track location and a GPRS phone module to transmit data to our ground station The BeagleBone will also have a custom made PCB on top of the previous one that will contain other essential payload circuitry Pre existing libraries such as OpenCV will facilitate the creation of the team s custom hazard detection software package The hazard payload will be mounted onto a rover that will be able to autonomously drive around once it has determined it has landed The objectives for this payload are shown in Table 44 in the Payload Science Value section This payload requires the team to demonstrate knowledge in embedded system design image processing circuit design and CAD modeling which are all topics taught at the undergraduate level Due to the rigorous nature of the University of Louisville s engineering program the electronics team is able to consist of all upper level undergraduate students Electronics Hardware Components One of the main design challenges the team is facing with this payload is having enough processing power due to all the systems that must be running To accomplish this the team chose the BeagleBone Black which will be the brains for the entire payload By using one microprocessor and off the shelve products
78. ble 7 Nominal parachute dimensions Construction The canopy will be made of MIL C 44378 0 75 oz rip stop nylon the reason this material was chosen is because the team had success using it last season The suspension lines will be made of 1 8 inch nylon para cord with 400 Ib tensile strength The harness that connects the suspension lines to the launch vehicle will be made of 9 16 inch tubular nylon with a tensile strength of 500 Ibs there will be one harness per parachute There will be ten Suspension lines per parachute as each parachute has ten gores To account for the loss of fabric during hemming and sewing the panels together the cut dimensions must be greater than the characteristic dimensions listed previously Figure 23Error Reference source not found shows the hem layout The shown dimension H will be inches so a total of two inches will be added to the total height of each gore Figure 23 Hem layout The individual gores will be sewn together in a French felled seam also known as a double lap seam as shown in Figure 24 The shown dimension S will be 72 inch so a total of 1 5 inches will be added to both Cs and Cv for each gore 2013 2014 RCR CDR gt Gore Dimension t gt i Sie WSIS Figure 24 Added fabric due to stitching Seam Construction Suspension Line Figure 25 Seam that will connect each gore panel together As stated previously the seam tha
79. bled before the full scale test flight at Thunderstruck which will take place during the first week of April Nose Cone Design The current design for the nose cone was researched and designed to provide the optimal degree of lift versus drag to meet our target speed and to accomplish the tasks set forth by the competition There are several designs from which we could have chosen including the tangent ogive the secant ogive the parabolic and the Von Karman designs The initial tyoe of cone that we selected was the tangent ogive as was used in the previous year s design The tangent ogive melds smoothly with the rest of the body provided that the equation is utilized properly Through our research we determined that the Von Karman design would be the best Suited to our goal reaching a speed of about 0 8 Mach Figure 3 below shows degrees of effectiveness for various nose cone designs with respect to varying Mach numbers 2013 2014 RCR CDR EN Ogive 42 Cone gt LV HAACK 193 333 Von Karma 473 4433 23 403 Parabola 35 3 4 Parabola 35 1 2 Parabola Power Le Power LASHED 0 8 10 1 2 1 4 1 1 8 2 0 MACH NUMBER Figure 3 Nose Cone Effectiveness Comparison As seen from the graph the Von Karman is ranked 1 for the desired Mach range in which the rocket will fly In addition it also has a relatively wide range ranked 1 which gives us a bit of leeway in case our speed varies Worse Fi
80. ce of the chamber Having the chambers next to each other could cause the cap to torque to one side and bind in the shell Figure 115 Section view of pyro cap assembly inside the fairing The pyro cap is secured into place by two 4 40 nylon screws highlighted in Figure 115 1 10 inch thick silicone O ring is placed within the O ring groove on the outside of the pyro cap prior to assembly A 1 4 20 threaded eyebolt is to be epoxied into the top of the pyro cap A section of 1 16 inch diameter nylon cord will be tied from the eyebolt on the pyro cap to the eyebolt mounted to the bulkplate to the side of the pyro cap assembly This will ensure that when the pyro cap is jettisoned from the fairing that it will not free fall to the round where it could cause damage people or property A black charge will be housed within the cap Two wires will be fed into the two inlet holes in the cap Each wire will be connected to an electric match thus allowing for redundancy in case one electric match fails When the stratologger in the altimeter housing determines the fairing is at the proper altitude to eject the payload it will fire the electric matches When the cap s ejection charge fire it will be jetisoned from the shell The cap will still be connected to the main body of the fairing via a kevlar string to ensure it is not lost during flight 2013 2014 RCR CDR 180 Payload and Recovery Section The final section of the fairing is se
81. cident a thorough safety checklist has been created and will be reviewed on launch day Throughout preparations it will be the responsibility of the safety officer to confirm that each of the necessary tasks for a successful launch are completed Two team members are required to sign off verifying that each required task has been completed in order to ensure a safe launch LOCAL STATE FEDERAL LAW COMPLIANCE The team has reviewed and acknowledged regulations regarding unmanned rocket launches and motor handling Federal Aviation Regulations 14 CFR Subchapter F Part 101 Subpart C Code of Federal Regulation 27 Part 55 Commerce in Explosives and fire prevention and NFPA 1127 Code for High Power Rocket Motors documentation will be made available to all members of the team The previously listed documents are included in the appendix Due to the length of Regulation 27 Part 55 a URL is given for the document MOTOR SAFETY Darryl Hankes the team mentor who has obtained his Level 3 TRA certification will be responsible for acquiring storing and handling the teams rocket motors at all times Team members Gregg and Zak whom are Level 2 certified are permitted to assist in this responsibility for the sub scale flights The full scale motors require a Level 3 certification so Darryl is the only person permitted to handle the competition motors If at any time 2013 2014 RCR CDR d another member of the team acquires the approp
82. cond stage motor can be dangerous The team is creating their own system since the commercial options such as the RocketTiltometer are all currently unavailable or very expensive The circuit and the 2013 2014 RCR CDR ra software to run it are all custom made and will run on an Arduino UNO platform To achieve this a PCB is being created that will mount on top of the Arduino s pins Tiltometer Layout At a high level the tiltometer is made of only a couple components as shown below Processes data sends ignition decision to motor ignitor Calibration status LED MPU6050 IMU Arduino UNO Reset button microcontroller Figure 36 Tiltometer components The MPU6050 is an IMU Inertial Measurement Unit that provides information on its current orientation to the Arduino UNO microcontroller Currently the team is using a breakout board of the MPU6050 but it will eventually be part of the Tiltometer PCB discussed later The MPU6050 provides its current orientation in terms of the device s angle with respect to the X Y and Z axes The microcontroller takes the raw angular information from the MPU6050 and updates an internal estimate of the device s actual orientation Then the tiltometer determines whether or not the rocket is tilted more than 40 degrees away from the Z axis If the rocket is tilted more than 40 degrees from the axis normal to the Earth s surface the Z axis in our case the processor sends a signal disall
83. d apart The onboard StratoLogger will fire the black powder charges causing the pyro cap to eject thus allowing the springs to pull the fairing open 2013 2014 RCR CDR IN PAYLOAD CONCEPT FEATURES AND DEFINITION Creating a launch vehicle with real world applications was the primary objective going into the design of the payload recovery system A faring was designed to allow a nonspecific payload to be encapsulated inside The fairing functions by housing an allocated payload within itself When the payload is ready for deployment the fairing is opened and releases the payload This method permits a payload of any size to reside within the faring as long as its dimensions are able to fit within the allowed space of the airframe A broad spectrum of payload shapes and functions can be used without interfering with the recovery By this methodology the team has developed a fairing system that has complete versatility However by adhering to this course of design multiple challenges arise Manufacturing such a design out of fiberglass poses an issue as wound fiberglass will warp when cut in half This would cause the fairing s shape to no longer mesh with that of the rest of the rocket To alleviate this issue prior to cutting the fiberglass in half six holes will be drilled around the body of the fiberglass where bulkheads will later be installed Once the holes are drilled the fiberglass will then be cut in half A 12 to
84. d e Propulsion Bay Stand e Magnetic Switch Magnet e Switch Rods e GoPro camera 1 Verify flight card has been properly filled out and permission has been granted by RSO to launch 2 Place rocket on launch pad 3 ___ Tilt and rotate the launch pad in desired direction or in direction ruled necessary by RSO 4 Secure all launch pad tie downs 5 Ensure proper connection has been made with ground station electronics 6 Armallaltimeters priority one cameras and payloads Check for correct LED readout beeping pattern etc 7 Remove igniter separate leads and run up into motor until igniter is fully seated Attach yellow plastic cap and run igniter out of the provided hole Form a loop in the igniter to keep it fully seated within the motor 8 Tapignition system leads together to remove any static buildup that could cause ignition Wrap igniter leads around each clip Drape the ignition system leads out of the direct path of the exhaust 9 Before leaving launch pad area double check for signs that all electronics are still operating correctly 10 Arm launch pad camera and begin recording 2013 2014 RCR CDR ra 11 Clear launch pad area and do not return until range has been reopened by the RSO 2013 2014 RCR CDR ra Safety Checklist During and After Flight DAF Flight Timer Signature First Event Observer Signature Time Second Event Observer Signature Time Landing Event Observ
85. d the rover will drive forward a few feet and send a final SMS thus completing the mission 2013 2014 RCR CDR 94 Software Boot Sequence The purpose of the boot sequence it to reliably initialize all relevant software and hardware components of the rocket payload and report any startup errors for debugging purposes Figure 92 shows a flowchart of our current boot sequence Changes since PDR The only change relevant to the software boot sequence since PDR is the substitution of the launch detection accelerometer with a pressure sensor This decision was made to increase confidence that the launch detection event is detected due to a rapid change in altitude rather than from experiencing a large sudden force which could occur from dropping the rocket for example Initialization The main driver of the boot sequence is an initialization script that is run every time the operating system is rebooted The system s software environment Linux on a BeagleBone reboots every time power is supplied to the board When the team assembles the rocket the board will be provided power which will start the operating system and thus begin the boot script The boot script initializes all hardware including the GPRS unit accelerometers motors etc Every hardware unit that fails to initialize properly is added to a list of incorrectly initialized devices 2013 2014 RCR CDR Initialize launch detection pressure sensor
86. d x it if not e Qonfirm that the startup script actually runs on startup without error 9 Ensure the payload starts without errors a lf an error occurs decide if we should abort launch or continue 10 Verify that the ground station device is ____ Fully charged or at least mostly charged a b Turned on ___ Receives text messages from a member s phone 11 Verify that the web server is a Running b Accepting FTP uploads At launch site 1 Insure that SIM card is inserted into GPS GPRS Cape 2 Screw BeagleBone into electronics platform Attach Cape and Custom PCB onto BeagleBone 4 _ Verify that the GPS antenna and GPRS antenna are a Screwed securely into the GPS GPRS cape b X Securedin place with electrical tape 2013 2014 RCR CDR LE 5 _ Insure that both boards are secure 6 Place C clamps around motors 7 Screw C clamps onto end plate of rover 8 Attach motor s shaft to coupler using grub screws 9 dnsure motors are secure 10 A Attach ESCs to electronics platform by using metal cover 11 Assemble Parachute Cam 12 Attach servo to Parachute Cam 13 Screw Parachute Cam assembly to electronics platform 14 Insure Parachute Cam is secure 15 Screw webcam to electronics platform 16 Attach LiPo batteries to electronics platform using metal cover 17 Attach antennas to GPS GPRS Cape 18 Wire all components to BeagleBone including batteries 19 In
87. d between the bulkheads Permanent assemblies ie fins inner tubes centering rings and bulkheads are assembled using Proline epoxy and J B Weld This ensures stability and permanent adhesion between parts The AV bays are riveted together to allow the bays to be removable after flight The first and second stages the booster and sustainer respectively are attached using two 4 40 shear pins located 180 degrees from each other These pins will release when the black powder charges ignite allowing for stage separation and clearance from the booster stage The motors will be inserted into a 2 953 inch inner tube which is epoxied to the centering rings and the fins The fins and the centering rings are in turn epoxied to the outer airframe thus ensuring a snug permanent fit In order to prevent the loss of the motor during flight a 75 millimeter Aeropack motor retention ring will be attached to the bottom of the sustainer and booster s motors The retention ring on the booster will have a flange while the sustainer will not The 75mm retention ring is shown below Figure 12 Aeropack 75mm motor retention ring 2013 2014 RCR CDR E AHH D HO CC U M DEPT eye 1 university e Loulsville Cry toctcuy 70 S70 4 0c pr sPITTIOT 1 Figure 13 Booster Fin 1000 ay OTe H D HO POHO See ea hn y
88. d not be toleranced so tight that they would become stuck together if accidentally closed too tightly In order to countreract this the radial dimension of the mating flange of Shell B was calculated and designed to a specific tolerance Table 51 shows the maximum and minimum clearances for the fitment of Shell B into Shell A Shell B Clearance Table 51 Fitment clearances for Shell B into Shell A Univer L a e Lauiry dia Pocket afi I I 2 301 4 Hinr Figure 112 Detailed drawing of Shell A 2013 2014 RCR CDR Dra MATERIAL SC ALUMNA A LCS z SHASP SES PARTS BE DZBURREO ARG CLEARED OF DEBRG PYRO t Unyeti o Fer Cilgy Rocker Acide LE i 4 Darin Figure 113 Detailed drawing of Shell Similar to the tolerances going into the design of the two shell halves the pyro cap went under the same rigorous precise design criteria to ensure a clearance fitment into the shells Table 52 shows the clearance fitment for the pyro cap into the assembly Pyro Cap Clearance Maximum in 0 026 Minimum in 0 006 Table 52 Fitment clearances for the pyro cap into the shell components The pyro cap is designed to house two separate chambers for black powder charges This is to ensure all rocket systems are fully redundant To save space the design called for the primary chamber to be a
89. d relatively small amounts of real estate in comparison to PCB size We will comfortably fit the regulating pressure and the PWM circuit on the PCB Layout design considerations include heat dissipation for the regulator placing charge capacitors close to regulator placing timing capacitors close to PWM IC and pin assignments from the microcontrollers GPIO pins Regarding the custom PCB the team decided to implement a hardware PWM setup instead of coding a software dependent PWM generator We have more experience with hardware systems and have decided it is the most feasible route for our payload The PWM control circuit that will take care of the interface is based on the TL494 PWM controller available from Texas instruments Design considerations for this circuit include generating 1 kHz 5V square wave then inverting the signal through an N channel MOSFET 55138 for it to finally be input into the ESC Some calculations for this circuit include the resistance capacitance combination frequencyosc 1 R C to allow 1 kHz operation and voltage to duty cycle conversion From the data sheet provided for the TL494 IC we found that the DTC dead time comparator controlled our duty cycle output The correlation found was 100 duty cycle at 3 volts and 50 at 0 volts We then needed to invert the signal through the MOSFET to use a duty cycle less than 5096 needed for the ESC The MOSFET also allows us to isolate the PWM circuit from the input of t
90. date with the latest version of the safety manual e violate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events 2 27 IY Sign Date 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e violate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events Legg Ace _ 2 24 14 Signature Date 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e fI violate these regulations realize that may not be able to participate in construction or launc
91. deployment bag in Nomex 6 __ Insert parachute into airframe Booster Altimeter Bay Required Equipment e Multimeter e Precision flathead screwdriver Verify battery has charge greater than 5V ____ Verify proper shielding Plug in battery to altimeter ____ Plug altimeters into terminal blocks ____ Verify correct charge is to correct block ___ Install altimeter bay into airframe I9 es Lower Fairing Altimeter Bay Required Equipment e Multimeter e Precision flathead screwdriver Verify battery has charge greater than 5V Verify proper shielding Plug in battery to altimeter Plug altimeters into terminal blocks Verify correct charge is to correct block nstall altimeter bay into airframe po Ds Nosecone Altimeter Bay Required Equipment e Precision flathead screwdriver e Standard flathead screwdriver ___ Verify battery has charge greater than 5V ____ Verify proper shielding ____ Plug in battery to altimeter ____ Plug altimeters into terminal blocks ____ Verify correct charge is to correct block ____ Install nosecone altimeter bay to the nose cone 2013 2014 RCR CDR nam dE E ee 2013 2014 RCR CDR ra Safety Checklist Fairing Payload To be checked and initialed by Fairing Payload Safety representatives Fairing Payload Representative Signatures 1 2 Prior to leaving for launch site Maintenance MT Required Equipment e Wrench sets e
92. e landed rover from parachute by parachute It will also be ejecting the pin holding the tested to make sure the parachute lines lines are ejected away from the rover The previous version was able to shoot the pin over 4 feet away References Kenji Nagaoka Masatsugu Otsuki Takashi Kubota Satoshi Tanaka Terramechanics based Propulsive Characteristics of Mobile Robot Driven by Archimedean Screw Mechanism on Soft Soil Taipei Taiwan IEEE 2010 4946 4951 Web 3 Jan 2014 2013 2014 RCR CDR IAN PAYLOAD CONCEPT FEATURES AND DEFINITION Creativity Uniqueness and Significance The hazard detection payload is unique in the competition as it is the being integrated onto a rover The significance of why a rover was chosen is because a hazard detection system could be a crucial system of any future rovers sent to other planets A rover also expands the capabilities of the hazard detection system since the rover can drive once it has landed thus continuing its mission but on the ground With further work the rover could potentially drive to the location it identified as a hazard to further investigate The rover s design allows it to go over many terrains due to its creative use of power screws for movement By using a rover the team hopes to engage the community in space exploration Also due to the many of the rover s components being 3D printed the team hopes to spread to the public the significance of using this
93. e BeagleBone will be inspected for any anomalies before each launch The LiPo batteries will be recharged to safe levels after each use The batteries will be stored in a special fire retardant bag The LiPo batteries will be transported and stored away from parts that could puncture the batteries The batteries will be inspected before and after each launch to insure they are not damaged All components will be inspected before flight to insure they are attached securely Testing will be conducted to insure all parts can withstand parachute opening shock Components on Custom PCB do not work The ESCs become non operational The Voltage Regulation circuit for the BeagleBone fails to provide the correct amount of power Parachute Cam system suffers structural failure upon deployment from fairing Parachute gets tangled with rover during descent The parachute cam system While soldering the components to the PCB a short could have been made PCB layout could have been incorrect The ESCs could have their protection circuit disabled The input signal from the PWM circuit could have fried the microcontroller onboard the ESC The LM7805 IC could be damaged resulting in incorrect regulation While soldering the LM7805 onto the PCB a short could be created on one of the pins stresses from opening the parachute exceed the ultimate strength of the components such as ABS ho
