University PDR Presentation Iowa...

Iowa State University PDR Presentation

2017-2018

1

Overview● Project Overview

● Design

● Subscale

● Safety

● Project Plan

● Conclusion

2

Project Overview

3

Team Structure

4

Mission OverviewRequirements:

• Reach an apogee of exactly 5,280 ft

• Safely recover rocket and land within 2,500 ft of the launch pad

• Fully reusable for another launch on the same day

• Perform 1 experiment onboard

• Visual recognition of ground targets

5

Design

6

Rocket Overview

7

Vehicle Requirements● Launch vehicle will deliver payload to altitude of 5280 feet

○ Preliminary simulations predict apogee of 5280 feet or higher

● The vehicle will be designed to be reusable and recoverable○ No major components will need replacing○ Recovery system ensures safe landing

● Total impulse of launch vehicle cannot exceed that of an L-class○ Total impulse of AeroTech L2200 below L-class limit

● Full-scale rocket model must be tested and recovered prior to FRR○ Test launch planned for February 17th

● All airbrakes should fail in the safest manner as possible○ Airbrakes on opposite sides are coupled○ Airbrakes will fail closed

8

Rocket Specifications:

• Length – 117 in.

• Body Diameter – 6 in.

• Weight - 48 lb

Rocket Features:

• Carbon fiber air brakes

• Split fin design

• Dual-parachute recovery system

• Onboard flight data processing and recording

9

Rocket Specifications

10

Nose ConeParachute Bay 2 (120”

Main)

Avionics Bay

Parachute Bay 1 (24” Drogue) Motor Mount

Flight Computer Bay

OpenRocket Diagram

• Center of gravity: 79.2 in (from nose cone)

• Center of pressure: 92.5 in (from nose cone)

• Stability margin: 2.19

11

Stability

Mass Statement● Nose Cone: 4.92 lbs

● Main Section: 18.05 lbs

● Motor Mount: 25.17 lbs (with motor)

Total estimated weight of 48.14 pounds

12

Section: Nosecone Parachute

bay 1

Avionics

bay

Parachute

bay 2

Flight

computer

bay

Motor

mount

Motor

Weight

(lb):

4.92 7.39 5.04 5.62 3.75 10.88 10.54

Mission Performance Predictions

13

Windspeed(mph)

Velocity off rod(ft/s)

Apogee(ft)

Velocity at detach(ft/s)

Optimum delay(s)

Max Velocity(ft/s)

Max accel.(ft/s^2)

Time to apogee(s)

Flight time(s)

Ground hit velocity(ft/s)

5 91.2 5646.3

76.8 16.4 669.3 429.8 18.7 102 17.8

10 90.6 5613.5

76.8 16.3 669.3 429.8 18.7 102 17.8

15 91.2 5567.6

75.5 16.2 669.3 429.8 18.5 100 17.78

20 91.2 5561.0

76.7 16.2 669.3 429.8 18.5 102 17.68

Mission Performance Predictions (cont.)

14

OpenRocket simulation for 10 mph wind

Materials

• 6” Bluetube airframe with couplers

• Five ½” birch plywood bulkheads

• Fiberglass nose cone and main fins

• Carbon fiber air brakes

• 3D printed exterior fins

• Aero-Epoxy

15

• Filament wound fiberglass

• Aluminum tip

• 33” long

Von Karman vs. Ogive

• More aerodynamic at subsonic

velocities

• Reduces drag

16

Nosecone – 5.5:1 Von Karman

• 75 mm Blue Tube motor tube

• Aeropack flanged retainer

• Load transfer through aft

compression

• 5 ½” Centering ring assemblies

17

Hardware

Split fins

• 4 sets of fins (8 total)

• Material

• G10 fiberglass

•Light

•Durable

Geometry optimization for fin flutter

• 45 different fin designs tested

18

Main Fin Design

Motor Thrust Curve● AeroTech L2200

● Total weight: 10.54 pounds

● Average thrust: 494.58 pounds

● Max thrust: 697.31 pounds

● Total Impulse: 1147.42 lb *sec

● Burn Time: 2.3 seconds

● Thrust to Weight Ratio: 9.89

19

Experimental Overview

20

System RequirementsNASA Derived Requirements

# Name: Requirement Verification

4.4.1 Team will design an onboard camera system to identify and differentiate 3 randomly placed targets.

A Raspberry Pi system and Pi cameras will acquire, store, and assess in-flight images during the flight.

4.4.2 Data to be analyzed in real time to identify and differentiate three separate targets.

Pi boards will use the input from the cameras to process and differentiate between the three targets on the ground.

4.4.3 Teams will not be required to land on any of the targets. We will be using a dual-deployment parachute recovery system without a targeted landing system.

