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edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Page 1: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Page 2: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Project Meteor is a university-based project

• short-term goal is to launch and place small payloads in low earth orbit

• long-term goal is to place such payloads on near earth asteroids and lunar surfaces

It is a hands-on, multi-phase, multi-disciplinary, teaching and research program for investigation and developing micro-systems engineering, science, and technologies for the exploration of outer space.

http://meteor.rit.edu/

Page 3: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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The Vertical Test Stand Team has been given the task to:

• Improve upon the horizontal test stand designed and built by last year’s Sr. Design Team, P06006- working with P07105 - Steel Rocket Team

• Design, develop, and build a Vertical Test Stand - working with P07106 – Guidance & P07109 – Flying Rocket

Teams

• Design and build a “Plug & Go” Data Acquisition System that will be interchangeable between the two stands

Page 4: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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• Replaced rusted rail system with new stainless steel “railroad tie”system that allows for storage away from the harsh elements in the bunker.

• Created a new mount for the load cell that is independent of the rail system.

• Replaced calibration wire with a lower gage that is more flexible and has a protective coating.

• Replaced original damaged linear bearings on rocket pillowblocks with new linear bearings.

Page 5: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

• Vertical Thrust Reading• Lateral Force• Plume Removal• Option for Roll• Acceleration Readings on Rocket• Rocket must be restrained safely• Pressure & Temperature Readings• Simple Set Up• Need Amplifier for Sensors• “Plug & Go” Data Acquisition System/Terminal

Blocks

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$��������"�$��������"�

Page 6: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Gimbal Design

Page 7: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Page 8: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Sensor Inputs

Thermocouple Inputs

Sensor Inputs

Thermocouple Inputs

Load Cell Amplifier

A/D Convert

er

A/D Convert

er

A/D Convert

er

Battery

Packs

Thermocouple DAQ BoxLoad Cell

Amplifier

A/D Convert

er

A/D Convert

er

A/D Convert

er

Battery

Packs

Thermocouple DAQ Box

RS232 Ports for A/D Converters

Power Switches

RS232 Ports for A/D Converters

Power Switches

Page 9: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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IN1

OUT2

GND

3

U7LM340-15

R510k

0

V

V

Output to A/D converter

+3

-2

V+7

V-4

OUT6

OS11

OS25

U3

LM741

+3

-2

V+7

V-4

OUT6

OS11

OS25

U4

LM741

V69VdcV7

9Vdc

V89Vdc

V99Vdc

R7

56kR610k

Input from Load Cell

R810k

VIN VOUT

GND

U8

LM320T_15

R9

39k

Linear Regulators

+3

-2

V+7

V-4

OUT6

U1

TLV2783

+3

-2

V+7

V-4

OUT6

U2

TLV2783

AA_Battery _11.5Vdc

R4

39k

Load_cell_output

30mVdc

0

AA_Battery _21.5Vdc

0

R2

12kR310k

Page 10: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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• Largest risk is restraining the rocket safely but still allowing the force measurements

• Conducted analysis of high stress areas to determine the factors of safety

• Lowest factor of safety on the working components is 6.3.

• Bunker containment for additional safety

18Bearing Binding and Torque on Bearing Shaft

20Axial Compression of Bearing Shaft

12Axial Tension of Bearing Shaft

127Support Bolt Shear Failure of Bolt Threads when 20 Threads ShareLoad

6.3Support Bolt Shear Failure of the Bolt Threads when one Thread takes entire load

95Load Cell Bolt Tension / Compression

Torque Unknown

75,000inlbf allowable

Torsional Bolt Failure

Torque Unknown

22,000inlbfallowable

Torsional U-Joint Failure

38Failure of U-Joint Bearing Tension (FEA)

115Failure of U-Joint Bearing Compression (FEA)

100Failure of U-Joint Bearing (Hand Calculations)

600Failure of Bearing on Bolt (Hand Calculations)

147Failure of U-Joint Bolt in Shear

125Failure of Yoke in Tension / Compression (Manufacturer's Rating)

Factor of SafetyLoad Case

Design Factor of Safety Table

Page 11: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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• Suggested the possibility of a 2 tier bunker system since rocket and plume exceed the size of the existing bunker