94. e Minimum tower the rocket Distance Table as established by unpredictable NAR The launch tower should be inspected prior to each use for Cracked weld on Fatigue and over The launch tower stressing during could potentially 3 any cracked welds Launch tower transportation become unstable is to be kept clean in order to be able to identify any cracks Minor cuts or scrapes to Shar edges of the launch pad Sharp edges on the Manufacturing personnel working 4 shouldbe ded dows ando launch pad processes with around and transporting the launch tower Brush fire caused by Dry launching Wait until the range safety officer rocket during launch has cleared personnel to burred 2013 2014 RCR CDR approach the launch pad and extinguish any fires that have been started The launch tower also has a blast deflector to prevent brush fires Table 23 Launch Pad Risk Assessment Stability and Propulsion Risk Assessment Cause Severity Probability Risk TET Motor fails to ignite Motor explodes on the launch pad 1 Faulty motor 2 Delayed ignition 3 Faulty e match 4 Disconnected e match Faulty motor 1 3 4 Rocket will not launch 2 Rocket fires at an unexpected time Rocket and interior components significantly damaged Follow NAR safety code and wait a minimum of 60 before approaching the rocket to ensure that the motor is not simply delayed
95. e information on the web site to indicate to visitors the event s seen and the payload s current hazard detection status Test results Data communications between the GPRS unit and the ground station have been tested and repeatedly proven to work The team has a functioning program that allows users to enter an arbitrary phone number to message A message will then be sent to that number with the current GPS coordinates read from the GPS unit The program is reliable enough that the team was able to use it at an educational engagement event to send participants messages from the rocket s electronics 2013 2014 RCR CDR an Data from the GPS unit has been verified to work in one location based on viewing the read in GPS coordinates in Google Maps The team plans to further verify the accuracy of the GPS device by testing in multiple locations to verify that the data is accurate in multiple locations and to read in GPS data repeatedly over a span of time 1 2 weeks in the same location to verify that the unit consistently gives accurate results It has been demonstrated that the team s web server is able to retrieve FTP uploads The team successfully transferred FTP files from their local computers to the web server and viewed their contents on the web server Launch Event Detection The goal of this part of the software package is to implement a system to reliably detect the rocket s launch apogee and landing events in order to tri
96. e takes into account a maximum offset of 10 degrees from vertical Additionally a mechanical rolling switch will be positioned inside of the sustainer stage ignition bay to detect stage separation If stage separation does not occur and or the altitude conditions are not met sustainer stage ignition will be aborted and the vehicle will continue through the rest of the programmed mission 2013 2014 RCR CDR Booster Stage The booster stage will serve a single purpose 1 Boost the sustainer to an altitude of 3 699 feet where the sustainer s motor will then ignite to propel the second stage to the target altitude of 10 000 feet The booster stage is comprised of a 6 0 inch diameter outer tube comprised of G 12 fiberglass At the top of the stage near the coupler and the sustainer ignition bay the RRC3 altimeter pair that governs the actions of the booster stage reside on a sled suspended between two threaded aluminum rods placed at 180 degrees from each other The logic for these two altimeters is listed in Figure 6 below Booster Recovery Stage Liftoff 2 5s Termine Separation Black 1 Black ee Powder Charge 1 Booster Terminal Separation ae Black DIUUR o Pow der T Charge 1 Apogee 1 0s Sania Separation Black Black Mm Powder Charge 3 Liftoff 3 0s Booster Apogee 1 0s Terminal Separation Black pos Powder Charge 2 Booster Blox 6 BS i E sar ae Black Block 6 RUE Charge
97. e used to set the baseline amount Then the program will enter a loop where it continually reads from the pressure sensor After each reading is taken the program will check if the difference between the reading and the baseline is larger than a pre defined amount When a large change in pressure is detected larger than the pre defined amount the launch event will be considered detected the program will exit its loop and an SMS will be sent indicating that launch has occurred To detect apogee the rocket will keep a running record of its most recent n pressure sensor readings The value of n will be determined by the team during testing The program will determine the sign of the difference between successive pressure readings 2013 2014 RCR CDR and wait until it detects a series of n readings where a certain percentage of the signs differ When apogee occurs the rocket s direction will be changing from up to down so detecting a difference in pressure sensor signs will indicate apogee Once apogee is detected an SMS will be sent indicating that apogee occurred The landing detection algorithm will also keep a record of the previous n readings Again the value of n will be determined during testing First the average of these n readings is calculated Then the difference between each of the n readings and the average will be calculated If any of these differences are larger than a pre determined threshold it is determined that la
98. e vessels included in the design of our rocket for this competition 1 10 The full scale test flight will take place at the event Thunderstruck which will take place in the first week in April The final system s functionality will be verified in the future at this event following the manufacturing and assembly of the full scale rocket 2013 2014 RCR CDR LS During the construction of the rocket workmanship must be taken as seriously as the initial design To ensure maximum precision the team will be making many components utilizing CNC machining technologies several of the components will also be made using standard machining processes Even without computerization accuracy within 0 001 is very feasible Through accurate machining careful assembly and thorough checks the team will be able to increase chances of mission success by eliminating potential problems due to poor workmanship In addition to the testing discussed in the PDR additional motor testing will be conducted on both types of motors for the sustainer and the booster These tests will take place when the motors arrive from Wildman Rocketry Separation events caused by black powder charges will be tested following the construction of the system The full scale manufacturing and assembly will begin following the delivery of parts in the next two weeks planned delivery date March 14th 2014 The full scale will take approximately three weeks and will be assem
99. eaded Rod Aluminum 3 ft D Ring 4 40 x 1 2 Nylon Screws Epoxy Clay J B Weld Dog Barf Wadding 1 Ib Cesaroni 75 mm 5G WT M3100Motor Cesaroni 75 mm 3G WT L1720 Motor Cesaroni 75 mm 5 Grain Hardware Cesaroni 75 mm 3 Grain Hardware Cesaroni Pro 75 mm Wrench Aero Pack 75 mm Retainer Body Aero Pack 75 mm Retainer Cap 6 Fiberglass Bulkplate 6 to 75 mm Fiberglass Centering Ring 6 Plywood Coupler Bulkplate 5 90 23 60 6 to 3 0 Plywood Centering Ring 6 20 18 60 Total 4 304 37 Table 57 Vehicle budget O O a wA OA elI NIA amp 2013 2014 RCR CDR IN Subscale Budget Total G12 Filament Karman Nose Cone 1 46 01 46 01 G12 Filament Airframe Tubing 1 ft 7 19 48 136 36 Gi2FilamentCoupler Tubing Qin 4 19 74 78 96 53 10 Acrylic Sheet 1 8 x 12 x 12 17 26 1 4 20 Forged Eyebolt Steel 6 2 89 17 34 1 4 20 Hex Nut Aluminum 6 41 6 80 1 4 20 U Bolt Aluminum 12 48 8 92 8 00 5 34 50 00 DogBarfWadding 1lb 1 500 5 00 Cesaroni 38 mm 2G IM H100 Motor 6 28 76 172 56 e NC NN 4 49 76 0 r 237 28 2 71 32 2 58 00 19 00 3 to 38 mm Plywood Centering Ring 6 263 15 78 Total 1 075 68 Table 58 Subscale budget Total Garmin Astro 320 GPS Unt 3 189 99 569 97 Ripstop Nylon 62 x 36 123 50 86 40
100. eason is that high winds could cause the rover to spin on descent which could blur the images the camera captures This could cause the software programs to misidentify a hazard A second variable will be the different shapes and sizes of the hazards that the software will be trying to identify For example a hazard we will scan for is a crowd which can be in any shape or color The next variable that could affect the payload is the data that the BeagleBone is handling If the BeagleBone captures an image which takes longer to process for hazards the transmission to the ground station would be delayed The next variable that this payload will experience is altitude At higher 2013 2014 RCR CDR IN altitudes the camera may have a harder time discerning shapes which could cause hazard misidentifications The final variable that will greatly affect the rover is the terrain as the power screws might react differently To fight against these variables the team will have to design several experiments to test how much the payload is atfected and attempt to find a solution Controls To test the functionality of the hazard detection payload the team has some options it can use as controls The main control will be at what altitude the rover is deployed from the fairing The team will attempt to deploy the rover at several altitudes to see when software is able to detect a hazard After an acceptable altitude has been identified this will become a co
101. ed using _ CN NXN CuN rFXr dm Cy nt Cn F 14 where Cnn is the nose cone center of pressure coefficient 2 for conical nose cones Xn is the computed by m 15 where Ln is the nose cone length Cnr in equation 14 is the fin center of pressure coefficient calculated using Cyr lt ja 16 E where R is the radius of the body at the aft end S is the fin semispan N is the number of fins Lr is the length of the fin mid chord line Cn is the fin root chord length and is the fin tip chord length Xr in equation 14 is calculated using 2 Ap Ap 1 Cr cR 17 where Xs is the distance from the nose tip to the fin root chord leading edge Xn is the distance between the fin root leading edge and the fin tip leading edge measured parallel 2013 2014 RCR CDR to body Equations 14 through 17 are also known as the Barrowman Equations The Theoretical Prediction of the Center of Pressure 1966 1 Vehicle Requirements 1 1 The target altitude for our rocket system is 10 000 feet above ground level This will be achieved by calibrating the mass ballast system to counter the booster and sustainer rocket motors 1 2 Our rocket will be utilizing two RRC3 altimeters two PerfectFlite Stratologgers for use in the nosecone to detect the apogee height and four Featherweight Ravens that will act in parallel to measure and report the altitude to the rest o
102. een added to the pre launch checklist to verify that the parachute cam servo is oriented completely counter clockwise This is verifiable by visual inspection The assembly will also be tested to ensure that the servo will rotate in the proper direction when used Physical electrical Launch apogee and Pressure defect in the sensor landing detection have a sensor data hardware strong possibility of being does not Holes to allow air to either incorrectly detected reflect actual enter are not present or not detected pressure in the pressure Each case is dealt with sensor bay separately below An inaccurate baseline pressure estimation will The Weather ch lead to not accurately determined detecting the launch time time render the baseline baseline However launch should pressure determination pressure is still be detected before or inaccurate when the not after launch actually rocket launches accurate occurs Apogee is not detected The system will continually loop checking for apogee Thus image processing and rover driving steps will never run constituting partial mission failure Apogee is detected early An entry has been added to the pre launch checklist to compare the pressure reading at time of payload initialization with time of launch to verify the difference is not too large The apogee detection message will be sent at the Apogee is The observed time range wrong time and image
103. ely before launch time This gives the team the information needed to make an informed decision on whether to launch or not Launch detection After the above boot sequence has completed the boot script will enter a loop where it continuously polls the pressure sensor to check for a launch event If the detected pressure difference is large enough that the system can guarantee it is coming from the rocket engines the script breaks out of this loop and enters the in flight phase of activities Data Communications The purpose of this part of the software package is to design a reliable and efficient method to communicate detection of environmental hazards sensory data and detection of discrete phases of the launch cycle to a ground station Changes since PDH The primary change made since PDR is the addition of an extra node in the communications system At the time of PDR there were two nodes in the system The BeagleBone Black and the team s web server For the final team design the team has 2013 2014 RCR CDR I GPS GPRS Black i J attachment FTP accepting web server added one extra node a ground station to the design The reason for adding this extra node to the system was to increase ease of development In the previously used system a direct network connection was required between the web server and the BeagleBone Black Doing this requires establishing an Internet connection over a cellular netw
104. equirements the board satisfies what features will help meet that requirement and how they will be verified Verification Testing The payload shall incorporate a camera system that scans the surface during descent in order to detect potential landing hazards The data from the hazard detection camera shall be analyzed in real time by a custom designed on board software package that shall determine if any landing hazards are present The data from the surface hazard detection camera and software system shall be transmitted in real time to a ground station The launch vehicle shall be capable of remaining in launch ready configuration at the pad for a minimum of 1 hour without losing the functionality of any critical on board component An electronic tracking device shall be installed in the launch vehicle and shall transmit the position of the tethered vehicle or any independent section to a ground receiver The recovery system electrical circuits shall be completely independent of any payload electrical circuits The USB and micro USB slots will insure a camera is able to connect directly Video4Linux libraries are already included on the BeagleBone The 1GHz Arm Processor and 512 MB DDR3 RAM will be capable of handling the processing involved The 2GB onboard storage and microSD slot will allow us enough room for code and data storage The BeagleBone is capable of having 4 capes stacked upon it allowing
105. er Signature Time Ground Station Operator Signature Video Recorder Signature Rapid Retrieval Team Member 1 Rapid Retrieval Team Member 2 Rapid Retrieval Team Member 3 Required Equipment e Stopwatch or phone timer e Magnetic Switch Magnets 1 Rapid Retrieval team members are to be within close vicinity to a vehicle ready to move within a few seconds notice 2 Start stopwatch upon liftoff and call out time in 5 second intervals until T 10 seconds until first event Continue to call out times until T 10 seconds to second event 3 Maintain line of sight with rocket at all times Indicate any observed anomalies out loud to alert spectators 4 While retrieving rocket disarm all rocket recovery systems first 5 Before disturbing the rocket note any damages and anomalies with root causes Document these for later examination 6 Disassemble the rocket looking for any signs of wear damage or fatigue Note what repairs will have to be made if any 2013 2014 RCR CDR ra After Flight Checklist To be checked and initialed by Recovery Safety representative Recovery Representative Signatures 1 2 ____ Inspect all shroud lines for any damage or burn marks ____ Inspect all shroud attachment points for damage 1 2 3 l nspect entire canopy for any damage or stretching 4 ____ Inspect deployment bag for damage Damage found on shroud lines Y N Notes Damage found on attachment points Y N No
106. er filament wound fiberglass nose cone with a caliber ratio of 5 1 2013 2014 RCR CDR aM The nose cone system being the leading edge of the rocket is integral to the overall performance of the rocket Due to the varying materials in the tip the rocket will be able to cut more smoothly through the air than if it were made of the material composing the rest of the shell Without the bulkhead residing in the base of the shell nose cone and fairing system would lack a recovery device and would therefore lack another essential stabilization The rocket nose cone being a static component of the overall system is a foundation piece It can change but the factors that would initiate a change are few and are relatively isolated to the mechanical aspects of the overall design Name of Part Design Type Size Ratio Filament wound Nose Cone x1 Von Karman 6in diameter 5 1 Fiberglass ABS Plastic tip 6in outer diameter Centering Ring x1 5in inner diameter Balsa Wood 0 5in thick Wooden Bulkhead 5in diameter Bulkhead x1 N A diameter G10 Fiberglass 0 14in thick Threaded Rod x2 N A 0 25in diameter Aluminum 6061 T6 3in long Threaded Rod 2 N A 0 25in diameter Aluminum 6061 T6 10in long 3 8 16 Thread 2 7 16 Width Stainless Steel Inside Edges Washers x4 de PURPOSE Stainless Steel Nuts x4 Standard Hex Nut 3 8 16 Stainless Steel Table 1
107. er section the lower sustainer the hazard detection payload and the nose cone with the fairing tethered to the nose cone Recovery Requirements The recovery system must meet the following requirements set forth by the Statement of Work SOW and those set forth by the team shown below to be considered a success 2013 2014 RCR CDR The parachute system s shall be designed and manufactured by the team Commercially available parachute systems shall not be used on the vehicle At landing each independent section of the launch vehicle shall have a maximum kinetic energy of 75 ft lbs The recovery system electrical circuits shall be completely independent of any payload electrical circuits The recovery system shall contain redundant commercially available altimeters The term altimeters includes both simple altimeters and more sophisticated flight computers Each altimeter shall be armed by a dedicated arming switch which is accessible from the exterior of the rocket airframe when the rocket is in the launch configuration on the launch pad Each arming switch shall be capable of being locked in the ON position for launch Removable shear pins shall be used for both the main parachute compartment and the drogue parachute compartment 8 An electronic tracking device shall be installed in the launch vehicle and shall transmit the position of the tethered vehicle or any independent section to a ground receiver 9 T
108. esponsible for designing and constructing a safe recovery system for the rocket A safety checklist will be used on launch day to ensure that all critical steps in preparing and packing the recovery system and all necessary components into the rocket are completed The team will comply with this rule and any determination the Range Safety Officer makes on launch day Table 29 NAR Safety Code Compliance 2013 2014 RCR CDR IN TEAM SAFETY A team safety meeting will be held prior to any construction in order to ensure that every team member is fully aware of all team safety regulations as detailed in the team safety manual which has been included in the appendix Each team member is required to review and acknowledge the safety manual As revisions are made and released team members are responsible for remaining up to date with team safety regulations The team safety manual covers the following topics e Lab Workshop Safety e Material Safety e Personal Protective Equipment regulations e Launch Safety Procedures e Educational Engagement Safety e MSDS sheets e Lab and tool specific rules If a violation to the contract occurs the violator will be revoked of his or her access to the lab until having a meeting with the safety officer to review and reconfirm compliance with the safety rules Prior to each launch a briefing will be held to review potential hazards and accident avoidance strategies In order to prevent an ac
109. f our systems We will be designating one of the Stratologgers as the altimeter for the official competition altitude 1 2 1 One of the PerfectFlite Stratologgers will be marked as the official competition altimeter 1 3 The rocket s flight systems are able to be re used battery systems and the motors can be removed and replaced with new units after each flight 1 4 Most of the assembly will be completed before arrival at the launch site The only remaining tasks to complete at the site will be the initialization of the electronic systems assembly of the motors assembly of the AV bays by way of installing rivets and attaching the motor retainers 1 5 Provided that new batteries are installed in each slot on the day of the launch the rocket will be able to last ten hours on the launch pad in a ready to launch state without change 1 6 The vehicle will utilize a standard commercial igniter which will be chosen following the assembly of the full scale rocket 1 7 As stated before the rocket will use a standard commercial igniter which will be capable of using the standard 12V direct current source 1 8 The motors the team has selected to use in the competition will be a Cesaroni L910 for the sustainer and L1350 for the booster This choice of Cesaroni as the supplier was based upon team familiarity with motors of this type Cesaroni motors are known for their ease of use reliability and performance 1 9 There are no pressur