21

System RequirementsExperimental Team Derived Requirements

# Name: Requirement Verification

T1.1 Clear image to identify targets on the ground. The cameras will be hard mounted to the side of rocket for the greatest stability during ascension.

T1.2 A full range image of the ground below the rocket. Five cameras are to be mounted to gain the greatest view of the targets on the ground.

T1.3 Analysis of the image(s) from the Pi cameras. Programed Raspberry Pi boards will take in, store, and differentiate the pi camera data.

22

Changes Since Proposal● Removed Gimbal Concept

○ Reduced mass and complexity○ Added Mission Assurance through increased Field of View

Change Old Version New Version Rationale

Camera Mounting Gimbal System Hard Mount Reduction of mass and costs

Number of Cameras Two cameras Five cameras Greater field of view with chosen method of mount

23

Target Detection System -Computational HardwareRaspberry Pi 3 Model B

CPU Quad Cortex A53 @ 1.2 GHz

GPU 400MHz VideoCore IV

RAM 1 GB SDRAM

Storage Micro-SD

Wireless 802.11n / Bluetooth 4.0

Video Output HDMI / Composite

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Raspberry Pi Camera Module V2

● Resolution

○ 8 megapixel native resolution high quality Sony IMX219 image sensor

○ Cameras are capable of 3280 x 2464 pixel static images ● Quality

○ Capture video at 1080p30, 720p60 and 640x480p90 resolutions ○ Software is supported within the latest version of Raspbian Operating

System

○ 1.12 µm X 1.12 µm pixel with OmniBSI technology for high performance (high sensitivity)

○ Optical size of 1/4"

Target Detection System - Camera Hardware

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Target Detection System - Power Supply Hardware

● UPS HAT module board & Battery

○ Cascading design to save mounting space

○ Retains GPIO pins for additional expansion board possibilities

○ 2.8 x 2 x 0.7 “

○ 62.37 grams

● Li-Ion Battery

○ 2500 mAh

○ 3.7 V

○ 2 Amps

26

Target Detection System Software

● The Raspberry Pi receives image stored

on a microSD card by the Pi camera

● Image is converted from RGB to HSV

● Copies HSV channel in grey channel and

processes

27

Electronics Bay● 12 inch coupler bay located between parachute bays

● Contains hardware

○ Raspberry Pi’s and Batteries

● Horizontally stacked circular plates

● Passageways for camera and battery wiring

● Five cameras mounted on rocket exterior

28

Camera Mounting● Full ground tracking field of view below rocket desired

● Minimum of 5 downward facing cameras

● Mounting angle of 24.4 degrees

295 Cameras vs. 6 Cameras

Camera Ducts● Mounting Point for Pi Camera’s

● Reduce drag from mounting the cameras directly

● Contain and protect cameras during launch and landing

30

23.86 mm

25 m

m 11 cm

Moving ForwardTesting and Verification:

● Ensure Program works● Stationary testing on platform

● Scaled down targets to simulate altitude view

● Each test will last for estimated launch duration

Next Steps:

● Look into reducing required number of Raspberry Pi’s● Continue development of software

● Test software in a simulated environment

● Iterate and continue to improve software

31

Apogee Control

32

Changes Since Proposal

Change Old Version New Version Rationale

Battery number and type 1 9V battery 2 LiPo batteries redundancy and longer lasting

Flight computer Arduino Pro Mini Arduino Duo used Analytic Hierarchy Process to choose between board options and Arduino came out on top, the Due has higher clock speed than the Pro Mini

33

34

Simulated Air Brake Deployment

Flight Computer Bay● Parts housed:

○ Flight computer and sensors

○ Airbrake servo governed by

flight computer

○ Servo winch

○ Pulleys

● Construction:

○ U-bolt with wing nuts

○ Finnish birch plywood

● 13.5 inches long

35

● Air brakes actuated by a servo controlled by the flight computer

● Flight computer continuously performs apogee calculations

● If the expected apogee is greater than 5,280 ft, the airbrakes will be

actuated

● This process is repeated until apogee is reached

36

Air Brake Functions

Flight Computer Comparison Results

-All Consistency Indices are below the .1 standard

0.4780 Arduino Due

0.2965 Raspberry Pi 3

0.2255 BeagleBone Black

37

Sensor Choices● Barometers

○ BMP180 (I2C)

● GPS Modules

○ U-blox Neo M8N (UART)

● Accelerometer

○ MPU6050 (3 axis) (I2C)

38

Control Flow

Flow diagram of flight computer code39

Target Computer Setup ● Purpose

○ Run Simulations for the airbrakes

● Program

○ Simulink Real time

● Host computer to target computer connection

○ Ethernet cable

● Target computer to target monitor

○ VGA cable

40

Results Conditions for 2016-2017 rocket run through simulation:

