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Auburn University Project “Wall-Eagle” CDR. Rocket Design.

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Presentation on theme: "Auburn University Project “Wall-Eagle” CDR. Rocket Design."— Presentation transcript:

1 Auburn University Project “Wall-Eagle” CDR

2 Rocket Design

3 Rocket Model

4 Detailed Sections

5 Mass Estimates SectionMass (lb.)Percentage of Total Weight Structure % Supporting Equipment % Electronics % Recovery % Motor % Total28.5N/A Mass Growth % Mass Allowance %

6 Ogive Nose Cone Low Coefficient of Drag Easy to manufacture Rated highest by team trade study Commonly used in professional and hobby rocketry

7 Nose cone dimensions

8 Trapezoidal Fin Very easy to manufacture Less drag than clipped delta fins, more than elliptical fins Quicker stabilization than elliptical fins and clipped delta fins.

9 Fin Dimensions

10 Internal bays Payload Bay Ballast Tank Avionics Bay Motor Section

11 Stability Center of Gravity: inches from nose tip Center of Pressure: inches from nose tip Stability: 2.29 calibers Calculations given from OpenRocket Mass additions are expected to be added forward of CG

12 Stability margin before apogee

13 Motor Selection

14 Motor Selection / Altitude Prediction Initial Motor selection is the Aero K960-P ▫R-P: Loki White, Plugged Initial thrust-to-weight ratio above required 5:1 Achieves above average thrust within ¼ second High initial thrust provides high stability off the rail

15 K960-P Thrust curve

16 Thrust-to-weight

17 Motor Selection/Altitude Prediction Maximum altitude achieved 3395 feet Mass increase of 12.97% altitude gives a projected 3045 feet Assumptions include smooth construction and 5 mph winds Mass increase of 25% would not allow rocket to reach desired altitude

18 K960-P Altitude vs. Time Figure 1.3: Altitude vs. Time K780R-P

19 K960-P Motor Specifications ManufacturerLoki Research Motor DesignationK960-P Diameter2.13 inches Length19.6 inches Impulse1949 N-sec Total Motor Weight3.85 lbm Propellant Weight2.05 lbm Propellant TypeLoki White Average Thrust225 Pounds Maximum Thrust345 Pounds Burn Time1.95 sec

20 Recovery

21 Overview

22 Parachutes Three parachutes required ▫Drogue – 20 inches* ▫Main – 140 inches* ▫Payload – 36 inches* * Estimates using standard round parachute without spillholes.

23 Parachutes Construction ▫Shape  Semi-ellipsoidal  No spill hole

24 Electronics Avionics bay ▫Two altimeters  Altus Metrum Telemetrum  PerfectFlite StratoLogger

25 Attachments Fasteners ▫Nylon Slotted Pan Head Machine Screws ▫Steel U-Bolts ▫Quick Links

26 Parachute Materials The parachute will be made of Ripstop nylon Ripstop’s tear resistant weaving is ideal for parachute making

27 Shock Cord Material The shock cord will be made of 1” tubular nylon 1” tubular nylon has excellent tensile properties A vendor has already been secured The Auburn team has worked with this material before

28 CO 2 Ejection System Increased safety More reliable at high altitudes Reduced risk of equipment damage

29 Commercial Systems Available from Rouse Tech and Tinder rocketry Viability of CO 2 systems repeatedly demonstrated in the field A single 12g cartridge is recommended for a 5” diameter rocket with sections up to 22” long.

30 Custom Designed System E-match ignites small Pyrodex charge Charge pushes cartridge against spring into an opening pin Cartridge is punctured and quickly releases CO 2 Section is pressurized with enough force to separate rocket and deploy parachutes

31 Custom Designed System Each system contains three CO 2 cartridges Each cartridge is separately controlled Dual fault tolerance

32 Ejection System Implementation Two ejection systems total mounted outside the avionics bay One system deploys drogue parachute and ejects payload bay Second system deploys main parachute Two altimeters, each controls two CO 2 cartridges on each system

33 Subscale Flight Results

34 Subscale Plans Phoenix Missile Works- ▫Sylacauga AL, January 11th Sizing: 80% Motor: J-425 ▫Total Impulse: 152 lbs-s Length: 68 inches

35 Flight Predictions Stability Caliber: 1.89 Altitude: 2926 ft Drift: 1000 ft with 5mph winds Recovery ▫Drogue at Apogee ▫Main Deploy 900 ft. ▫Backup for 700 ft.

36 Flight Data Altitude Achieved: 3600 ft. Stability: Visually very stable Main Deploy failure. ▫Probable cause: Additional friction between nose cone and body. ▫Damage sustained: Minimal Second Subscale Flight Planned ▫January 31st

37 Autonomous Ground Support Equipment – Project WALL-Eagle

38 Overall Final Design

39 AGSE Design Overview

40 Launch Pad Box Dimensions

41 AGSE Payload Hatch

42 Payload Hatch Function Seals payload bay during flight Hatch opens and closes autonomously with a microservo Must be closed autonomously Guides robotic arm into payload bay

43 Payload Access Plate and Positioning Single access plate revolves on slightly tightened hinges Hinge operates with microservo Will allow remote opening and closing Will resist loose swiveling, but may be easily closed and locked using small force Optical markers to guide robotic arm

44 Payload Hatch Closing Process Robotic arm will reach over the rocket to push the door closed The arm will press down with enough force to latch the door shut The latch will be a simple mechanical lock mounted inside the mold line Edges of door sealed with rubber sealant