110. f the rover will be to traverse the given landscape with the unconventional transportation The approach to the experiment will be in predicting distance travelled and efficiency of travel with the technology being qualified on the rover Our method of investigation pertaining to the locomotion will be to design the optimal algorithm for traversing the given terrain Tests will be conducted on several terrains to insure that using power screws Is a viable method of locomotion Similar to the image processing a pass or fail will be given to the system The experimental logic behind the pressure sensor will be to insure that it can accurately read different pressure values These values are of significance as it tells the payload what altitude it is at This is important not only for payload events such as activating the parachute cam but it provides a method of analyzing the rover s parachute This will be good in determining if it was sized correctly The approach that will be taken is to have several launches with the pressure sensor on a rocket and then comparing these values to an altimeter If the values are similar than it will be given a pass Tests and Measurement To insure that the Hazard Detection Payload works the team will conduct several experiments that will test each of the payload s critical components Table 46 shows the 2013 2014 RCR CDR IN tests the team currently plans to conduct as well as what measurements would qualify
111. ft diameter Deployment Velocity Deployment Velocity ft s ft s Terminal Velocity ft s 15 583 Terminal Velocity ft s 17 102 Fabric Type MIL C 44378 Type IV ripstop nylon Fabric Type MIL C 44378 Type IV ripstop nylon Shroud Line Material 1 8 inch nylon para cord Shroud Line Length in Shroud Line Length in 123 75 Thread Type Nylon Thread Seam French Felled Seam Recovery Harness Type 9 16ths tubular nylon Recovery Harness Length Recovery Harness Length ft 15 ft ft 25 ft 2013 2014 RCR CDR Harness Airframe Harness Airframe Interface U Bolt Interface Lower Sustainer Ejection Parachute Rover Parachute Round Annular Round Annular 10 104 ft diameter 4 783 ft diameter Deployment Velocity 26 11 ft s OMS tase _ ft s 18 99 1 8 inch nylon para cord 1 8 inch nylon para cord Shroud Line Length in Thread Type Nylon Thread French Felled Seam Recovery Harness Type Recovery Harness Length Recovery Harness Length ft 15 ft ft 0 ft Harness Airframe 1 4 inch U Bolt quick link Harness Airframe Custom parachute cam system descibed Interface Interface in CDR f Energy of oer Upper Energy o Each Booster ice rover Each Section ft Section ft bs 6 6 25 w fF Milestone Review Flysheet Institution University of Louisville Milestone CDR First Stage or Single Stage Apogee Recovery Recovery System Properties Recovery System Properties MissleWor
112. g both able to separate the booster and provide redundant recovery events at apogee at half of the price of the Raven There are two black powder charges at apogee 1 0 seconds this is due to the combination of one altimeter being in backup mode and the other being in apogee only mode 2013 2014 RCR CDR 2 7 Stage Motor Ignition T m Second Stage Motor Ignitor 1 First Stege Burnout First Stage Burrjout 3 55 Second Stage Motor Ignitor 2 Using OpenRocket and taking an iterative approach with the new larger vehicle it was determined that to achieve the highest altitude that the 2 stage motor will have to provide thrust 3 0 seconds after burnout In the following flowchart it shows the ejection charge as being 3 0 and 3 5 seconds those values are placeholders until we are able to statically test the motor The motor will be tested on a static thrust stand and the time taken from sending the ignition signal until the motor produces thrust will be documented and then subtracted from the 3 0 second delay Two ignitors will be used with one from each Raven for redundancy Figure 45 2nd Stage ignition logic Apogee Event Apogee Powder Charge 1 Apogee oe mmm Black Powder Charge 2 Figure 46 Apogee recovery logic The apogee event uses two Stratologger s that deploy at apogee and apogee 1 0 seconds This is a standard dual deployment for high powered rocketry
113. gger other events in the rocket control algorithm Drawings and specifications There are three separate algorithms used to detect different events in the rocket s lifecycle launch apogee and landing detection 2013 2014 RCR CDR au Launch Detection Apogee Detection Landing Detection Begin launch Begin apogee Begin landing detection algorithm detection algorithm detection algorithm Set baseline pressure average Read in pressure of 5 readings Read in pressure Rocket direction Get the average of Read in pressure sign of the reading the last n set of differences in the Yes readings Yes last n readings No read in pressure baseline gt pre defined A Are gt 30 of readings signs different than rocket direction Difference between any reading and the average gt pre defined A Yes Y Yes Y Send SMS indicating launch has occurred Send apogee Send landing detection SMS detection SMS End launch detection algorithm End apogee End landing detection algorithm detection algorithm Figure 96 Pressure sensor event detection The launch detection algorithm will first detect a baseline pressure This is the air pressure experienced while the rocket sits on the launch pad An average of five readings from the pressure sensor will b
114. gure 4 Nose Cone Effectiveness Comparison 2 Figure 3 2 relates a generalized version of the first indicating that the LH Haack and the Von Karman are the two most effective designs for the flight The equations used to generate the Von Karman LD Haack type cone in our SolidWorks renderings are shown by Equations 18 and 19 2013 2014 RCR CDR 1 _ sin 20 TE 5 Csin 0 18 C 0 for LD Haack 19 The components chosen are shown in the exploded view of the nose cone bay below The cone itself is of the Von Karman design while the specialized parts washers bolts and U bolt will be supplied by a hardware manufacturer Additionally the nose cone will house a GPS sled to track the section upon separation from the main vehicle The recovery portion of the nose cone and fairing section will be described later Figure 5 Von Karman Nose Cone As mentioned before we chose to use the Von Karman design because we discovered that it provided the optimal ratio of lift versus drag for our intended speed The tip of the cone made out of machined aluminum ensures a perfect point and more rigid surface for decreased deformation during landing At the rear of the cone is an elongated shoulder which will allow us to ensure a snug fit with the rest of the rocket s body This particular piece will be purchased through Rocketry Warehouse and will be according to the specifications specified It will be a six inch diamet
115. h activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events dho Jh 03 27 14 Signature Date 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e violate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events 2 24 2014 oignature Date 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e violate these regulations realize that may not be able to participate construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events lt a Um 0 2 24 H
116. hase single day call amp text service for smart phone 3 day plan Turn on Smartphone and make call to activate SIM card Turn off Smartphone and remove SIM card Install SIM card onto GPS GPHRS cape Ensure all libraries are installed and configured on the BeagleBoard a Libraries i ___ li SciPy ii NumPy 2013 2014 RCR CDR n po fw em ues iv GPRS libraries see the GPRS unit s user manual for installation instructions 1 ppp Point to Point Protocol v AAdafruit beaglebone io python used to control the parachute release servo vi Ensure the revision from Feb 7th 2014 is installed and configured Library revisions are at https github com adafruit adafruit beaglebone io python commits master Installation guide is at http learn adafruit com setting up io python library on beaglebone black 8 Configuration a GPRS unit Firmware section 7 1 in the user manual i Ensure HDMI is disabled in the file boot uEnv txt see section 4 in the user manual li Ensure the GPRS unit is set up to send data in the 850MHz 1900MHz band See email from Duarte Carona on Feb 3 2014 See also 3 5 7 1 56 of the GPRS AT command list b Payload program c ___ Does our systemd service point to the correct path of the startup program See the field ExecStart in etc systemd system programName service d QConfirm that the startup script is executable chmo
117. hazard Based upon this we will be able to determine how accurate the system is and make modifications to eliminate any errors Data transmission accuracy will also be done with visual inspection by comparing how many data packets were sent to how many were received as well as checking if any of the data is corrupt Fortunately a few of the components we plan on using contain datasheets which allow us to check how accurate they are The table below summarizes the accuracy of these components for which there is data available The accuracy for other components will be further investigated and added to this table in future reports 2013 2014 RCR CDR Accuracy Description Telit GE864 GPS Receiver GPS is accurate to less than 2 5 meters when its between 40 C and 80 C Sensitive up to 163dBm on 48 channels BMP180 Pressure Sensor The pressure is accurate from 0 12hPa and its resolution is 0 01hPa Table 47 Component Accuracy Description 2013 2014 RCR CDR 164 SAFETY AND ENVIRONMENT PAYLOAD Safety Officer The safety officer for the University of Louisville team is Emily She is responsible for overseeing the actions of the rocketry team making sure that all applicable FAA laws are observed and ensuring the general safety and well being of both the team and the public Environmental Concerns The only environmental concern from this payload is a potential fire This could be caused by the failure of one
118. hazard will occur A severity value between 1 and 4 has been assigned to each hazard with a value of 1 being the most severe In order to determine the severity of each hazard the outcome of the mishap was compared to an established set of criteria based on the severity of personal injury environmental impact damage to the rocket and or damage to equipment This criteria is outlined below in Table 19 Severity Could result in death significant irreversible environmental Catastrophic 1 effects complete mission failure monetary loss of 5 or more Could result in severe injuries significant reversible Critical 2 environmental effects partial mission failure monetary loss of 500 or more but less than 5k Could result in minor injuries moderate environmental effects Marginal 3 complete failure of non mission critical system monetary loss of 100 or more but less than 500 Could result in insignificant injuries minor environmental Negligible 4 effects partial failure of non mission critical system monetary loss of less than 100 Table 19 Severity Criteria A probability value between 1 and 5 has been assigned to each hazard with a value of 1 being most likely The probability value was determined for each hazard based on an estimated percentage chance that the mishap will occur given the following e All personnel involved have undergone proper training on the equipment being used or processes being performed e Al
119. he team will always follow up with coordinators or educators whom we are working with to Figure 118 Elementary School Engagement evaluate the success of our programs The newest addition to our curriculum this year includes a 6 week aerospace program at a local school Shawnee Academy Complete details of this new and exciting program are included below In addition to this new program we will continue to foster the relationships formed in the past years by connecting again with our most successful and valuable events A complete list and description of planned events for the season are included below 2013 2014 RCR CDR Engineering Exposition E Expo Since 2006 the JB Speed School of Engineering Student Council has hosted the largest student run event on the University of Louisville s campus the Engineering Exposition The event is geared towards celebrating strides in engineering as well as getting the local youth interested in the field During the event the professional engineering societies on the University of Louisville s campus set up educational games and scientific demonstrations for the elementary and middle school aged participants Figure 119 Launching Paper Rockets at UofL Last year the team participated in the event and reached out to over 350 students with a customized water rocket competition Teams of three elementary aged students were encouraged to use their creativity and problem solv
120. he ESC so that the ESC does not get overloaded We were successful in controlling the motor with the design explained above 2013 2014 RCR CDR I Though our team has been planning the PWM circuit since the PDR was presented a major change involves the IC chip used for PWM control After having difficulty using the MC34023 IC our electronics team could not locate supporting documentation for applications of the IC given on the data sheet Fortunately we located a different IC more suitable to our needs in terms of output voltage and ease of hardware implementation the TL494 included better documentation and was more easily constructed in lab The inverter was also added to our PWM circuit for isolation concerns and voltage differences in the ESC input when compared to the TL494 output Figure 90 Barometric Pressure Sensor Circuit For the custom made PCB board we have designed for external connections The 3 cell LiPo battery will be connected to the ESC s and TL494 PWM controller through 2 pin JST XA model connector The connectors are rated for 250V 3A each The 2 cell battery 7V will be connected with the JST connector as well It will be regulated through the LM7805 on the PCB then routed to another 2 positions JST XA header From the XA header a joining XA housing will be received and connect directly to the microcontroller s barrel plug Though it would be desired to receive the battery terminals directly to the PCB our team cou
121. he duct tape around the coupler tubing created too much friction between the staging couplings It was determined that when the sustainer motor ignited the pressure created in the coupling section between the two stages was large enough to cause the violent explosion Once the two stages separated the dramatic change in pressure between the inside of the coupling and the outside pressure caused a rapid evacuation of the air within the motor and coupling section The team determined that this quick release of air sucked out any and all burning particles of propellant that would have continued to light the motor The team had to go back and rebuild the booster airframe and altimeter bay in order to make the rocket flight ready The team discussed different staging strategies with its mentor and determined that it is more desirable to have a more loose fit than a more snug fit For the second flight the team made sure all connections were correct again with the electronics and then prepared to couple the two stages This time the team sanded the coupler tubing to allow for a smooth and easy coupling Once together a small piece of masking tape was applied across the mating section of the two stages Two small slits were cut into both sides of the tape so as to allow for easy tearing during stage separation 2013 2014 RCR CDR Figure 21 Second launch of the subscale The rocket was set on the launch rail the electronics were turned on
122. he new separation design a test parachute was created and tested for drag characteristics and recovery logic has been documented CHANGES TO PAYLOAD CRITERIA 1 The fairing deployment system requires a custom pyro cap to be ejected from the fairing In order to make our launch vehicle s system fully redundant the team has designed the pyro cap to have two separate black powder chambers with two electronic matches routing into either chamber Similar to the above change the team has added a second altimeter housing to the fairing system This altimeter housing will be in control of the second black powder chamber added to the pyro cap CHANGES MADE TO PROJECT PLAN Currently there have been no notable changes to the project plan The team has had minor issues with a couple purchasing orders but they do not plan on this having an effect on the overall timeline laid out in the project plan 2013 2014 RCR CDR HAN VEHICLE CRITERIA DESIGN AND VERIFICATION OF LAUNCH VEHICLE Design Overview Nain Recovery B Rover Bay Drogue Parachute Bay NS Figure 1 Vehicle bay layout ter Stage Recovery Bay Booster Stage Propulsion Bay Sustainer Stage Sustainer Stage lantion B ay Propulsion B ay This year the major vehicular design is being based upon two central missions the first being using multiple motors in an inline staged format and the second being a fairing system designed to release an autonomous rover to c
123. he piston is pushed upwards By pushing the piston upwards the four ball bearings will fall into the empty space beside the spring The purpose of the ball bearings is to hold the pin as it has a grove for the bearing to fit into With the ball bearings out of the way the spring decompresses and ejects the pin The pin has a hole to allow the parachute lines to go through To prevent these components from coming out of the housing a cover made out of clear acrylic will screw onto the front To add to its custom uniqueness the school s mascot will be cut into the cover All of the plastic components will be 3D printed and are currently awaiting delivery by the university s prototyping lab The pins are machined out of 1018 Low Carbon Steel which has a yield strength of 54 000psi so it will be able to sustain the force from opening the parachute without any problems To insure that the plastic and the entire system as a whole can sustain the stresses from holding the entire payload a gauge will be used to test how much force it can sustain before breaking 2013 2014 RCR CDR IN Servo Cover x Ball Bearings Spring v Piston gt Housing Cover N N Servo Adaptor Housing Screws Figure 107 Exploded View of Parachute Cam Control algorithm 2013 2014 RCR CDR Has the rover landed yet _ Wait 10 seconds for Begin parachute
124. he recovery system electronics shall not be adversely affected by any other on board electronic devices during flight from launch till landing The recovery system must meet the following requirements which have been set forth by the team 10 The recovery system shall create an opening such that the recovery harness will not fail 11 At landing the hazard detection payload at a landing kinetic energy less than 25 ft Ibr 12 Every recovery event will feature redundant ejection charges 13 The recovery system shall not create opening shock high enough that the recovery harness suffers damage 14 All suspension lines are to be removable in the event of an incident and they need replaced Parachute Selection Parachute are broken down into the following types solid textile slotted and rotating Knacke 5 3 With four parachutes being used during descent and all of them being in the air simultaneously the chances of a midair collision are much higher than one active parachute as seen in a dual deployment scheme By keeping all parachutes the same type the flight path will be more similar than if each was different for this reason it was deemed that all parachutes will have the same geometry Geometry The parachute geometry was selected to minimize the total mass of all parachutes To accomplish this the geometry with the highest drag coefficient and minimum area was chosen Table 4 shows drag coefficient ranges vs parachute geometr
125. hour without losing the functionality of any critical on board component 5 An electronic tracking device shall be installed in the launch vehicle and shall transmit the position of the tethered vehicle or any independent section to a ground receiver 6 The electronic tracking device shall be fully functional during the official flight at the competition launch site 7 The recovery system electrical circuits shall be completely independent of any payload electrical circuits 8 The rover must successfully release its parachute once landed 9 The rover must travel at least 20 feet once it has landed 10 The system should report any errors preventing full functionality 11 The system should wait until the launch phase of operation to perform in flight activities 12 The system should send an acknowledgement of the launch event in real time to the web server Table 44 Payload Objectives Payload Success Criteria To be able to call the objectives mentioned above a success the payload must meet a few criteria so that it can be called a success Success of the mission includes detecting apogee recording local hazards landing safely and collecting transmitting environmental data to a designated device Explaining further on the mission success we are testing unconventional locomotion methods on this rover given a safe landing is 2013 2014 RCR CDR IN achieved The vehicle is moved along by the thick screws
126. iate The 1 hour without losing the Fire retardant material will motors will be tested to functionality of any critical be useful in case of fire operate with the chosen on board component LiPo Table 36 LiPo Battery Requirement Feature and Verification Table Payload Power Distribution In the system level view of the power distribution our team s largest electrical concerns for the rover are battery life communications and allocating power to each component We will be separating the power that runs to each motor as well as the BeagleBone power by using separate batteries for the microcontroller and battery supply respectively Each battery will be regulated down from the battery voltage to each respective voltage that the components will need The power for the microcontroller will be regulated by the 2013 2014 RCR CDR I LM7805 IC The power line for the motors will be regulated by the ESC s used in our current setup We will be utilizing the LM7805 voltage regulator shown below to give a regulated power supply to the BeagleBone The 2200mAh 2 cell LiPo battery that is being used to power the microcontroller will provide up to 7 4 volts to the board This voltage will then be stepped down by the LM7805 and exclusively power the BeagleBone Per this regulator s datasheet it will output a typical value of 5V 4 This tolerance is well within what is needed for input to the BeagleBone micro With the small delt