Max altitude● Simulation: 4921 ft● Actual apogee: 4916 ft

Max velocity● Simulation: 564 fps

41

Recovery

42

Recovery Systems

● 24” Drogue parachute opens at apogee

● 120” Main parachute opens at 800 feet

● Black powder ejection charges

● Rocket separates to deploy parachute

● Parachutes secures to rocket through

u-bolts

43

Parachute Bays● Shock cords - kevlar and nylon● Attached to u-bolt assemblies● Anti-zippering ball on shock cords

Parachute bay 1

● Drogue parachute - 24”● Between avionics bay and motor mount

Parachute bay 2

● Main parachute - 120”● Between avionics bay and nose cone

44

Configuration 1 (Drogue):● Descent rate: 106 ft/s● Parachute: 24” elliptical ● Shock cord: 33 ft nylon

Configuration 2 (Main):● Descent rate: 15 ft/s● Parachute: 24” elliptical and 120”

elliptical ● Shock cord: 27 ft nylon

45

Configuration 1 - Drogue

Rocket Weight (on descent) 44.4 lb.

Parachute Size 24 in.

Descent Rate 84.45 ft/s

Configuration 2 - Main and Drogue

Parachute Size 120 in and 24 in.

Descent Rate 14.76 ft/s

Forward Section Avionics Section Motor Mount

Section Weight 4.91 lb. 16.16 lb. 16.8 lb.

Impact Energy 16.67 ft-lb 54.85 ft-lb 57.02 ft-lb

Parachute Configurations

Avionics Bay● Coupler also houses the Electronics Bay

● Copper tape lined

● Altimeters

○ AIM USB

○ Perfectflite Stratologger

● Recovery system comprised of redundant altimeters,

power supplies, and ejection charges

● Ejection charge masses will be calculated by CDR

46

Drift calculation

Regardless of wind speed, rocket will remain within launch field maximum radius

47

Safety

48

Safety ● Team Members

○ Team Safety Officer - Nick Holaday

○ Second Safety Officer - Briana Staheli

○ Technical Communication - Sarah Kreutner

● Team Responsibilities

○ Maintain record of trainings and briefings for all CySLI team members

○ Prepare Risk Assessment Tables

○ Prepare Build and Launch Procedures

○ Oversee all safety concerns and legal compliances

49

Risk Severity

50

Risk Probability

51

Risk Assessment Matrix

52

Facilities and Safety Policies● Policies

○ Use of Facilities

○ Iowa State Safety Policies

○ Team supervision during build

● Facilities

○ Make 2 Innovate Student Lab

○ Boyd Engineering Lab

○ M:2:I Conference Room

○ Howe Hall Computer Lab

53

CySLI Website https://m2i.aere.iastate.edu/cysli/

Maintained with all current team information, Student Launch Initiative documentation, and M:2:I documentation by Technical Communication Lead, Sarah

54

Risk Assessment● Lab and machine

○ Hazards that could occur due to the laboratory equipment and machinery

● Rocket

○ Hazards that could be caused to or by the rocket

● Avionics

○ Hazards that could occur due to the avionics system of the rocket

● Experimental

○ Hazards that could occur due to the experimental factor of the rocket

● Environmental

○ Hazards that could occur due to the environment around the rocket

55

Compliance with Laws● Iowa State Rocketry Laws

● Minnesota State Rocketry Laws

● NAR and TRA requirements

● Required NAR supervisor will be Gary Stroick

56

Handling of Rocket Motors● Purchase and Storage

○ Online Vendor- Off We Go Rocketry

○ Due to ISU safety policy, purchased and handled by Team Advisor Gary Stroick

○ M:2:i Director Matt Nelson will handle in between delivery and launch

○ Shipped with HAZMAT safety precautions

● Handling and Transportation

○ Fullscale delivered and handled by Gary Stroick

○ Project Lead Becca will handle subscale motor

○ Properly secured and stowed away during all transit

57

Range Safety Regulations

1. Certification

2. Materials

3. Motors

4. Ignition Systems

5. Misfires

6. Launch Safety

7. Launcher

8. Flight Safety

9. Launch Site

10. Launch Location

11. Recovery System

12. Recovery Safety

58

Documentation ● Identifying hazards

○ Each subteam provided a list of possible hazards

○ Comply with NAR, and NFPA 1122 model rocket safety codes

● Procedure Approval sheets

○ Signatures needed from all members of build and launch team

○ Ensures knowledge of safety requirements during build and launch

● Log sheets

○ Log flight info and data during check before launch

● Supervision

○ Safety officers present during all build and launch events

59

NASA Safety Regulations● All CySLI team members have agreed to follow the specific NASA SL Handbook regarding Launch Safety.

