Auburn University Project “Wall-Eagle” PDR

Rocket Design

Rocket Model

Detailed Sections

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

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

Nose Cones Type of ConeCoefficient Of Drag MassEase of Manufacturing Total Ogive3227 Haack3216 Ellipsoid1124 Conical1337

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.

Fins Type of FinStabilityEase of manufacturing DragTotal Trapezoidal Clipped Delta Elliptical771024

Motor Selection

Motor Selection / Altitude Prediction Initial Motor selection is the Aero K780R-P ▫R-P: Redline, 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

K780R-P Thrust curve

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

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

K780R-P Motor Specifications ManufacturerAeroTech Motor DesignationK780R-P Diameter75 mm Length15.5 inches Impulse2371 N-sec Total Motor Weight5.95 lbm Propellant Weight2.8 lbm Propellant TypeRedline Average Thrust175 Pounds Maximum Thrust216 Pounds Burn Time3.0 sec

Secondary Motor Secondary motor is the CTI L-610 Mass increase of 25% altitude simulated 3245 feet Increased mass would utilize ballast tank Would require an increased fin size for maintaining stability

Cesaroni L-610 Motor Specifications ManufacturerCesaroni Technologies Incorporated Motor DesignationL-610 Diameter75 mm Length15.5 inches Impulse N-sec Total Motor Weight8.71 lbm Propellant Weight3.5 lbm Propellant TypeRedline Average Thrust137 Pounds Maximum Thrust197 Pounds Burn Time5.1 Seconds

Recovery

Overview

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

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

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

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

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

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

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

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.

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

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

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

Autonomous Ground Support Equipment – Project WALL-Eagle

Overall AGSE Concept

AGSE Payload Hatch

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

Payload Access Plate and Positioning Single access plate revolves on hinge Hinge operates with microservo Will allow remote opening and closing Optical markers to guide robotic arm

Payload Access Plate and Positioning Single access plate revolves on hinge Hinge operates with microservo Will allow remote opening and closing Optical markers to guide robotic arm

Payload Hatch Animation

AGSE Payload Capture & Transport

Robot Arm Capabilities Needs at least 4 degrees of freedom Controlled by central master-controller Detect Payload via IR sensors ▫Backup: Navigate to predetermined location Be able to lift 4 oz. payload Navigate over payload and rocket hatch

Fabricated vs. Purchased Fabrication Advantages: ▫Customizable for any purpose ▫Cost-effective ▫Deep subsystem educational merit ▫Unique and original ▫High scientific merit Purchase Advantages ▫Commit team-member time elsewhere ▫High-performance ▫Reduce risk of subsystem failure ▫Compensate for lack of team- member experience ▫Customizable parts ▫High scientific merit

Decision: Purchase Robot Arm Chose to purchase commercially available arm. High performance, legacy, and affordability warrant purchase of arm. Arm like Lynxmotion AL5B or AL5D possible choices.

CrustCrawler AX-12A Smart Robotic Arm ~22” maximum reach 5-6 degrees of freedom Most value and capabilities for the price Completely customizable Price - $830

CrustCrawler AX-12A Key Features 1mbs serial communication protocol Dual actuator design in the shoulder and wrist axis for maximum lifting capability (2 to 3 pound (.907kg to 1.36kg) Fully ROS,MATLAB,LABVIEW Compatible! Rugged, all aluminum construction for maximum kinematic accuracy (1mm - 3mm) Hard Anodized finish for maximum scratch and corrosion resistance Compatible with ANY micro-controller/computer control system / programming Language (Open Source!) The only robotic arms that feature feedback for position, voltage, current and temperature Smooth, sealed, self lubricating ball bearing turntable Fully adjustable initial base angle (3) integrated mounting tabs for easy mounting to a fixed or mobile base (5) Gripper options to choose from Full control over position (300 degrees), speed, and torque in 1024 increments Automatic shutdown based on voltage or temperature with status indicator LED Sensor engineered gripper design accepts, pressure sensors, IR detectors, CCD cameras and more!

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

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

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

AGSE Launch Rail and Truss

AGSE Truss Constructed out of durable carbon fiber Designed to support the full weight of the rocket Connected to two electric gear motors Rotates from horizontal to 85° Returns to horizontal after rocket launch

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

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

AGSE Igniter Insertion System

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

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

Igniter Insertion System Extension of 21 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

Igniter Inserter System

Master Microcontroller and Full System Operation

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

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

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

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

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

Test Plans Full system test (normal conditions) Off-design rocket mass Off-design payload configuration Partially drained batteries Power failure during AGSE sequence Dropped payload

Safety Section

Construction Safety Techniques All members sign a form for their understanding of lab safety practices Proper personal protective equipment will be easily accessible and in good condition Proper hazardous material disposal units will be easily accessible Proper safety equipment is in place in all labs

Testing Safety Techniques Proper protective systems will be in use during testing practices Safe testing guidelines will be posted in the testing facilities Testing equipment will have sign-out sheets Testing checklist will be proactively filled out

Operations Safety Techniques Safe range practices will be strictly enforced Checklists for transport, assembly, and launch procedures will be completed Locations for safe observation of Auburn launches will be marked off Personnel will be properly trained for launch and recovery procedures

Incident Safety Standard operating guidelines are in place for different emergencies with easy access Material Safety Data Sheets will be posted in all facilities Proper precautions will be taken to ensure a safe working environment Emergency incident operations will be required training for all organizational personnel

Educational Outreach

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

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

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

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

Additional Information Budget Summary Timeline Summary

Questions