127. ify the motor selection provides the necessary exit velocity The launch pad will be coated in graphite prior to each launch in order to minimize friction Should the failure mode still occur the issue should be further examined to determine if the cause was due to a faulty motor or in the booster needs to be redesigned 1 A tiltometer will be placed in the rocket to determine the angle of flight If the angle of flight is too high the sustainer motor will not fire and the rocket will fully recover 2 The coupling between the booster and sustainer will be sanded down to have a loose fit preventing the two sections from getting stuck together during flight Test altimeters to make sure they are fully operable prior to flight Altimeters have special bays designed to ensure secure mounting throughout the flight Should altimeters continue to fail a redesign would need to be evaluated to ensure proper ignition 2013 2014 RCR CDR altitude achieved 1 Test altimeters to make sure they are fully operable prior to flight Altimeters have special 1 2 3 Sustainer bays designed to ensure secure motor will not mounting throughout the flight fire and the 2 The tiltometer will not allow the malfunction 2 Tiltometer rocket will sustainer to ignite at an angle Sustainer does not achieve an greater than 40 Tiltometer will be e malfunction 1 4 Moderate ignite dia altitude significantly tested
128. images from BGR Blue Green Red to HSV Hue Saturation Value allows color differentiation Implementation will be applied on the most common hazards that we expect to encounter when we are in flight Some of these hazards include water roads and crowds of people The current plan is to detect these hazards and then add more hazard types later depending on development progress Color variation and edge detection methods Another approach that will be taken includes detecting edges and color variation to detect objects This works by providing an input image from a live camera feed and processing it through numerous image manipulations using OpenCV One such input would be smoothing the original images using the Gaussian kernel thus making the output with a lot more depth Then change the image from BGR to HSV using a defined color range thus filtering that out 2013 2014 RCR CDR Dm Figure 97 Salt Flats unfiltered launching area PLE 4 er FILI am nu Figure 98 Salt Flats filtered launching area where the cars and mountains are added to the hazard list and filtered Hazard data transmission After detecting the different hazards our program will store a list of these for a real time data feed which is transmitted to the ground station and then later a web server The web server will have the FTP protocol enabled which the program on board the BeagleBone
129. ing descent the fairing will open and safely deploy the payload Milestone Review Flysheet Please see Milestone Review Flysheet Instructions Institution University of Louisville First Stage Both Stages Together or Single Stage Second Stage If Applicable Vehicle Properties Vehicle Properties Total Length 101 Gm Airframe Material G12 Fiberglass Fin Material Fin Material G10 Fiberglass Motor Properties Motor Properties Max Average Thrust Ib 438 394 Ibf Stability Analysis 2253 10 ft Center of Pressure in from nose 3 0s Center of Gravity in from nose Igniter Location Sustainer Milestone CDR Static Stability Margin 2 23 Stability Analysis Thrust to Weight Ratio Center of Pressure in from nose 93 053 Rail Size in cuiae io augen Center of Gravity in from nose 84 36 Rail Length in 120 inches Static Stability Margin Rail Exit Velocity ft s 42 9 ft s Thrust to Weight Ratio 8 28 e A Ascent Analysis 843 ft s Maximum Velocity ft s 843 ft s Maximum Mach Number Maximum Mach Number 0 75 Maximum Acceleration ft s 2 311 ft s 2 Maximum Acceleration ft s 311 ft s 2 Target Apogee 1st Stage if Multiple Stages 3534 ft Target Apogee ft 10000 Recovery System Properties Ascent Analysis Maximum Velocity ft s Booster Parachute Apogee Fairing Parachute Configuration Round Annular Round Annular Size 8 9 ft diameter 8 25
130. ing skills to design their own unique water rocket In preparation for the competition members of the University of Louisville USLI team visited various schools to mentor the students and to educate them on the scientific reasoning behind why the activity works On the day of the exposition the team assisted the students in launching their water rockets using water pressure Awards were given to teams in various categories in the competition The event proved successful and the team s booth received high praise from the host This year the team plans to host the second annual water rocket competition during the 2014 Engineering Exposition with the goal of increasing participation in the event while continuing to provide an equally educational and creative hands on rocket building experience for the students Boy Scouts and Cub Scouts Over the course of the past year the University of Louisville USLI team has worked with local Boy Scout and Cub Scout Troops to assist in the earning of the Space Exploration merit badge The achievement of this badge is no easy feat The Scouts are required to attend a day long program which includes space history lessons as well as building and launching small model rockets Events will be planned throughout the year to encourage more of our local scouts to explore the realms of space and to earn their merit badge Engineering is Elementary Last year the team traveled to middle and elementary schools in the Louisvil
131. ing the interface between the BeagleBone microcontroller output to the PWM data input of the ESC The main research went into generation of a suitable PWM signal to be used to drive the ESC With our current setup we are able to power both brushless motors with one 3 cell 2200maH battery With use of the ESC comes an ability to shut down the substantial power draw of the motors for launch standby With the allowance of a motor standby we only have to power the ESC not full motor potential while awaiting launch The ESC requires only 120mA at 5V for operation This allows our team the option to run the ESC from the competition start or we can wake up the device from liftoff The standby option would allow us to bypass any unforeseen booting issues with powering the motor controller from a cold boot at launch time Requirements Features _ Verrification Testing The launch vehicle shall be capable of remaining in launch ready configuration at the pad for a minimum of 1 hour without losing the functionality of any critical The regulation circuit for the BeagleBone will insure that it doesn t overdraw too much power thus draining the battery The motors will have their own battery Tests will be done that these circuits operate as intended on board component Table 37 Power Distribution Requirement Feature and Verification Table Custom PCB Our team is designing a custom printed circuit board to contain the v
132. ks RRC3 PerfectFlite Stratologger Altimeter s Timer s MissleWorks RRC3 Altimeter s Timer s PerfectFlite Stratologger Mula 0 00000000 Garmin ASTRO DC 40 Garmin ASTRO DC 40 Transmitters 151 880 MHz Locators Frequencies 151 880 MHz Model Frequency 1 Model Frequency Power Power 3 W 4 Drogue Parachute 5 Drogue Parachute grams grams 4 6 7 1W 4 5 el GENS Black Powder Charge Size Black Powder Charge Size Main Parachute grams 67 Main Parachute grams Lower Sustainer Recovery Rover Recovery Recovery System Properties Recovery System Properties FeatherWeight Raven3 PerfectFlite Stratologger Altimeter s Timer s FeatherWeight Raven3 Altimeter s Timer s PerfectFlite Stratologger Locators Frequencies Garmin ASTRO DC 40 Locators Frequencies GPS GPRS Cape for BeagleBone Black 2013 2014 CDR NN Black Powder Charge Size Black Powder Charge Size Drogue Parachute Drogue Parachute grams grams Mandatory Payload Optional Payload 1 Optional Payload 2 Ejection Charge Tests Sub scale Test Flights Full scale Test Flights Payloads Overview Overview The launch vehicle will ride on its booster motor until motor burnout Seconds after burnout a black powder charge will be fired by an onboard StratoLogger to separate the booster stage from the sustainer stage The onboard Raven altimeter will contorl the ignition of the sustainer s motor s
133. l personnel have read and acknowledged that they have a clear understanding of all rules and regulations set forth by the latest version of the safety manual e Personal Protective Equipment is used as indicated by the safety lab manual and MSDS e All procedures were correctly followed during construction of the rocket testing pre launch preparations and the launch 2013 2014 RCR CDR ram e All components were thoroughly inspected for damage or fatigue prior to any test or launch The criteria for the selection of the probability value is outlined below in Table 20 Probability Almost Certain 1 Greater than a 9096 chance that the mishap will occur Between 25 and 50 chance that the mishap will occur Between 1 and 25 chance that the mishap Unlikely 4 will occur Improbable Less than a 1 chance that mishap will occur Table 20 Probability Criteria Between 50 and 90 chance that the mishap Likely 2 will occur Through the combination of the severity value and probability value an appropriate risk level has been assigned using the risk assessment matrix found in Table 21 The matrix identifies each combination of severity and probability values as either a high moderate or low risk The team s goal is to have every hazard to a low risk level by the time of the competition launch Those that are not currently at a low risk level will be brought down through redesign new safety regulations or any
134. l to instruct them MSDS documents will be readily available at all times and should be thoroughly reviewed prior to working with any chemical 1 Nitrile gloves shall be used when handling hazardous materials 1 Personnel are familiar with locations of safety features such as an eye wash station 2013 2014 RCR CDR rA Damage Soldering iron equipment while 2 soldering Dangerous fumes while soldering is too hot Prolonged contact with heated iron Use of leaded solder can produce toxic fumes Leaving soldering iron too long on plastic could The equipment could become unusable If parts of the payload circuit get damaged they could become inoperable Team members could become sick due to inhalation of toxic fumes Irritation could also Occur 1 Safety goggle are to be worn at all times when handling chemicals 2 When working with chemicals producing fumes appropriate precautions should be taken such as working in a well ventilated area vapor masks fume hood The temperature on the soldering iron will be controlled and the team is experienced in soldering The soldering iron will be set the correct temperature For temperature sensitive components we can use the sockets to solder our ICs to The team will use well ventilated areas while soldering Fans will be used The soldering iron will only be on parts for the recommended amount of time cause pla
135. lats in Utah Since the cape uses a cell phone module the power transmission is controlled remotely by the closest cellular base station The station dynamically assigns a power level with the intent to maintain good signal to noise ratio while limiting interference overloading and power consumption The Telit GE 864 GPRS module is rated for different classes which control the power levels it can be assigned by the base stations The GPS module is also assigned an operating range called a level but this is not controlled by the base stations The information for each of the modules onboard is shown below 2013 2014 RCR CDR IN Module Class Level Power W Sensitivity dBm MHz 1800 1900 GPRS 850 900 ops 8572 49 Table 32 GPRS and GPS Frequencies Power and Sensitivity Figure 79 T Mobile Coverage for Louisville KY 2013 2014 RCR CDR ID Figure 80 T Mobile Coverage for Bonneville Salt Flats Utah Figure 81 T Mobile Coverage for Elizabethtown KY 2013 2014 RCR CDR Delphi Figure 82 T Mobile Coverage for Ash Grove IN The data will be transmitted from the cape to a cell phone that will act as our ground station A continuous stream of data packets will be sent from this unit to the ground station The content of these packets will either indicate that no hazards have been detected or every hazard that has been detected will be listed along with the type of hazard This cape is specifically
136. ld not locate a compatible header for the board side connection As for the remaining connections servo ESC data lines we will be using open 3 position headers We are designating orientation of the connections i e Data through use of silk screen labels to be printed on the manufactured circuit boards Pins used for custom PCB will be assigned from pins not in use by GPRS cape This is determined from the GPRS cape datasheet Requirements Features _Verrification Testing The recovery system The PCB will be custom The PCB is not tied to any electrical circuits shall be made so the team can circuitry for the recovery of completely independent of insure that all the payload the rocket any payload electrical circuits needed are on this circuits board 2013 2014 RCR CDR 131 The rover must The accelerometer to Tests will be done to insure successfully separate itself detect landing and servo the components on the from the parachute once connections for the PCB work correctly landed Parachute Cam will be on this PCB rover must travel at The PWM circuit for the Tests will be done to insure least 20 feet once it has ESCs will be on the PCB the circuit works correctly landed Table 38 Custom PCB Requirement Feature and Verification Table Overall Flight Algorithm The hazard payload will all be controlled by the BeagleBone Black microprocessor which
137. le area to teach science technology engineering and math STEM subjects while providing positive role models for the students The team will continue to visit local schools to teach space history space exploration and rocketry to young students in addition to the core 2013 2014 RCR CDR 96 STEM subjects The Engineering Fundamentals Department at UofL will be providing the materials for the lessons and supporting these educational engagement activities Louisville Science Center The University of Louisville is thrilled to be able to continue its partnership with the Louisville Science Center The Science Center allows the team to be an active part of their educational environment They also allow the team to periodically display our rocket SO science center employees can discuss our project with visitors Additionally they have the ability to educate and entertain visitors with a paper rocket activity developed by the team The Science Center has been extremely gracious in allowing the team to facilitate workshops for visitors as well as participation in Engineering Week at the Science Center The Academy at Shawnee High School 6 Day Program Curriculum Day One Mercury and Gemini Program History This lesson will go over selected missions of the Mercury and Gemini programs and their objectives It will highlight several achievements of America such as Alan Shepard becoming the first American in space and John Glenn becoming the
138. lf contained This means that the section is completely seperated from the elements The payload has to be constrained safely within the fairing In order to do so the chosen method of constraint will be to have foam that is specifically designed for aerospace applications CNC d to a precise geometric structure to securely house the payload Figure 116 View representation of one half of the fairing system oeperately a section of foam will be CNC d to house the parachute for the payload Utilizing these foam inserts allows for a modular design of the rocket in the sense that any sized payload can be launched as long as its dimensions fit within the airframe of the rocket Only a new foam piece would have to be machined Furthermore by housing the payload inside of the foam inserts the payload will be allowed to easily slip out of the fairing once it begins to open 2013 2014 RCR CDR General Plastics of Tacoma Washington FR 7100 series multi use core and modeling foam board has been chosen to be used in the teams fairing application Not only is it offered in a variety of densities it is a closed cell foam material This means the the foam will not absorb water or moisture Therefore there is little worry of the material warping due to environmental changes The material is Known for its durability and will suite the objective of the payload as requiered Specifically General Plastics FR 7110 closed cell foam w
139. lty is within the skills of the members on this team due to the rigorous nature of the University of Louisville s engineering program 2013 2014 RCR CDR IN PAYLOAD SCIENCE VALUE Payload Objectives The success of the recovery mission depends directly on the success of the scientific payload The camera on the rover will contribute substantially to the success of the mission through visual recognition of hazards while the payload is in decent The purpose of this payload will be to scan the terrain for potential landing hazards using a custom software package The data from the hazard camera will have to be processed onboard and transmitted to a ground station in real time The hazard detection payload must meet the following objectives in Table 44 as set forth by the Statement of Work SOW to be considered a success Requirements marked with an asterisk are those set additionally by the team 1 The payload shall incorporate a camera system that scans the surface during descent in order to detect potential landing hazards 2 The data from the hazard detection camera shall be analyzed in real time by a custom designed on board software package that shall determine if landing hazards are present 3 The data from the surface hazard detection camera and software system shall be transmitted in real time to a ground station 4 The launch vehicle shall be capable of remaining in launch ready configuration at the pad for a minimum of 1
140. m the body of the rover leading to a chance that the rover cannot move forward causing partial mission failure The servo will continue to rotate to the end of its allowed range because PWM signal is never stopped which could damage the servo s gears If the exception is thrown before the servo has been t the 3 on started the servo will no rotate which will lead to parachute not being released and possible n critical mission failure The servo cam will not rotate the correct direction This will cause the parachute to not be released from the rover body Overall 4 5 5 1 the 2 Overall 5 Overall 5 2013 2014 RCR CDR Added an entry to the pre launch checklist to ensure that the correct version of the PWM is installed and configured Added an entry to the pre launch checklist to ensure that the correct version of the PWM is installed and configured The PWM code will be tested multiple times to insure there is no bug The code will be tested to insure there are no bugs present The cables will be inspected to insure they are plugged in securely A try catch block is placed around the entire servo rotation program If any exceptions are encountered the program will exit with a return code indicating an error has occurred The process executing the servo rotation program will restart the servo rotation program up to 3 times if an error is encountered An entry has b
141. max material this failure mode is unlikely The cables and bulkhead connecting the recovery system to each segment of the rocket are designed to withstand expected loads with an acceptable factor of safety Should the rocket become ballistic all personnel at the launch field will be notified immediately Table 25 Recovery Risk Assessment Vehicle Assembly Assessment Severity Probability Risk 2013 2014 RCR CDR Cause Mechanism Rocket drop INERT Rocket drop LIVE Black powder charges go off prematurely Seized nut or bolt due to galling or cross threading Mishandling of the rocket during transportation Mishandling of the rocket during transportation 1 Altimeters send a false reading 2 Open flame sets off charge Repetitive uninstalling and reinstalling of parts made of Minimal damage and scratches to components of the rocket Low 1 Minimal damage and scratches to components of the rocket if no charges go off 2 Charges prematurely go off resulting in a serious safety threat to personnel in the area and significant damage to the rocket 1 2 Charges prematurely go off resulting in a serious safety threat to personnel in the area and significant damage to the rocket Component becomes unusable potentially Low Low Low The rocket has been designed to be durable in order to survive loads encountered during flight and upon landi
142. meter A 9V battery is currently expected to power the Arduino and the attached Tiltometer PCB The current layout of this PCB is shown in Figure 42 F a N Tiltometer 02 0 Figure 42 Layout of the Tiltometer PCB As can be seen the circuit for the MPU6050 is as far from the terminal blocks connecting the igniter and Raven The reason for this is to prevent any parasitic effects on the MPU6050 Both of the terminal blocks are rated for 600V 30A so they should be able to 2013 2014 RCR CDR a7 withstand the power required to light the igniter The Tiltometer PCB is able to contain all the components on a board the same size as the Arduino UNO Therefore the Tiltometer will only measure 2 x2 1 and it will be oriented vertically in the rocket as shown in Figure 42 Once the Tiltometer s PCB has been manufactured and assembled several ground tests will be conducted to insure that it operates as intended before being placed on the rocket Any further revisions will be documented in later reports Flight Path and Recovery Logic The proposed flight path is shown below in Figure 43 with the events shown in sequential number ay 4 D gt 2 1 3 Figure 43 Proposed flight path Event one is the stage separation event two is the second stage motor ignition event three is the apogee event event four is the ejection of the lower sustainer and event five is the opening