This was agreed to in the Safety Agreement Form and re-discussed during all briefings.

1.6.1. Range safety inspections of each rocket before it is flown. Each team shall comply with the determination of

the safety inspection or may be removed from the program.

1.6.2. The Range Safety Officer has the final say on all rocket safety issues. Therefore, the Range Safety Officer has

the right to deny the launch of any rocket for safety reasons.

1.6.3. Any team that does not comply with the safety requirements will not be allowed to launch their rocket.

60

Subscale

61

Subscale testing● Launching subscale test on

November 11th

● Pearson Farms in Mitchellville, Iowa

62

Subscale testingSubscale will be ⅓ size

63

Subscale Testing● Testing aerodynamic properties of the airframe

○ Replicate placement of CG and CP● Testing altimeter (Stratologger CF)

○ Ride-along mode

64

Verification Plan

● Verification Checklist to ensure proper assembly and preparation

○ Subscale construction

■ Parts are securely epoxied together

○ Loading the motor

○ Packing the parachute

■ Correct packing

■ Untangled shroud lines

■ Secured to airframe

65

Subscale Launch Safety● Safety Briefings

● Subscale Build

● Build/Launch Procedure Sheets

● Subscale Procedure for Launch

○ Prep Black Powder Charges

○ Recovery Charge and Coupler Installation

○ Motor Installation

○ Safety Tests (Shake Test)

66

Project Plan

67

68

ScheduleCompetition Timeline

Description Completion DatePDR Q & A 10/12/2017Website and PDR Due 11/3/2017CDR Q & A 12/6/2017CDR Due 1/12/2018FRR Q & A 2/7/2018FRR Due 3/5/2018Launch Week 4/4/2018-4/7/2018PLAR Due 4/27/2018

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Equipment Costs $5,800

Material Costs $1,150

Travel $4,000

Total $10,950

Budget

Questions?

70

Backup Slides

71

Rocket Design Backup Slides

72

Nose ConeVon Karman vs. Ogive

● Most Aerodynamic at subsonic

velocities

● HAACK series nose cone

● C value = 0

● High aspect ratio 5.5:1

73

Motor Mount● Construction

○ Centering rings epoxied to inner tube

○ Then, epoxied to inside of airframe

○ Fins are epoxied in place using fin mounting jig

● 26 inches long

● Motor retainer

○ Prevents motor movement during flight

74

Fins● Flutter velocity of fore fin is 898 ft/s

● Flutter velocity of aft fin is 1153 ft/s

● Safety margin of 27.0%

● Waterjetted from G10-Fiberglass

● Through-the-wall fin mounting

● Fins aligned with fin mounting jig

75

Secondary Fins● Reduces drag caused by exterior pulleys

● Aesthetic cover

● Help guide cables to airbrake surfaces

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● 120” Main● 24” Drogue● ⅜” U bolts● ⅜” Quick links / ¼” quick links● ½” nylon shock cord● Kevlar shock cord protector● Kevlar chute protectors● Anti-zipper ball● Slider release ring ● Deployment bag

77

Recovery Hardware

Drag-V=sqrt((8*m*g)/(pi*rho*C*D^2)

Main parachute

V = sqrt((8*222.714*9.8)/(pi*1.22*2.2*3.048^2)) = 14.929 m/s

Drogue parachute

V = sqrt((8*222.714*9.8)/(pi*1.22*1.55*.371612^2)) = 145.889 m/s

78

Apogee Control Backup Slides

79

Why the M8N?

80

Flight Computer -Used the Analytic Hierarchy Process to help with flight computer decision

Arduino Due Raspberry Pi 3 BeagleBone Black

Processing Speed - + +

Code Portability + - -

Community + + -

Sensor Use Ease + - +

81

Simulink Mother blockMain block with sub-blocks

● Rocket Motor Block● Dynamic Block● Drag Block

82

Motor Thrust BlockIntegrates Thrust Profile to obtain:

● Burned Impulse● Fraction of Impulse Burned● Motor Mass

83

Dynamics BlockUses mass, thrust, and drag to obtain:

● Acceleration● Velocity● Altitude

84

Drag Block

Uses velocity and altitude to find:

● Drag with respect to change in altitude

● Equation:

85

Safety Backup Slides

86

Forms, Briefings, and Trainings ● Forms

○ Safety Compliance Form

● Briefings

○ Introductory Safety Briefing

○ Build Briefing

○ Subscale Launch Briefing

● Trainings

○ Personal Protective

○ Fire Prevention

○ General Shop Safety

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