45 AGSE Payload Capture & Transport

46 ~29” maximum reach (nearly 7-inch extension) 5 degrees of freedom Most value and capabilities for the price Completely customizable Price - $830 Infrared sensors installed Modified gripper Modified CrustCrawler AX-12A Smart Robotic Arm

47 Key Design Features Our modified design lifts 2+ pounds Fully ROS,MATLAB,LABVIEW Compatible! Rugged, all aluminum construction for maximum kinematic accuracy (1mm - 3mm) Hard Anodized finish for maximum scratch and corrosion resistance The gripper will use pressure feedback to verify capture of payload Full control over position (300 degrees), speed, and torque in 1024 increments Sensor engineered gripper design includes IR sensors to scan ground and ensure mission success Can grip with three points of contact Minimal moving parts as robot arm can reach to close and latch door

48 Robot Arm Gripper Requirements Able to hold cylindrical payload Support 4 oz. weight Reach ground/reach payload bay Able to rotate at the wrist Able to sense that payload has been obtained The Big Grip Kit from the CrustCrawler AX-12A series robotic arms meet criteria plus more

49 IR Sensors Affixed to front of grabber, scans dark ground (grass/dirt) for light surface (payload). Arm engages payload once detected. If payload dropped, search and capture of the payload may be repeated until mission success

50 IR Sensors Payload Detection and Orientation

51 Contingency: Preprogrammed Location Use preprogrammed location of payload in case IR sensors plan doesn’t work out Can choose location of payload, so static coordinates suffice Easier, but will cause launch failure if payload dropped

52 AGSE Launch Rail and Truss

53 AGSE Truss Constructed out of durable carbon fiber Designed to support the full weight of the rocket Connected to two metal wires at top of truss Rotates from horizontal to 85° via winch Returns to horizontal after rocket launch

54 AGSE Truss Bottom is counterweighted to ease lifting Measurements ensure bottom does not contact the ground Rocket attached to truss via slotted rails Attachment rails double as launch rails ensuring launch stability Truss will lock in vertical position once erect via winch system and blast plate

55 AGSE Truss In launch position, blast shield protects sensitive components Igniter insertion system extends into motor Rocket is then ready for inspection

56 AGSE Igniter Insertion System

57 Igniter Insertion System Toothed insertion system DC electric motor drives the tooth extender into the mast Initiated with a program that is linked to the AGSE controller

58 Igniter Insertion System Located 6-8 inches below the base of the rocket. Main motor is protected by the blast plate Rise through a whole in the blast plate to access the rocket

59 Igniter Insertion System Extension of 26.6 inches Igniter pause at full extension E-match attached to tip of the insertion system is in contact with motor Inspection and arming of the rocket Countdown ensues, followed by blast off Dowel diameter will not choke motor

60 Igniter Inserter System

61 Master Microcontroller and Full System Operation

62 Master Microcontroller Single microcontroller drives all AGSE functions ▫Simplifies design ▫Minimizes risk ▫Eliminates communication between multiple microcontrollers Arduino mega used

63 Electrical Schematic for AGSE

64 Launch Controller

65 Subsystem Connectivity All autonomous systems connected through microcontroller ▫Only launch controller handled independently Single start, pause, and reset switches

66 Nominal AGSE Process Start command received Robotic arms commanded to find payload Arm deposits payload in rocket Payload bay hatch closes Launch rail raised Igniter inserted Sequence pauses Launch button depressed Rocket launches

67 AGSE Flow Chart System inspected prior to launch In some cases it is possible to reset and re-run sequence in an error has occurred

68 Risks Power Failure Programming Errors Equipment Assembly Errors Component Synchronization Failure Sequence exceeds allotted time (10 minutes) System unresponsive Damage from environment (humidity, rain)

69 Test Plans Full system test (normal conditions) Speed test for winching system Off-design payload configuration Partially drained batteries Power failure during AGSE sequence Dropped payload

70 Safety Matthew Austin Phillips Safety Officer Auburn University Student Launch

71 Environmental Effects AGSE ▫Humidity ▫Radio Interference Airframe ▫Weather ▫Fire hazard Recovery ▫Weather ▫Fire Hazard Outreach ▫Weather ▫Fire Hazard ▫Lost Rockets

72 Other Additions Updated risks and mitigations Operators manuals Test equipment sign-out sheets Materials sign-out sheets Standard Operating Guidelines MSDS NAR Regulations

73 Educational Outreach

74 7 th Grade Rocket Week Students Learn About: Gravity and g-forces Newton’s Laws of Motion Elementary rocketry Science, technology, engineering, and mathematics Teamwork and communication

75 7 th Grade Rocket Week Students Work Hands-On: Assembling an Alpha rocket in teams of 2-3 Sanding, gluing, and painting rockets Initiating and observing rocket launches

76 Educational Outreach Programs Auburn Junior High School/Auburn High School Rocket Team ▫Mentor team to compete in Team America Rocketry Challenge ▫Teach students design and technical writing methods ▫Provide facilities and equipment for team use Boy Scout Merit Badge University ▫Teach troops about space exploration ▫Supervise Alpha rocket assembly ▫Award Space Exploration Merit Badge

77 Educational Outreach Programs Tuskegee Airmen National Historic Site Field Trip ▫Guide Drake Middle School students on half-day field trip Samuel Ginn College of Engineering E-Day ▫Present AURA and Student Launch teams to prospective students AURA Movie Night Event ▫Show Apollo 13 at Tiger 13 Cinemas ▫Provide Q&A with engineers and students

78 Additional Information Budget Summary Timeline Summary

79 Questions

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