143. minimum required compressive strength was determined The simulated maximum acceleration of the launch vehicle was used to determine the force on the rocket From there the force was applied tested against the smallest cross sectional area of the foam inserts This gave the team an estimated pressure on the foam at the weakest point By applying the safety factor the required compressive strength was determined Comparing this data against the material properties of offered products from General Plastics FR 7107 was determined to be the optimum foam material to be used for our application Requirements Features Verification The payload shall safely A specific foam material will Tests will be conducted contain the payload during encompass the payload with a subscale model that and protect the payload will simulate launch from the stresses conditions Analysis will be throughout flight conducted of the foam and mock payload post launch to determine what changes need to be made if any At a predetermined altitude A two piece aluminum cap A subscale version of the the fairing shall deploy the and shell component fairing deployment system payload safely containing a black powder will be designed Multiple charge holds the fairing tests will be conducted together Two extension during subscale flights to springs create a torque ensure the system which tries to pull the fairing functions as planne
144. mission failure Failure of the web server to receive data updates would result in failure to display launch events in real time to web based users which is a partial mission failure Inability to use the brain of the rover would result in complete mission failure Loss of battery will result in payload electronics to be unpowered Depending on when the battery catches fire the entire payload could be destroyed Damage to people and property could occur All parts are crucial to payload performance so loss of any part would result in mission failure Overall 4 Moderate Overall 4 7 2013 2014 RCR CDR ground station is powered on fully charged and properly receiving text messages before launch The team has verified via T Mobile s online coverage map that the launch field at the Bonneville Salt Flats as well as other launch fields have wireless coverage The team will contact the web hosting service to ensure that access should be available during the launch time frame A pre launch checklist item has been added to verify that the above has been completed Added an entry to the team s pre launch checklist to verify that FTP credentials in the ground station s source code match the current valid credentials for the web Server All The team has possession of 3 BeagleBone s which can be swapped out in case one fails The BeagleBone will be flashed with the latest Linux OS Th
145. n image Further tests will be detection camera shall be processing library that can conducted to verify that analyzed in real time bya is compatible with the OpenCV can detect custom designed on BeagleBone OpenCV can hazards via BeagleBone board software package be coded to detect certain that shall determine if objects landing hazards are present Rover Design A rover was chosen to integrate the electronics onto the rocket The reason for choosing a rover layout is that it adds significance to the hazard detection part of the payload since this system could be used to detect landing zones for future rovers going to other planets Figure 102 shows the layout of the rover with all the hardware modeled to scale The rover design is based off the ZIL 2906 vehicle designed by the Soviet Union to retrieve cosmonauts in difficult terrain as well as the Hot Wheels Terrain Twister which is an RC toy The rover is 5 11 wide 4 64 tall and 17 45 long and is expected to weigh around 5 Ibs but this might vary slightly as the weight of the 3D printed components are still unknown The rover is sized to fit inside of the 6in diameter airframe for the fairing The parts requiring 3D printing have already been sent to the rapid prototyping lab at the university and the team is awaiting their delivery 2013 2014 RCR CDR M9 Figure 102 Rover Model 2013 2014 RCR CDR 50
146. n press will then be used to slowly press the semi circle birch bulkheads into place Three wood screws will then be screwed into the holes previously drilled out This will secure the shape of the fiberglass temporarily while high strength epoxy is applied to permanently constrain the bulkheads in place This system of manufacturing the fairing will be tested during the subscale build and will prove reliable to the quality of the final product 2013 2014 RCR CDR IN SCIENCE VALUE The fairing has two primary objectives Firstly the fairing must securely house the payload and keep it safe throughout flight The second objective is to successfully and safely deploy the payload at the predetermined altitude If either of these objectives fail the mission will fail To keep the payload safe the team had to be certain their choice of foam would be able to withstand the stress of flight The team sought guidance and opinions through various companies who design foam materials used specifically in aerospace applications Exact documentation on how the foam will hold up would be near impossible to calculate do to the various unknown variables the launch vehicle could experience during flight The foam will be rigorously tested both in subscale launches and on the ground in the workshop In order to ensure a safe deployment of the payload the action of the fairing must be smooth and precise One point of failure could be the hinge that the fairing
147. n soldering the sensor to the PCB each pin will be inspected to insure there is no short that could cause the sensor to fail The team added a safety window of 1 2 seconds to the amount of time the servo rotates This will ensure that if the servo does not rotate for the entire time length the parachute will detach The sleep function will be tested multiple times to insure it works as intended The code to send the PWM signal to the servo pin fails The code that waits for Servo rotation to complete fails An exception is encountered during execution of any function calls in the servo rotation code The parachute cam servo is rotated in the incorrect direction exception or has a bug and exits early 1 The software library used to send PWM signals is not installed on the device 2 The software library used to send PWM signals to the servo is not the correct version 3 The software library used to send PWM signals to the servo contains an internal bug The library function used to wait for rotation to complete contains an internal bug Power loss is experienced There are bugs in the programming language implementation used There are bugs in the PWM library used There is a programming error in the servo rotation code During assembly a team member does not know which way the servo should be oriented to be sure that it rotates The parachute is not cleared fro
148. nd a program will be written that when the tiltometer is angled at an unsafe angle turns the LED on and when the tiltometer is at a safe angle turns the LED off This test will verify that the program correctly identifies safe vs unsafe angles and that the signal to disable the second stage motors simulated via the LED will behave properly Electrical System The tiltometer s basic function will be to read angle values from an accelerometer and gyroscope and based on the angle it will allow current to flow from a Raven altimeter to the motor igniter or block it An MPU6050 IC will be used to read angles since it contains a 3 axis accelerometer and gyroscope in one package which simplifies the circuitry The electrical schematic of the current tiltometer revision is shown in Figure 41 2013 2014 RCR CDR ET ET ARDUINO Figure 41 Tiltometer s Electrical Schematic The MPU6050 IC uses I2C communication protocol which reduces the amount of pins needed on the Arduino compared to UART or SPI communication This chip operates from 2 375 3 46V which is why it is tied to the Arduino s 3 3V power bus Some of the technical specifications of the accelerometer and gyroscope are shown in Table 10 Parameter Accelerometer Gyroscope 250 9 s 500 s 0 1 9 s g Sensitivity 0 1 9 s g Frequency Table 10 Specifications for Accelerometer and Gyroscope on the MPU6050 IC The circuit for the MPU6050 IC has been already been p
149. nderstand that it is my responsibility to remain up to date with the latest version of the safety manual violate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events A c 2 26 4 Signature N Date 2013 2014 RCR CDR 210 RIVER CITY ROCKETRY UNIVERSITY OF LOUISVILLE SAFETY COMPLIANCE FORM By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document understand that it is my responsibility to remain up to date with the latest version of the safety manual e flviolate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events Signature Date 2013 2014 RCR CDR EIE RIVER CITY ROCKETRY UNIVERSITY OF LOUISVILLE SAFETY COMPLIANCE FORM By signing this form agree to comply with all safety rules and regulations set forth by the safety manual read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e lf violate these regulations realize
150. nding did not occur When all n readings from the pressure sensor are less than the threshold landing is detected because the values from the pressure sensor are suitably stable Once landing is detected another SMS will be sent indicating the landing event OpenCV The software package that is going to be used is an open source library for image processing called OpenCV short for Open Source Computer Vision Library As the name implies OpenCV is free to use under the open source BSD license OpenCV is designed for computational efficiency with a strong focus on real time image processing applications Due to its wide popularity OpenCV supports languages varying from C is a cross platform library which has Linux support Not only does OpenCV support the same operating system OS as the BeagleBone Linux but it has full support for numerous programs written in C Python and Java OpenCV is currently used in various applications such as robotics motion tracking and object identification thus making the perfect tool for our requirements Our choice of language will vary from Python to C and will be combined for the most optimal solution on the BeagleBone This will help us effectively track hazards The task of obstacle detection will not be a trivial one as not all hazards can be detected with simple algorithms The OpenCV library requires certain color ranges which would define the hazards in this case This process of converting
151. ne ESC used per motor The ESC will be getting a Pulse Width Modulation PWM signal from a circuit on the custom PCB the team will create This PWM signal will be used to control the speed and rotation of the motors by generating a three phase AC signal Controlling the ESC via the PWM circuit instead of the using code will allow the BeagleBone to concentrate on more important tasks These ESCs have a built in overload protection circuit and feature a small fan unit to cool down the ESC in case it overheats A 35 amp ESC was chosen since each motor can draw up to 20A but to protect the ESC from any sudden spikes a higher value ESC was chosen These ESC s are used for RC cars which enables the motor to rotate in clockwise and counterclockwise directions and will be useful for our rover application The retail price per ESC is around 32 which is within the team s budget Requiemens Features X _Verrification Testing rover must travel at The overload protection The ESCs have been least 20 feet once it has circuit will prevent the verified to work with the landed motors from drawing too PWM circuit and with the much power from the motors Ihe overload motors The ESC can also protection has also been output the required 3 proven to work as it would phase signal that s not allow higher voltages to required to run brushless pass that would damage motors the motors Table 34 ESC Requirement Feature and
152. new technology Through the creative use a rover the team is able to have a unique payload to differentiate from the rest of the teams in the competition Besides being a creative method of engaging the public the hazard detection system performs a complex task which is currently the subject of several scientific projects The reason is that object detection recognition is a very important topic that could allow the automation of many tasks By using OpenCV and an off the shelf webcam the team is able to reduce the costs of the detection system which would allow others to repeat or further expand the system from their own computers To move the system away from the computer the team is using the BeagleBone Black which is unique platform since it is a Linux microprocessor which is much powerful than a Raspberry Pi or Arduino The BeagleBone is significant to the payload as it is capable of running several complex tasks and is compatible with many systems already available One such system is the GPS GPRS cape the team is using to obtain and transmit data The use of SMS to transmit data is significant as it allows the payload to send data to anyone who has a modern phone as well as to any enabled webserver Overall this payload achieves many complex tasks that could be useful for future planetary missions and is also able to engage the public due to the unique rover design which is sure to attract attention Level of Challenge The payload this year
153. ng Careful handling should be practiced while transporting the rocket The rocket has been designed to be durable in order to survive loads encountered during flight and upon landing Careful handling should be practiced while transporting the rocket All electronics will be kept in their OFF state for as long as possible during preparation Open flames and other heat sources will be prohibited in the area Through proper choice in materials appropriate pre load and proper installation the risk of galling can be eliminated 2013 2014 RCR CDR materials prone to ruining galling expensive custom machined parts Amount of rework depends on the location and component that seized Table 26 Vehicle Assembly Risk Assessment Environmental Hazards to Rocket Risk Assessment Cause Severity Probability Risk When planning test launches the forecast should be monitored in Unable to test order to launch on a day where Bu entire system weather does not prohibit launching or testing the entire system 1 When planning test launches the forecast should be monitored 1 Unable to in order to launch on a day where launch weather does not prohibit 2 Damage launching or testing the entire Rain N A electrical 1 4 Moderate system components 2 Have a plan to place electrical and systems in componenis in water tight bags the rocket Have a location prepared to store the entire rocket to
154. ntrol point for the rover A second control the team has is what hazards the software will be looking for By narrowing it down to a few hazards the system resources will be freed up thus increasing performance A third control the team has is how the data is encrypted when sending it to the ground station By choosing an encryption method the latency in data transmission may be decreased A final control point is the design of the rover This will allow the camera to be orientated in the best orientation possible so that it can better detect hazards Relevance of Expected Data The data that is collected from the hazard detection payload is very significant as object recognition via images is a topic that is of great importance By having a successful payload the team will be able to demonstrate a possibly cheaper method of achieving this By improving upon the information obtained from the team s payload this system could be used by others to detect terrain hazards for other rovers sent to other planetary bodies By doing so the best landing zone could be identified thus potentially improving the mission s success Accuracy Error Analysis Due to the software for this payload being built from scratch the accuracy of the components being using will have to be done by visual inspection The team will have to compare the images taken from the webcam with the processed data to insure that the software package was able to correctly identify a
155. ociation TRA Member Number 11019 Contact Information nocturnalknightrocketry yahoo com or 270 823 4225 LAUNCH VEHICLE SUMMARY The launch vehicle is comprised of two separate stages a booster stage and a sustainer stage The two stage rocket will be constructed out of fiberglass and is estimated to weigh in at 50 4 pounds To deliver the rocket to its predetermined altitudes the rocket will host a Cesaroni M3100 WT motor in its booster stage that will be succeeded by a Cesaroni L1720 WT motor in the launch vehicle s sustainer stage Four separate recovery systems will be implemented in insure all sections of the rocket land within the kinetic energy guidelines Altimeter bays have been modeled for the booster lower and upper sustainer PAYLOAD SUMMARY The team will focus on designing an efficient two stage rocket featuring a fairing system that will deploy a custom hazard detection system By adding a booster stage to the rocket will allow the team to fly the hazard detection system to an appropriate altitude in order to carry out its mission s goals The team has developed a custom rover that will host the hazard detection system The goal of the rover is designed to be able to interpret the data obtained by the hazard detection system and plot out a safe course to maneuver along once on the ground A fairing has been designed to safely house the rover Once the 2013 2014 RCR CDR FI rocket has reached its designated altitude dur
156. of Mobile Robot Driven by Archimedean Screw Mechanism on ooft Soil 4946 4951 Also based on this study the pitch for the threads was chosen to be 4 inches and the blade height is 3 8 inches Due to the size limitations of the 3D printers each screw will be made out of two parts To hold the power screws together plastic cement will be used on the tabs that join the two halves Screws will be added if more support is needed and if that doesn t hold a redesign will be made The total length of each screw is 10 8 inches Figure 105 shows an exploded view of the power screw assembly to better illustrate how it will be built 2013 2014 RCR CDR 152 Grub Screws H 2 P Shaft Coupler pP ari D Shaft V Bearing Hub Power Screw Rear Power Screw Front Hub Bearing w As be seen from the above image a 74 diameter x 12 long steel D shaft will run through the middle of the screws An aluminum hub on each end will attach the D shaft to the power screws Four 6 32 screws will screw the hub into a flange inside of the screws These hubs then have a grub screw that go through it and screw into the flat part of the D shaft To support the shaft an aluminum mounted bronze bearing is being used on each end The bearings then screw into 3D printed supports with 8 32 screws which are not shown The D shaft then attaches to the motor shafts via a coupler This coupler uses two grub screws similar to the hubs Finall
157. of both a handheld receiver and transmitter unit The unit will be taken off of the collar and attached to each section The unit advertises a seven mile range and updates location every five seconds GPS GPRS Cape s E amp a Figure 35 GPS GPRS Cape More information on the GPS GPRS Cape can be found in the Hazard Detection Payload Criteria Any rocket section or payload component The nose cone booster and lower which lands untethered to the launch sustainer will have a Garmin Astro DC 40 vehicle shall also carry an active electronic tracking device The electronic tracking device shall be fully functional during the official flight at the competition launch site dog collar and the hazard detection payload will utilize a GPS GPRS cape The GPS cape can be tested by verifying that GPS coordinates are being sent to the ground station The Garmin Astro DC 40 collars can be verified to be working by verifying position with the handheld receiver Table 9 GPS verification Tiltometer The goal of this device is to sense the inclination of the rocket with respect to the Earth s surface in order to prevent the rocket from firing its second stage motors at an un safe angle After PDR it was determined that an extra safety measure needs to be added to the rocket to ensure that it does not fire its second stage engine at an unsafe angle For example if a gust of wind rotates the rocket firing the se
158. of the fairing payload and the ejection of the hazard detection payload Each event is described in more detail in Table 11 2013 2014 RCR CDR ra Booster motor burnout Ejection of booster section Ignition of sustainer after coast time designated in At booster apogee parachute is ejected 613 3699 Ignition of second stage motor Lower sustainer ejection 7500 Lower sustainer under parachute Fairing payload and nose cone under pilot parachute Fairing opens and payload is released 5000 Nose cone descends under initial pilot parachute Payload descends under parachute Table 11 Description of ejection events Nose cone ejection oustainer under pilot parachute Recovery Logic Booster Recovery d m Liftoff 2 5s Stage Separation Black Powder Charge 1 Booster Separation Black Powder Charge 1 Booster Separation Black Powder Charge 3 Apogee BI Terminal Block 1 Apogee 1 05 Stage Separation Black Powder 1 Booster Apogee 1 0s Terminal Block 4 Powder Charge 2 rapi Apogee 2 0s armina RE CM Block 6 Powder Charge 4 Figure 44 Booster recovery logic The booster will be the first section to be recovered at motor burnout two MissleWorks RRC3 s will be used to separate the booster from the sustainer These altimeters were chosen for bein
159. offsets to the negative of the reading For example if the read in of the acceleration is 1N 2N 3N gt the accelerometer s offset would be set to 1N 2N 3N gt This has the effect of making the device s current orientation be the reference point from which future orientation changes are compared To verify that the calibration settings are reasonable the tiltometer will take a single reading from the IMU after the device settings are in place If the read in value is larger than a certain threshold determined during testing it will indicate that the tiltometer is currently in motion and thus that the calibration settings cannot be trusted If this event occurs the calibration phase will restart up to a maximum of three times to try again If the calibration phase completes three times without success a calibration failure LED will be lit to indicate the problem for the team to debug Once proper orientation offsets have been entered the tiltometer begins its primary activity of updating its estimate of its current orientation 2013 2014 RCR CDR p Update angle estimate phase To update the tiltometer s estimate of the rocket s current orientation the previous three angle measurements are considered These measurements are designated Angles The angle at time n Angles The angle at time n 1 Angles angle at time n 2 To determine Angles the raw angle measurements are read in from the attached IMU Then
160. oltage regulator IC a barometric pressure sensor and a PWM controller for driving the ESC We obtained the footprint of the BeagleBone s GPIO pins for the basis of the final PCB To construct the schematic and layout our electronics team is using KiCAD design software This prototyping company has been recommended by previous colleagues at General Electric as well as fellow students Soldering of the PCB boards will be done by hand by the electronic team This ensures quality on a one by one basis rather than dependence on a mass manufacturing procedure We will use Advanced Circuits to fabricate the bare PCB boards for reliability and quick turnaround 2013 2014 RCR CDR IN PWM Generating Circuit Figure 89 PWM Controller Circuit Our team has already made discrete versions of the PWM and power regulating sub circuits for testing and qualification Still needed is the construction of the pressure sensing circuit We will follow an application circuit given on Sparkfun com for our initial testing The same design will be added to the board layout barring any design flaws discovered through testing By qualifying discrete circuits we ensure functionality of our PCB when we have it manufactured and we can fix any bugs found in the circuits Any re works after manufacturing will be implemented by hand on the manufactured board for time efficiency Normally availability of space on PCB s is of great concern Fortunately our circuits nee
161. omplete the desired mission The inline staging requires a look at the efficiency of all systems including but not limited to the following overall mass of components component material choices reducing unused bay space and using designs which improve precision during manufacturing of individual components and assembly of the overall vehicle Due to the demands of the inline stage format recovery systems are at the forefront of the sub systems Figure 2 illustrates the vehicle recovery flight path Figure 2 Vehicle recovery flight path 2013 2014 RCR CDR nmm As shown in figure 2 the vehicle descends in four separate pieces which will require precision and accuracy when packing each system Applicable Formulations lt is appropriate to outline basic equations used in vehicle calculations Three core values must be calculated to assess the stability and success of the rocket peak altitude center of gravity and center of pressure The peak altitude is found through a precise sequence of equations The average mass is first calculated using m M Me 2 1 where mr is the rocket mass me is the motor mass and Mp is the propellant mass The aerodynamic drag coefficient kg m is then computed by k lt pCpA 2 where is the air density 1 22 kg m Cp is the drag coefficient and A is the rocket cross sectional area m Equations 1 and 2 are utilized to calculate the burnout velocity coefficient m s
162. one Black Figure 76 BeagleBone Black As previously mentioned the brain of the hazard detection operation is a BeagleBone Black BBB which is a Linux based microprocessor The BeagleBone is responsible for reading in data from various sensors such as the camera performing processing on that data and taking action accordingly The BeagleBone has a 1GHz Sitara ARM Cortex A8 Processor with 512MB of onboard DDR3 RAM and also comes with 2GB of storage and features a microSD card slot allowing for more storage if necessary The BBB is capable of using I2C SPI UART analog and PWM through one of its many 65 GPIO pins The BeagleBone also has built in USB micro USB microSD card HDMI and Ethernet terminals All of these options will allow us to choose a wider range of components to use on the payload The BeagleBone is capable of being used as a standalone computer and thus has an integrated SGX530 3D Graphics Engine that will be useful for image processing To power the BeagleBone only 460ma 5V are required The BeagleBone weighs in at only 1 40z with dimensions of 3 4 x 2 1 inches The BeagleBone is also capable of handling up to four PCBs stacked on top of it without any significant performance 2013 2014 RCR CDR HAN deterioration which will be very useful for our application Due to the intense processing that will have to be done the BBB is the perfect single board computer for the hazard detection payload Table 30 shows the r
163. ontally for an extended period of time The rocket lands on unstable ground which gives way after a period of time more than 10 seconds and rover activities will Overall 4 never occur constituting partial mission failure If launch is determined early its possible that the rover will attempt to move forward inside its housing and release its parachute causing destruction of the payload after descent If rocket launch is determined late it s possible that image processing activities will not occur during rocket descent leading to partial mission failure The launch apogee and b 5 Thorough testing will be done during ground station leading to 2 4 development to rule out most preventable partial non essential mission failure The parachute will not release from the rover and the rover will not move forward causing partial mission failure If landing is improperly detected while the rover is still inside the rocket body the rocket s wheels would turn possibly causing damage to the foam in the rovers housing Also the The current rocket design is not able to handle unpredictable ground conditions at the landing site The risk from this error has been deemed acceptable 2 5 Overall 4 parachute would be released from the rover on the launch pad causing almost certain destruction of the rover and payload after descent 2013 2014 RCR CDR Table 48 H
164. oon after separation Overview The fairing payload was designed around keeping in mind the possiblity of real life applications Custom machined foam inserts sit inside the fairing and safely house the mandatory payload and the mandatory payload s parachute recovry system An aluminum cap and shell constrains the fairing shut until a black powder charge in the cap disengages the cap from the shell The extension springs on the U bolts on top of the fairing can then pull the fairing open The mandatory payload safely slips out of the fairing Test Plans Status and Results An assembled rocket be ground tested by placing the desired black powder chage in the proposed areas The ejection charge will be remotely activated to determine how well the ejection charge worked Subscale testing will be utilized to test dual staging procedures The team will also test the vehicle s stability through subscale launches A subscale version of the fairing payload will be devloped and flown on the subscale launch vehicle in order to test out the functionality of the system The full scale will test both mandatory and optional payloads Additional Comments This time is to motor thrust to accomplish this time when motors are received we will staticly test one and determine when to ignite the motor to achieve thrust at the 3 second time that was stated 2013 2014 RCR CDR 6 CHANGES MADE SINCE PDR CHANGES TO VEHICLE CRITERIA Since the PDR the la
165. or any cuts burns fraying loose stitching and any other visible damage 3 Shroud lines are taut and evenly spaced 4 ___ Fold parachute 5 Place folded chute into deployment bag 6 ____ Secure deployment flaps using shroud line and rubber bands Pilot Parachute 2 PP2 Required Equipment e Rubber bands e Hook e Clamp e Booster parachute deployment bag e Swivels 1 Parachute canopy is laid out flat 2 I nspect canopy and lines for any cuts burns fraying loose stitching and any other visible damage ____ Shroud lines are taut and evenly spaced ____ Fold parachute ____ Place folded chute into deployment bag ____ Secure deployment flaps using shroud line and rubber bands Fold shock chord lS Booster Altimeter Bay Required Equipment e Standard flathead screwdriver 1 Verify altimeters are properly programed 2 Screw altimeters into sled 3 Attach 9V battery to sled Lower Fairing Altimeter Bay Required Equipment 2013 2014 RCR CDR LEN e Standard flathead screwdriver 1 ____ Verify altimeters are properly programed 2 Screw altimeters into sled 3 Attach 9V battery to sled 4 ___ Screw titometer into sled Nosecone Altimeter Bay Required Equipment e Standard flathead screwdriver ____ Verify altimeters are properly programed Screw altimeters into altimeter sled ____ Attach 9V battery to altimeter sled ____ Attach GPS to GPS sled
166. ork This approach proved more difficult than anticipated and the team has decided to first transmit data to a ground station where it is then forwarded to the web server The primary reason for making this adjustment is that the team is confident that there will not be any issues uploading data to the web server from an Android based ground station During development there were issues attaining a reliable Internet connection on the BeagleBone Black so it was deemed safer to add extra complexity for a stronger guarantee that file uploading will work Data Transmission Data will flow in the following manner in the system Clients access flight data on the web site hosted on the web server 4 Android Device Ground Station Figure 94 Data Flow Layout The BeagleBone Black is the central component of the payload integrating data from the hazard detection camera and using the GPRS attachment to transmit data processing results to the ground station The GPS GPRS attachment provides GPS coordinates and the velocity of the payload with respect to the Earth s surface The BeagleBone Black processes the camera s and GPS unit s data and generates a text message to be sent to the ground station The text message contains timestamp associated GPS coordinates and a list of every hazard detected in the most recent image that was processed The SMS message structure is as follows 2013 2014 RCR
167. owing firing the second stage motor Otherwise the microcontroller sends a signal indicating that firing the second stage motor is safe 2013 2014 RCR CDR 40 Figure 37 Tiltometer firing ranges Red safe to fire Yellow not safe to fire Z is perpendicular to Earth s surface The tiltometer also contains a reset button and a calibration status RGB LED The reset button is used to reset the tiltometer program so that calibration estimates are accurate on the launch pad Whenever the reset button is pressed the tiltometer will restart its primary program to obtain updated calibration parameters The calibration status LED indicates to the team whether or not device calibration was successful so that the team can know if the device is safe to use Angular estimation algorithm The algorithm used to calculate the rocket s current inclination involves the following steps 2013 2014 RCR CDR ra Note Attempts starts at 0 as the start button been Yes pressed Begin _calibrateSensors Wait 80 seconds Attempts gt 3 Is each component of the read in orientation lt Set x y and z gyro and accelerometer offsets to the read in value Attempts 1 Y Light LED signaling successful calibration Y End calibrateSensors 0 Set Angles n 2 Angles n 1 and Angles n to O
168. p resolution The C920 is also able to go down to 480p in case less resolution is needed so that the BeagleBone can process the images This webcam also includes H 264 video format for better compression The autofocus on the camera can be turned off which will be crucial as there will be a significant amount of movement during descent and having the autofocus feature active will be a hindrance An advantage of using the C920 webcam is that there was already proven compatibility between it the BeagleBone and OpenCV image processing software library The camera will be connected to the BBB using the BeagleBone s on board USB port The C920 weighs in at 4 80z and has an unfolded dimension of 2 8 x 7 5 x 8 9 inches The foldable stands for the camera will also make integration onto the rover easy by allowing us to screw it onto the electronics platform This camera retails for 70 on Amazon making it affordable Table 31 shows the requirements the camera satisfies what features will help meet that requirement and how they will be verified Requirements Features X Verification Testing The payload shall 15 megapixel photo The webcam has been incorporate a camera capability 1080 tested to work with the system that scans the resolution will insure good BeagleBone surface during descent in clarity order to detect potential landing hazards The data from the hazard H 264 video compression The BeagleBone has been
169. parachutes load motors and develop a pre launch checklist Finally the students will launch their rockets and compare altitudes 2013 2014 RCR CDR 98 APPENDIX 1 SUPPLEMENTAL INFORMATION 2013 2014 NASA USLI Team Organizational Diagram ead D per Dhwani Shah Web Develooment tt eee eee ecnanical Engineenng Team 2013 2014 RCR CDR 99 APPENDIX 2 SAFETY DOCUMENTS River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to date with the latest version of the safety manual e fI violate these regulations realize that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events pol Ww ge J 36 11 2013 2014 RCR CDR River City Rocketry University of Louisville Safety Compliance Form By signing this form e agree to comply with all safety rules and regulations set forth by the safety manual e have read and am familiar with the entire document e understand that it is my responsibility to remain up to
170. path to 1 5 Low become unpredictable Rocket will become unstable and 1 5 Low unsafe during flight 1 Internal components supported by the bulkheads will no longer be secure 1 5 Low 2 Parachutes attached to bulkheads will be left ineffective Table 24 Stability and Propulsion Risk Assessment Recovery Risk Assessment Confirm all personnel are alert and at a distance allowed by the Minimum Distance Table as established by NAR Examine external epoxy beads for cracks prior to launch Through prediction models appropriate material selection and a secure factor of safety this failure mode can be nearly eliminated The bulkheads will be designed to withstand the force from the motor firing with an acceptable factor of safety 1 Electrical components could be damaged and will not operate as intended during flight 2 A catastrophic failure is likely A portion of the rocket or the fairing would become ballistic Cause Severity Probability Risk Rocket does not split to allow for recovery system deployment 1 Not enough pressurization to break shear pins 2 Coupling has too tight of fit 1 2 Rocket follows ballistic path becoming unsafe 1 The separation section of the rocket will be designed to ensure that the black powder charge provides sufficient pressurization allowing the rocket to separate and deploy its recovery system 2 The coupling between the sec
171. piece of 3D printed ABS plastic in which with three additional 3D printed parts that hold the camera into place will be screwed into Figure 56 Rendering of GoPro sled 2013 2014 RCR CDR ra i L 2 40 ha oz on MATEHAL ABS 1 OFeWEr SPCCEFD P r Sustainer 2 4 cpu eii See BOM ase N A ee University of Louisville lt ween once d N River City Rocketry N A miogel 10 gt rd gt 4 2013 2014 Design ow mae 1 3 SHEEI T Gt 1 Figure 57 GoPro sled nase GoPro Sled an mamat ABS ueirsi ONEWEr _ a Back Plate See BOM nush PRAE TS AE University of Louisville FAS MR DRE AIC om z E x River city Rocketry N A praes v zur tee 201 se 2013 2014 Design Deral e ow merit 7 at LN gt DHICSEP IOM SwEEIL 1 Gt Figure 58 GoPro backplate 2013 2014 RCR CDR PART NUMBER ems 7 2 ere tee 3 1 s GT MATER AL UMITS QTRFEWET SEED s ase See BOM linsa Dei APER BCH University of Louisville m T 4 River City Rocketry Maas me 0 an ar 2013 2014 Design mac Ai aar SwEEIL T Gt Figure 59 GoPro BOM Nose Cone Avionics Bay Figure 60 Rendering of nose cone avionics bay 2013 2014 RCR CDR ra The nose cone avionics bay consists of two
172. raph presentan P photograph End image Send packet with confirmation of launch via GPRS as apogee been reached Yes Y Send packet reporting that apogee is reached Send packet to ground station with time GPS and hazard list Has the rocket landed yet Send packet indicating landing event Y Release parachute i Drive rover forward a short distance Y Send end of mission SMS Tiltometer setup The first step in the flight algorithm is to initialize the tiltometer The setup program will set the proper accelerometer and gyroscope offsets on the tiltometer so that the device considers its orientation on the launch pad as its frame of reference If tiltometer calibration fails an LED will be lit indicating that the failure occurred to alert the team The tiltometer is not part of the hazard detection payload but is included in the flowchart as it is part of the flight activities for the rocket Pre launch preparation During pre launch preparation every device in the payload will be powered on and checked for successful startup If any device fails to start it will be added to a list of devices that failed to start The failed devices list is then used to light a set of LEDs indicating which devices failed to start or that no devices failed to start which allows the team to decide to
173. rdware 8 ____ Tighten all 4 leveling screws so that the base is stationary Be careful not to over torque 9 Slide assembled rocket into guide rails and check for clearance If clearance is not sufficient troubleshooting may be necessary 10 Upright Launch Pad and level the guide rails using leveling screws Be sure all screws are tight 11 Drill four holes in ground for tensioning lines 12 Stake down tensioning lines using stakes 13 Fine tune adjustments for tensioning lines using turnbuckles 2013 2014 RCR CDR ra Safety Checklist General Procedures and Before After Launch Overall Body Assembly Checklist OBA To be checked by Safety Officer upon completion of all sub team assemblies Safety Officer Signatures 1 2 Required Equipment e Allen Wrench Set SAE e Phillips Head Screwdriver large e Flat Head Screwariver Large e Small Screwdriver Set Small e Socket Wrench Set for 4 20 Nuts e Polishing Cloth e Masking tape 1 Insert and secure SMD bay into the lower airframe Ensure that all viewing and vent ports are aligned correctly 2 ____ Insert and secure Recovery bay on top of the SMD bay Align rod holes and run the rods down until they engage with the transition plate Attack corresponding 14 20 nuts to the rods at the transition plate end 3 Secure down the corresponding 20 nuts Do not over torque 4 ___ Attach all parachutes and shock cables to bulkhead See Recovery Checklis
174. riate certification they will be added to the list of people permitted to handle the team s motors By having obtained at minimum a Level 2 certification the individual has demonstrated that he or she understands the safety guidelines regarding motors Any certified member of the team that handles or stores the team s motors is responsible for following the appropriate measures The motors for both test and competition launches will be transported by car to the launch site SAFETY COMPLIANCE AGREEMENT The University of Louisville USLI team understands and will abide by the following safety regulations declared by NASA The following rules will be included in the team safety contract that all team members are required to sign in order to participate in any builds or launches with the team 1 Range safety inspections of each rocket before it is flown Each team shall comply with the determination of the safety inspection 2 The Range Safety Officer has the final say on all rocket safety issues Therefore the range Safety Officer has the right to deny the launch of any rocket for safety reasons 3 Any team that does not comply with the safety requirements will not be allowed to launch their rocket 2013 2014 RCR CDR 115 HAZARD DETECTION PAYLOAD CRITERIA TESTING AND DESIGN OF PAYLOAD EXPERIMENT Overview of Hazard Detection Payload The purpose of the hazard detection payload is to scan the terrain for any potential landing h
175. roline epoxy to the inner tube centering rings and the outer airframe to ensure complete stability and adhesion to the rocket The overhang on either end of the tab will allow the epoxy to bind to a larger surface area than if the tabs extended all the way along the root chord As stated before the fins used on the rocket s booster and sustainer are constructed out of G 10 fiberglass and have the dimensions listed in the table below G 10 fiberglass is well known for its use in model rocketry and is renowned for its strength and high factory of safety when under stress Below is a rendered image of one of the booster fins The fin has a tab that is inserted into the body of each stage which will be epoxied using Proline epoxy to the inner tube centering rings and the outer airframe to ensure complete stability and adhesion to the rocket The overhang on either end of the tab will allow the epoxy to bind to a larger surface area than if the tabs extended all the way along the root chord There are six wooden bulkheads in areas that bear little to no stress and therefore do not need high strength heavy weight materials Six G10 fiberglass bulkheads supply high strength materials in stress bearing locations and one 6061 T6 aluminum bulkhead provides the strength needed to withstand the stress input in that area 2013 2014 RCR CDR 20 several aluminum threaded rods are included in the design These allow electronics to be mounte
176. roven to work as a standalone system using a breakout board with the Arduino Further testing will be done once the Tiltometer PCB is manufactured and assembled The method this circuit works is that the Raven s output will be connected to the input terminal block on the Tiltometer s PCB and the motor s igniter will be connected to the output terminal block An N channel mosfet will act as a switch to allow the current from the Raven to flow to the igniter as long as the Arduino keeps a high signal output on the mosfet s gate An FQP30NOGL mosfet is being used as it is rated for 60V and 30A which is more than what the Raven will output 2013 2014 RCR CDR 460 If the MPU6050 IC detects the angle is greater than 40 degrees the Arduino will pull the signal low on the mosfet s gate This will cause the mosfet to switch off and no current will flow to the igniter If the angle is less than 40 degrees the mosfet will stay on The mosfet circuit has been tested to work on its own and further tests will be done to insure it works with the entire system The 30A current should not be seen by the Arduino but in case the current does flow to the Arduino two fuses are at the negative and positive terminals of the power source for the Arduino The fuses will blow if the current going to the Arduino exceeds 7A therefore protecting it from being fried The circuit will also include a reset button and an RGB led to indicate the status of the Tilto
177. rs The term altimeters includes will utilize Featherweight Ravens for both simple altimeters more apogee detection the rest will contain sophisticated flight computers PerfectFlite Stratollogers for altitude ejection Table 13 Altimeter bay verification Kinetic Energy During descent the kinetic energy of the vehicle will vary depending on which parachute is currently deployed and what parachutes are yet to be deployed The kinetic energy is determined via mV F 29 26 where m is the total recovery mass V is the descent velocity and gc is the dimensional constant The descent velocity is calculated using equation 2 The kinetic energy at landing is shown in Table 5 and the kinetic energy for the vehicle during the lower sustainer ejection and rover ejection are shown in Table 14 Vehicle Mass Descent Kinetic Event Ibs Velocity ft s Energy ft Ibf Lower Sustainer Ejection 26 11 404 52 Rover Ejection 18 99 113 11 Table 14 Event kinetic energy 2013 2014 RCR CDR nam Test Results Drag Characteristics The drag coefficient for the circular annular parachute is listed as a range to accurately size the parachutes the drag characteristics have to be known for various fluid conditions and the effect on construction techniques will have on the drag of the parachute To accomplish this a test parachute was constructed that had a five foot nominal diameter This parachute was then to
178. s By combining equations 1 and 2 the area can be calculated by mfg pC Eg 22 The nominal diameter is then determined by D 23 Table 5 shows the estimated mass total parachute area nominal diameter and landing velocity for the launch vehicle sections and hazard detection payload 2013 2014 RCR CDR RE Section E ft Ib m Ib s A ft Do ft V ft s Booster __60 15 9 62 567 8 9254 15 583 Lower Sustainer 60 18 80 185 Upper Sustainer 60 147 53 479 8 2518 16 206 Hazard Detection Payload Table 5 Vehicle mass parachute area parachute diameter and landing velocity This value of Do was used to determine the individual gore dimensions as shown in Figure 22 h REF jer j CANOPY PROFILE CONSTRUCTED I L Figure 22 Parachute and gore layout The general gore dimensions and parameters are shown in Table 6 Knacke 6 23 Table 6 Parachute gore dimensions Cv is then calculated using 2013 2014 RCR CDR ME Cy Na 24 where Na is the number of gores Cs is then calculated using c 2mm 25 S N Using equations 24 25 and the ratios shown in Table 6Error Reference source not found all relevant construction dimensions and the results are shown in Rocket Section Ng Cv in Cs in h in a in b in 33 65 38 09 36 86 38 68 Upper Sustainer Hazard Detection Payload Ta
179. s The Range Safety Officer will have the final say over any safety issues The team will comply with this rule and any additional precautions that the Range Safety Officer makes on launch day 2013 2014 USLI Proposal EL last launch attempt before allowing anyone to approach the rocket 6 Launch Safety will use a 5 second countdown before launch will ensure that a means is available to warn participants and spectators in the event of a problem will ensure that no person is closer to the launch pad than allowed by the accompanying Minimum Distance Table When arming onboard energetics and firing circuits will ensure that no person is at the pad except safety personnel and those required for arming and disarming operations will check the stability of my rocket before flight and will not fly it if it cannot be determined to be stable When conducting a simultaneous launch of more than one high power rocket will observe the additional requirements of NFPA 1127 7 Launcher will launch my rocket from a stable device that provides rigid guidance until the rocket has attained a speed that ensures a stable flight and that is pointed to within 20 degrees of vertical If the wind speed exceeds 5 miles per hour will use a launcher length that permits the rocket to attain a safe velocity before separation from the launcher will use a blast deflector to prevent the motor s exhaust from hitting the ground will ensure
180. s a Logitech C920 model It is a commercially available component that will be powered via USB from 2013 2014 RCR CDR the payload The C920 consumes 240mA at 5V Although a datasheet was not readily available for the GPRS cape our team researched the main communications chip on the sensor Per the GE864 datasheet the GPRS module uses only 62uA of power when in standby desirable for idle launch delays At full power the maximum load of the cape can reach 420mA Therefore the max load for the BB and cape combined to under 1A We expect to be able to keep the current power scheme assuming that our power supply stresses do not increase out of useful margin for launch performance However with the current design we can account for increased power needs through purchasing commercially available LiPo batteries with a larger mAh rating On further testing we will need to test the motor systems to collect data for startup peak and continuous running power needs of the motors and ESC s This has already begun at an isolated sub system level The sub system will include the PWM circuit battery ESC and motors The isolated testing will validate our intended setup to show that we can power the selected motors at the chosen duty cycle for a liberal amount of time Once the sub system is tested and qualified we will begin testing at an integrated level on the assembled rover For testing purposes we have used equipment made available to u
181. s through LVL1 maker space in Louisville KY Also available are the electronic labs at the University of Louisville We are using load components to simulate power consumption Oscilloscopes are being used to analyze and troubleshoot our PWM signal being sent from the PWM controller to the ESC Esc BeagleBone Black L Battery Figure 88 Payload Power Distribution As shown in the illustration below we will have a distributed power system for the rover For power sourcing we have isolated the receiver power bus from the motor power bus Due to the noisy nature of motor to disrupt sensitive communications circuits we wanted to keep the sources separate to ensure reliability of signal operations transmissions In our power design we are using a modular ESC electronic speed controller to interface the 3 cell LiPo to the brushless motors A desired feature of the ESC is the built in overload protection that will add to our safety as well as reliability of the rover With this overload protection we can protect against damage to our motors as well as unfortunate battery discharges that can cause fire and damage to the rover as well as its environment Our team is making use of modular ESC for the precision of control we will gain with our 2013 2014 RCR CDR IN three phase motor While this is a substantial benefit it does come with its own challenges We have gained a lot of experience while designing and implement
182. sections were snug a small strip of duct tape was applied on either side of the stage coupler All systems were checked again and the rocket was placed on the launch rail ready for launch 2013 2014 RCR CDR Figure 19 First launch of the subscale The booster motor fired and lifted the rocket to its estimated altitude The Raven altimeters in the booster altimeter bay successfully ignited the sustainer motor Almost immediately after sustainer motor ignition a loud explosion occurred and the sustainer s motor went out The booster was rapidly jettisoned back down towards the ground The sustainer continued to arc over and deployed it s drogue parachute at apogee Since the rocket never made it above the altitude where the main chute deployment was programmed into the StratoLogger the rocket immediately fired the black powder charges for the main following drogue deployment After further analysis of the rocket and all of its components the team saw that all electric matches were fired Due to the violent deceleration of the booster section the altimeter bay at the top of the booster was forced down into the lower airframe Even though the black powder charges for the booster main parachute fired the coupler was unable to be jettisoned due to the deformation of the accident 2013 2014 RCR CDR 26 Figure 20 Damaged components from the booster stage s altimeter bay The team determined that the addition of t
183. shers and hex nuts on both sides Immediately attached to the U bolt will be a carabineer The carabineer will also be attached to a 1 8 inch aluminum ring which has shock cord sewn into it The reason the shock cord was sewn is to provide strength as a sewn connection is stronger than a tied connection and with the carabineer still allows for the shock cord to be removable when needed Attachment line At the top of the shock cord will be a swivel sewn into the shock cord The other end of the swivel will attach to an aluminum ring which will have all of the parachute suspension lines Those Suspension lines will be lines through the deployment bag as to avoid tangling during operation Because this section does not have anything to pull on the deployment bag the bag itself will be connected to an eye bolt on the bottom of the fairing payload so when the lower sustainer is ejected the separation of the two vehicle sections will open the bag allowing the parachute to Figure 30 Lower sustainer function recovery harness Hardware PerfectFlite Stratologger Altimeter be 680 IF 6 7 7 us T aeea StratoLogger by PerfectFlite Figure 31 PerfectFlite Stratologger The PerfectFlite Stratologger altimeter is a common altimeter used in high powered rocketry It records its altitude at a rate of 20Hz with a 0 196 accuracy In previous testing the altimeter was found to be accurate to 1 foot The Str
184. single bore The secondary chamber is a ring that wraps around the central chamber Figure 114 shows the overall design of the pyro cap 2013 2014 RCR CDR LN MATER AL 4067 ALURIKUM ALLOY 2 REMOVE ALL SHARP EDGES 3 PARTS TO BE OFBURRED AND CLEANED DCBENS Bi University ot HN Bva Cile Poche BONERS 4 Dian Figure 114 Detailed drawing of the pyro cap Black Powder Chambers in Center Ring Volume 29 0 79 1 16 Table 53 Black powder compartment dimensions Table 53 details the overall dimensions of the black powder chambers To be fully redundant the secondary chamber s volume was increased by one and a half This was to ensure that the event which the primary chamber s ignition fails to jettison the pyro cap the secondary cap will fire with more overall pressure Various designs for the pyro cap were brought forth The current design was chosen for various reasons For one having two chambers concentric about one another allowed for great space savings in an area of the rocket where space is limited Seconaly by having the two chambers concentric about one another when the black powder charges fire and 2013 2014 RCR CDR eject the cap the cap will be jettisoned in the direction of the axis of the cap assembly This will allow for a zero net torque on the system and the force applied to the cap will be evenly distributed along the inner fa
185. stic to melt producing toxic fumes Potential burns to Team members The team member do not pay team members while could suffer minor attention while soldering soldering to severe burns Team members will be encouraged to follow all safety protocols related to soldering 2013 2014 RCR CDR Team members Failure to correctly could suffer regulate power to electrical shocks The circuits will be analyzed before they are powered to insure they don t pull too much power Power supplies will also be set to the correct levels Overcurrent from power source while circuits during which could cause testing testing burns to heart arrhythmia Table 22 Lab and Machine Shop Risk Assessment Launch Pad Risk Assessment Cause Severity Probability Risk _ echanism Outcome aue Vale Level Mignon 0 If the launch pad is Confirm that all personnel are ata Un level ground unstable while the distance allowed by the Minimum Unstable launch or improperly rocket is leaving Distance Table as established by tower staked launch the pad the NAR Ensure that the launch pad tower rocket s path will is stable and secure prior to be unpredictable launch The launch tower The launch pad should always be Un level ground could tip over placed on a level surface Unleveled launch or improperly during launch Confirm that all personnel are at a pad leveled launch making the flight of distance allowed by th
186. sure that boot up program detects no errors 20 _If errors occurred solve problems 21 Once boot up program indicates no errors attach parachute to pin on the Parachute Cam 22 Inspect rover to insure all components are securely mounted 23 Insert Rover into Fairing 24 Say Good bye 25 X Starttracking GPS coordinates for the rover Post flight Inspection 1 Verify all components are still attached to rover and undamaged a Camera b 2LiPos c BeagleBone and attached Capes d Parachute Cam System e 2EbSOs f 2Motors 2 ____ Verify Data is saved on Webserver 3 ____ Go over data acquired Safety Checklist Recovery To be checked and initialed by Recovery Safety representatives Recovery Representative Signatures 1 2 2013 2014 RCR CDR LEN Prior to leaving for launch site Booster Parachute BP Required Equipment e Rubber bands e Hook e Clamp e Booster parachute deployment bag e Swivels 1 Parachute canopy is laid out flat 2 nspect canopy and lines for any cuts burns fraying loose stitching and any other visible damage 3 Shroud lines are taut and evenly spaced 4 ___ Fold parachute 5 ____ Place folded chute into deployment bag 6 Secure deployment flaps using shroud line and rubber bands Lower Sustainer Parachute LSP Required Equipment e Rubber bands e Hook e Clamp e Booster parachute deployment bag e Swivels 1 Parachute canopy is laid out flat 2
187. t perform as 2 3 Moderate intended Black powder charges have s designed to overcome the shear strength of the shear pins allowing the rocket to separate easily 2 The coupling between the two sections will be sanded down to have a loose fit preventing the two sections from getting stuck together during flight opecial foam inserts are designed to house both the rover and the parachute in separate compartments The foam inserts will keep the parachute shielded from the pinch point of the fairing when opened The parachute is housed above the rover to ensure they do not become entangled during deployment Batteries will be checked for sufficient charge during launch day preparations If the launch is delayed and the batteries have been left on batteries should be rechecked for a sufficient charge to power the systems 1 A pyro cap was specially designed and machined for this system to ensure secure connection of the e matches to the black powder charges rover being 2 The designed pyro cap allows deployed for two separate black powder charges and e matches It is unlikely that the entire system will fail due to the redundancy T Springs were selected with a high Springs become Fairing does Rover will not ec d 2 4 Low enough tension in mind to remain dislodged completely open deploy cs secure on the fairing Springs will be monitored for signs of fatigue and replaced as necessary
188. t on proper parachute folding techniques 5 Attach upper airframe to the bays and secure into place with corresponding bolts 6 nsert properly folded parachute and deployment bad into bay Ensure no entanglement with shock lines occurs 7 Organize and insert shock cables and drogue into upper airframe 8 Align nose cone with shear pin holes and insert into upper airframe 9 _ Insert shear pins into holes utilizing a small flat head screw driver Ensure that all shear pins are tight fitting and will not fall out during ascent 10 X Attach completely assembled propulsion bay to completely assembled transition bay The acrylic transfer will have to couple with the propulsion bay properly to be seated 11 Clean transition section of any debris from assembly operations 12 Tape motor igniter to the outside of the propulsion bay in a place easily seen by the field RSO 13 A final visual inspection will need be done to ensure all systems are go 2013 2014 RCR CDR 87 At Launch Pad Checklist ALP To be checked by Safety Officer upon completion of Overall Body Assembly and Launch Pad Assembly Safety Officer Signature Launch Team Signatures All signatures must be included for a Go at launch Stability and Propulsion Representative Recovery Payload Representative Electronics Representative Launch Pad Representative Team Captain Required Equipment e Pen or pencil e Level 2 Certification car
189. t will hold the parachute together will be the French felled seam it will consist of two straight stitches running along the outer edge of the seam as shown by the two outermost dashed lines in Figure 25Error Reference source not found A third stitch will run along the center of the seam that will connect suspension line sleeving to the edges of the parachute and will form permanent attachment points for the suspension lines After each gore has been hemmed along the edges that do not connect to another panel a flat panel will be laid out At the outer edge of the panel a layer of 1 2 inch double sided seam basting tape will be applied this is to ensure that the panels are perfectly aligned when sewing 2013 2014 RCR CDR seam Tape VA Figure 26 Applying seam tape to gore panel Gore Panel Then the other panel will be aligned next to the edge of the seam tape once the alignment is finished the original panel will be folded over the added panel to hold them in place The second panel will be then folded over to complete the seam Figure 27 Seam construction Suspension Line Attachment The suspension lines will be attached to the parachute via sewn in attachment loops The loops will be made of suspension line sleeving and will be sewn in as shown in Figure 28 oix inches will be sewn up the edge of the panel to maintain strength This will allow for all suspension lines to be removable in the e
190. te was a huge success for the team both years By having a presence on Kickstarter River City Rocketry has been able to share with the community their passion for science and rocketry Louisville Cardinal The Louisville Cardinal is the independent student newspaper at the University of Louisville The newspaper is widely read and respected by the students at the university In years past River City Rocketry took the opportunity to sit down for interviews with the Louisville Cardinal This has allowed students from all over the university to see what the team is doing and the progress they have made TM Registered Student Organization n the Spring of 2012 River City Rocketry has been a Registered Student Organization RSO at the University of Louisville Since receiving RSO status the team has been able to reach out to the Student Senate as well as several of the universitys Student Councils to gain support and increase the knowledge of rocketry at UofL The team has received very positive feedback and was elected last year s Best New RSO 2013 2014 RCR CDR ITI r za ITI 5 ask November 11 January 1 February 21 April 11 June 1 11 3 11 24 12 15 1 5 1 26 2 16 3 9 3 30 4 20 5 11 5 6 22 jE qi I B5 af F i a p O Recovery Subsytem Fairing Subsystem Hazard Detection Payload _ qu j T Id T F LE Lim 2 r2
191. tes Damage found on deployment bag Y N Notes Mark area where tearing or stretching was found on canopy Damage Notes 2013 2014 RCR CDR Repair Plan Altitude Achieved Motor Used Location Temperature Pressure Wind Speed Event 1 Success Y or N Event 2 Success Y or N Captain Approval 1 2 2013 2014 RCR CDR SAFETY AND ENVIRONMENT VEHICLE SAFETY PLAN Safety Officer Responsibilities The safety officer for the River City Rocketry team during the 2013 2014 season is Emily she is responsible for ensuring the overall safety of the team students and the public as well as compliance with all laws and regulations The following are the Safety Officer s specific responsibilities e Establish and brief the team on a safety plan for various environments actions and materials used e Remain active in the design construction testing and flight of the rocket in order to quickly identify any new safety hazards and to ensure the team complies with the team safety plan e identify safety violations and take appropriate action to mitigate the hazard e Enforce proper use of Personal Protective Equipment PPE during construction testing and flights of the rocket e Make MSDS sheets and operator manuals available and easily accessible to the team at all times e Provide plan for proper purchase storing transporting and use of both motors and energetic devices e Ensure compliance
192. that may not be able to participate in construction or launch activities e will strive to follow these safety procedures and encourage safety throughout the team and at educational events aw 0227 14 Signature Date 2013 2014 RCR CDR DN
193. the most extreme value in the set Angles Angles 4 Angles is discarded To determine which angle is the most extreme the following calculation is performed A1 Angles Angles A27 Angles 4 Angles A3 Angles Angles valToDiscard the value common to MAX A1 A2 A3 MID A1 A2 A3 Finally the current angle estimate Angles is set to the average of the two non discarded values This process is done to ensure that if a single angle reading from the IMU is much larger or smaller than the rest IE a temporary electrical spike occurs that angle will not be included in the estimate of the rocket s orientation Once the rocket s angle estimate has been updated the program will check if the angle with respect to the z axis is greater than 40 degrees If it is the program will send an electronic signal disallowing firing of the second stage motor by setting the pin connected to the mosfet low discussed later Otherwise a high signal will be sent allowing firing of the second stage motor Test results The team has verified that the MPU 6050 IMU provides angle data to the Arduino UNO The team has verified that angle readings are responsive to physical rotations of the device The team has also verified that readings from the IMU do not drift over short timeframes 30 minutes The team has also made significant progress developing the angle visualization test program explained below and just needs to make a few t
194. the payload section Stage Separation enm 5 m A A A ASASASS A Bulkplate LLLL LL ZLL LLL LL N Booster Harness The booster harness consists of a 2 inch wide 6061 6 aliminum U bolt steel 3 16 inch eye bolt 9 16 inch tubular nylon shock cord deployment bag and pilot parachute The eye bolt is part of the hardware that comes with CTI pro 75mm motor casings and the shock cord will be attached via carabineer and sown in aluminum ring The shock cord will also be attached to a separate aluminum ring which will attach to the shock cord that comes from the stage separation coupler as shown in Shack Card Airframe J mm Attachment Hardware N RAASKISI At the top of the shock cord will be a swivel sewn into the shock cord The other end of the swivel will attach to an aluminum ring which will have all of the parachute suspension lines Those suspension lines will be lines through the deployment bag as to avoid tangling during operation Motor Tube Figure 29 Booster harness 2013 2014 RCR CDR Above the deployment bag will be a small pilot parachute which will be a student created 1 ft cross parachute the purpose of the pilot parachute is to pull the deployment bag and allow the full parachute to deploy successfully Lower Sustainer Harness The harness for the lower sustainer consists of a 2 inch wide 6061 T6 aluminum U bolt attached to the bulkplate through wa
195. tions will be sanded down to have a loose fit preventing the 2013 2014 RCR CDR 2013 2014 2013 2014 RCR CDR CDR two sections from getting stuck together during flight If separation does not occur the rocket will follow a ballistic path becoming unsafe All personnel at the launch field will be notified immediately Multiple altimeters and e matches are included into systems for redundancy to eliminate this Rocket follows failure mode Should all Altimeter or e match Parachutes will ballistic path altimeters or e matches fail the failure not deploy becoming recovery system will not deploy unsafe and the rocket will become ballistic becoming unsafe All personnel at the launch field will be notified immediately Deployment bags will be specially made for the parachutes This will 1 Parachute gets 1 2 Rocket allow for an organized packing P stuck in the e that can reduce the chance of the arachute does not deni tb follows ballistic 1 4 Moderat hule open eployment bag path becoming oderate parachute becoming stuck or the 2 Parachute lines f lines becoming tangled Should become tangled the rocket become ballistic all personnel at the launch field will be notified immediately The rocket falls with a greater The parachutes have each been kinetic energy carefully selected and designed to Rocket descends Parachute is than designed 2 5 L safely recover its particular OW
196. tor retention ring Do not over torque Set completely assembled bay on stand do not rest on fins DEO Iw Sustainer Propulsion Bay Assembly Checklist PBA To be checked and initialed by S amp P Safety representative Required Equipment e 5mm Casing e Cesaroni L1720 WT e Aeropack 75mm flanged e Propulsion Bay Stand ____ The team mentor will be responsible for preparing motor within casing ____ Slide motor casing fully into the motor mount tube ___ Attach motor retention ring Do not over torque Set completely assembled bay on stand do not rest on fins Es o e c Safety Checklist Hazard Detection Payload To be checked and initialed by Payload Safety representative Hazard Payload Assembly 2013 2014 RCR CDR FE Payload Safety Representative Signatures 1 2 Required Equipment e Payload Smartphone with SIM card e BeagleBone Black e Logitech C920 Webcam e 25 2200mAh LiPo Battery 35 2200mAh LiPo Battery e Parachute Cam e Servo e GPS GPHS e GPS amp GPRS Antennas e Custom PCB e 2x ESCs e 2x Motors e 2x Motor Clamps e Rover Body e Smartphone Charger e LiPo Battery Charger e BeagleBone USB Cable e Mini small Phillips screwdriver e Pliers e Volt Meter e Toolbox with extra components Prior to leaving for launch site ___ Ensure Lithium Polymer batteries are fully charged ____ Ensure Smartphone is fully charged Go to T Mobile website and enable purc
197. unch vehicle has undergone 3 primary changes 1 Visually the most notable change since the PDR has been the rocket s change in height Due to an underestimation in the packing size of the recovery systems the lengths of the various sections of airframe had to be increased This brought about a change in total height of the rocket to 198 inches Due to the aforementioned design change since PDR the team had to change out the motor selection for both the booster and sustainer Previously the rocket was slated to be powered by a Cesaroni L1350 CS motor in the booster and a Cesaroni L910 CS in the sustainer Due to the increased weight of the rocket the booster will now host a Cesaroni M3100 WT motor while the sustainer will be powered by a Cesaroni L1720 WT motor After subscale testing the team noticed that the coupling method for the rocket s staging was inefficient The subscale had a section of coupler tubing which was permanently epoxied at the base of the sustainer with a 3 inch offset The booster section s upper airframe was joined at this section It was noted that the sustainer s motor exhaust temperatures were negatively effecting the resin within the overhanging coupler tubing With the fear of failure in mind the team now has the coupling section of tubing permanently fixed to the upper portion of the booster stage There is no airframe overhanging the motor anymore The altimeter sleds and bays have been redesigned to fit t
198. unlwwnalhr of Loulavilie eter MI mE Cry toctc uy rir E 70 2 20 4 Ocsor hhh eo nm manm sPITTIOT 1 Figure 14 Sustainer Fin 2013 2014 RCR CDR ay ATL ENSE moe ee BOM 7 f E univenity of Loulavilte a Cry toctcy Be 70 2 70 4 Ocsor shiTrior 1 ay h o r PO Y ee BOM 7 University ei Loulsville Cry toctcuy 70 2 70 4 cigpnr wool 1 Figure 16 Fiberglass Brace Mass Statement The current mass of the rocket with motor is 72 5 lbs This number is our target to hit whether by removing or adding additional weight The amount of weight added through 2013 2014 RCR CDR S mass compensation will never exceed 10 of the rocket s total weight A weighted ballast system will be integrated to maintain the stability margin Factoring in the added weight due to epoxy the rocket has a mass tolerance of four pounds before it drops below the target altitude of 10 000 feet Our predictions have the rocket weighing in at this target with every component simulated Through accurately weighing each component and overriding mass estimates in OpenRocket simulation software we have high confidence in our predictions SUBSCALE FLIGHT RESULTS The subscale build and flight allowed the team to gather an enormous amount of data and hands on knowledge of complex rocketry design The
199. using or metal pin Ejection from fairing could cause the parachute lines to get tangled with rover due to incorrect packing 1 The parachute after being disconnected is carried by Depending on what parts fail on the custom PCB failure could range from the BeagleBone not obtaining any power to not being able to control the motors and servo This would result in mission failure If the ESC fails to operate the motors to run the rover would not move This would result in partial mission failure damaged from power the payload s brain to This would be a mission failure The rover will fall without parachute which will result in its destruction upon landing Damage to property and people could also occur The rover could potentially descend without an active parachute leading to its destruction upon landing resulting in mission failure The rover cannot move forward thus resulting in The BeagleBone could get overload which could cause 1 become non operational 2013 2014 RCR CDR Overall 4 1 3 2 4 Each component will be carefully soldered onto the PCB and it will be inspected after all parts have been placed to insure everything is soldered correctly The PCB layout will be inspected by all electrical engineering students on the team before sending out to be manufactured The ESCs will be inspected to insure the voltage protection is enabled An oscilloscope
200. vel this will not pose a problem as the RRC3 is a barometric altimeter with no orientation dependence Lower Sustainer Avionics Bay Figure 54 Sleds of the lower sustainer avionics bay The lower sustainer avionics bay consists of two separate 3D printed ABS sleds one holds the tiltometer and Raven altimeters and the other is a mount for a GoPro camera Both the tiltometer and Raven s will screw in directly to the sled using tapped holes for nylon 4 40 screws This sled will have to hold two Raven altimeters plus power perches one Arduino which will function as the tiltometer and one 9 volt batteries The two Raven s will be opposite of the tiltometer and will be activated through the power perch magnetic switch Last year s team utilized the magnetic switch through the air frame successfully and during sub scale testing the magnetic switch was activated through the airframe and thus will not be an issue 2013 2014 RCR CDR ra Lower Sustainer on MATEHAL ABS z Altimeter Sled See BOM lausn N A nm n RS University of Louisville River City Rocketry 2013 2014 Design SwEEL T Gt 1 Figure 55 Tiltometer sled The GoPro camera mount is beneath a wooden bulkplate that rests underneath of the altimeter sled the bulkhead will be covered in aluminum tape to shield the altimeters from the GPS unit stationed within the lower sustainer The GoPro mount consist of one solid
201. vent of damage to the lines or the canopy Panel otitching Loop Figure 28 Parachute suspension line attachment design 2013 2014 RCR CDR ra Requirement The parachute system s shall be designed and manufactured by the team Commercially available parachute systems shall not be used on the vehicle At landing each independent sections of the launch vehicle shall have a maximum kinetic energy of 75 ft lbs Verification The raw material will be purchased through vendors but the construction of the parachute will be done by students as described above The size of each parachute has been determined to keep the maximum kinetic energy below 60 ft lbs based on the experimentally determined drag coefficient of the parachute geometry The landing kinetic energy has been set lower due to the hard landing surface At landing the hazard detection payload at a landing kinetic energy less than 25 ft Ibr The size of the parachute has been determined to keep the maximum kinetic energy below 25 ft lbf based on the experimentally determined drag coefficient Table 8 Parachute verification Recovery Harness The booster lower sustainer upper sustainer and hazard detection payload will all have recovery harnesses the booster and lower sustainer will be described here and the upper sustainer will be described in the fairing payload section with the harness for the hazard detection payload being described in
202. ware exceptions occur the program will return an ERROR status This status will tell the calling function that an exception occurred If an error occurred the calling function will restart the servo rotation code up to a maximum of three tries If no errors are returned from the parachute release sequence or the number of failed attempts is 3 or more the rover will continue and attempt to move 2013 2014 RCR CDR 56 forward When the parachute fails to release three times consecutively it is assumed a software or hardware error has occurred and that it is best to attempt to move forward even if the parachute is still attached Test Results The team has verified that the servo rotation portion of the parachute release system is operational The team wrote a program that successfully rotates the servo 180 degrees clockwise which fulfills the primary requirement of this system The team has also verified that the parachute release device will properly release the parachute from the rover body The next step for the team is to integrate the servo into its housing to test and verify that rotating the servo will properly trigger the parachute release action Requirements Features Verification Testing The rover must The Parachute The system will be tested to successfully separate itself system is specifically insure it can sustain the from the parachute once designed to detach the forces from opening th
203. weaks to get it working satisfactorily Test plan The team s current testing plan for the tiltometer involves the following tests Angle visualization The team is currently developing a program to visualize in 3D the current orientation of the rocket This program will display the current angles read in from the tiltometer in real time by rotating a 3D model This test will verify that the data coming from the IMU is accurate and that the calibration step properly calibrates data reading offsets 2013 2014 RCR CDR 44 Most recent reading Actual 6 5 14 8 356 3 Figure 40 Angle visualization program Angle drift test Along with tests to make sure the read in orientation is accurate a test will be performed to determine if sensor readings drift significantly over time The team has already tested this prior to CDR and did not encounter significant drift in sensor readings over short timescales lt 30 minutes The team plans to leave the tiltometer in the same position for a few hours and then graph the readings to determine if the sensor drifts over longer timeframes If significant sensor drift is encountered the tiltometer algorithm settings will be modified to eliminate the drift Angle safety detection test Once the angle visualization test is completed the team verify that when the tiltometer is angled at an unsafe angle the second stage will not be fired To do this an LED will be connected to the device a
204. wed behind a vehicle Figure 64 Drag testing shows the hook up to the test vehicle Car Hitch Force Transducer Shock Card eee Figure 64 Drag testing To avoid forebody wake effects the amount of shock cord will be five times the width of the vehicle before the length of the suspension lines The resulting force will be measured with a force transducer a second seat not shown for clarity will allow a passenger to easily read the results of the device These values will then be used to calculate the drag coefficient according to 2F oAV 27 where Fa is the measured force is the density of the fluid V is the fluid velocity relative to the parachute and A is the reference area To measure the fluid velocity a flow anemometer was used in conjunction with the test vehicle so that the effects of the wind could be accounted for without wasting trial runs The resulting average values are shown in Table 15 oF Table 15 Results from drag testing 2013 2014 RCR CDR ra References 1 Knacke T W Parachute Recovery Systems Design Manual 1st edition 1 Santa Barbara California Para Publishing 1992 5 3 Print 2 Knacke T W Parachute Recovery Systems Design Manual 1st edition 1 Santa Barbara California Para Publishing 1992 5 3 Print 3 Knacke T W Parachute Recovery Systems Design Manual 1st edition 1 Santa Barbara California Para Publishing 1992 5 3 Print 2013
205. will be used to analyze the signal generated by the PWM circuit All The team has access to 3 BeagleBone boards in case one becomes non operational The circuit will be tested to insure it correctly regulates voltage before getting hooked up to the BeagleBone 2 he PCB will be inspected to insure all pins are correctly soldered The parachute cam system will be tested numerous time to insure that it withstand the impact stresses from opening the parachute upon deployment If needed the thickness or material of the system will be changed The rover and its parachute will be carefully placed into the fairing to insure they do not get tangled Tests will be conducted to insure tangling does not occur upon deployment 1 Itis not possible for the team to control Low the weather conditions at the landing location The team realizes this is a does not clear the chute away from the body of the rover The parachute release code executes before the rocket has launched or during rocket ascent The landing event is not detected properly The code that rotates the servo does not wait long enough for the servo to rotate wind gravity on top of in front of the rover The parachute cam system does not supply sufficient force to lift the attached section of the parachute from the body of the rover The code could read incorrect values from the pressure sensor that cause the servo to
206. will use to send and receive data to and from the devices The medium between the two will be a phone the ground station which will receive a text message from the BeagleBone which will then be forwarded over to the web server using an app which will watch for a specific phone number for the message This app will then transfer it over to the web server through FTP as mentioned before The real time hazard data will be first 2013 2014 RCR CDR compressed on the BeagleBone into a 0 1 format This format will then be interpreted and sent over to the web server which will cause the hazards list to be shown in real time on the server OpenCV Hazard Detection Process Yes Figure 99 First steps of the object detection Initialize all necessary functions while dealing with any errors Start capture from the main method 2013 2014 RCR CDR D Yes Figure 100 Second steps of the object detection Start taking input images from the camera feed and start checking for accurate and non blurry images Add detected hazards to a Hazard List If no hazards found restart main method 2013 2014 RCR CDR 147 takePicFromCam Com pressResult SendMessagetoServer Yes restartMain Figure 101 Third step of object detection Capture image from camera and created hazard list and compress the result for remote send Send message to server and confirm the send Restart main method again and continue with repeat
207. ws this was done so that in a catastrophic failure the screws shear and the altimeters have an increased chance to survive All sleds will also be 3D printed out of ABS this was done to reduce the mass of each of the sleds After being printed the sleds will go through and acetone treatment to strengthen them 2013 2014 RCR CDR ram Universal Components Battery Holster The battery holster that houses the 9 volt batteries will be the same on all described avionics bays The holster consists of two parts the base and the cover that screw into each other using two 4 40 nylon screws Each component of the battery holster will be printed out of Makerbot ABS plastic this is done to make the design as lightweight as possible and to allow for custom mounting if needed j University of Louisville River Clty Rocketry vesgr SHEET 1 OF MATERIAL ARS m BOM A DESIO AEEIM CHS H mme N A Univer sy of Louis LH f 2013 2014 Design SHEET 1 OF Figure 49 Battery holster cover 2013 2014 RCR CDR 52 ratte Z tater merce 1 seme 1 Battery Holster Te ROM ee Assembly ANISH University of Louisville River City Rocketry 2013 2014 Design SwEEL Gt 1 Figure 50 Battery holster assembly Booster Avionics Bay Figure 51 Booster altimeter sled The booster avionics bay consist of a sled designated for two battery holsters and two Missle
208. y the drag coefficient is based on total area including the vent hole and all openings Knacke 5 3 Parachute Geometry Lower Upper __ Triconical 08 2096 Extended Skirt 10 Fla 08 09 FlatCicuar 1 075 08 Conical 075 09 Extended Skirt 14 3 Fla 0 75 09 95 Hemishperical 2013 2014 RCR CDR ra Cross 0 6 0 85 Ringslot Disc Gap Band Conical Ribbon Flat Ribbon Guide Surface Ribbless Ribbon Hemisflo Guide Surface Ribbed Table 4 Drag coefficient range vs parachute geometry The triconical had the highest upper drag coefficient and the annular had the highest lower drag coefficient The annular was chosen because the average of the range was the highest The annular also has an advantage of using less fabric as each individual gore is smaller due to the size of the vent hole Sizing The terminal velocity of each rocket section was calculated by y _ 20 where E is the maximum landing energy this value is lower than what is stated in the statement of work SOW due to the hard landing surface is the total mass of the section to be recovered Ibm and gc is the dimensional constant The steady state velocity under parachute is calculated by 2mg V 21 where g is acceleration due to gravity is the density of air Ca is the drag coefficient of the parachute and A is the parachute area including vent holes and opening
209. y to make sure everything is held securely Loctite 680 Metal Retaining Compound will be used Figure 105 Exploded View of Power Screw Assembly Requirements Verification Testing The rover must travel at 3D printed power screws The 3D printed screws will least 20 feet once it has will be used to move the be tested on several terrains once delivered They will also be tested to insure they sustain stresses from landing Parachute Cam This system is one of the highlights of the rover as it is all been custom made The purpose of the parachute cam is to detach the parachute from the rover to prevent from having to drag the parachute around leading to potential snags after the rover lands The 3D model can be seen in Figure 106 The reason that the Parachute Cam was placed near the rear is so that the rover can fall with the camera facing down due to the rover s weight distribution As can be seen from the model below the main cam was changed from PDR so that the piston could have support while being inactive 2013 2014 RCR CDR Figure 106 3D Model of Parachute Cam When the pressure sensor on the custom PCB determines that it has landed it causes the BeagleBone to activate the servo that is attached The servo is attached to a cam which holds the piston in place The spring acts to push the piston downwards and by rotating the cam 180 degrees the spring is over powered and t

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