• Create a “clamshell”around the test stand itself to provide an additional layer of safety

Page 12: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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• Nose cone coupling cannot be designed until flying rocket team completes rocket design

• The design of board layout cannot be completed until the other teams submit their required sensors

• Bunker is still to be designed since rocket size and shape is still unknown

Page 13: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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• Redesigned horizontal test stand to be used tomorrow for steel rocket testing

• Working on compiling a risk assessment to be submitted week 11

• Finalizing design of bunker and vertical test stand

Page 14: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Still using the software that came with the A/D ConvertersMetDetermine what software to use to integrate the systems1.6

Needs improvement, but will work much better than the previous set-upMetBuild the Data Acquisition “box”1.5

Current amplifier will amplify signal between 9 and 10VMetBuild a more effective amplifier for the Load Cell1.4

TC wire received, thermal tape ordered, method developed

Met (need to test)

Improve Thermal Measurements/Calculations for full length of rocket1.3

New calibration rope and pulley spacingMetCalibration System/Method needs to be improved for better

accuracy1.2

Rails replaced with SS rails, new test stand configurationMetRail & Bearing System needs improvement1.1

DetailsNeed StatusCustomer NeedNeed Number

Horizontal Test Stand Customer Needs

Page 15: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Waiting on information from the other teams involved

Not MetThe Data Acquisition System for the horizontal stand will be interchangeable with the vertical stand and will incorporate anynecessary modifications the flying rocket requires

2.9

One bolt attachment, simple, can store parts out of the elementsMetSimplified Setup Procedure2.8

Bunker design still to complete, height of rocket unknownNot MetSafety Issues with Bunker Stability2.7

Flying rocket still to specifyNot MetPressure & Temperature Readings; work with flying rocket group2.6

Deal with vibrations using accelerometersMetVibrations2.5

Rocket restrained with large factor of safetyMetRocket Restraint2.4

Bunker design still to complete, height of rocket unknown

Not MetPlume Removal/Deflection2.3

Single axis accelerometers spec'd outMetAcceleration Readings2.2

Vertical, lateral and torsional force readings capableMetForce Readings2.1

DetailsNeed StatusCustomer NeedNeed Number

Vertical Test Stand Customer Needs

Page 16: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Page 17: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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$1,563.89Total Expenditures:

$59.00$59.00EA1� ?+�...+���0� ���� ?����������

7�+������7�+1���( ��&������85�RS Adapters

$495.00$495.00EA1� ?+�...� 5+1� ���� ?����������1+" ������� ?+�...� 5�� �� �7�+1���������"��������&��������������������������� ���"�&���

Thermocouple DAQ

$17.61$0.70EA25( �1.���� ���6�%1�5��"����) ���+�+-6 &����Plug

$8.26$0.33EA25( �1.���� ���6�%1�5��"����) ���+�+-6 "�&�Receptacle/Cap

$7.90$0.32EA25( �1.���� ���6�%��5��"����) ���+�+-6 &����Plug

$6.80$0.27EA25( �1..��� ���6�%��5��"����) ���+�+-6 "�&�Receptacle/Cap

$9.11$0.09EA100( �1����� ���6�%�"6������) ���+�+-6 &�������Sockets

$9.23$0.09EA100( �1����� ���6�%&������) ���+�+-6 &�������Pins

$4.56$4.56EA16811A22) ") �����+5���@ �� �� ��&��������) �"��� �&���A�B ����C ��/�0��-���� Hi-Temp. Tape

$15.90$2.65EA64443K723) ") �����+5���@ �� +8���������������� �������8�&��0 ��������',A�8�&����*���@ �>�@ ����8������...�8�?

Threaded Pipe Fitting

$175.14$29.19EA6�.�,D�/) ") �����+5���� � +��������+) ����� �����&&������E F � ���! �Shaft Supports

$187.44$93.72EA2��/�D1�) ") �����+5���1,G �����E G ! � �@ ��������8��"���������������������� ��SS Shaft

$279.44$69.86EA4��//D��) ") �����+5���E F ( ��������8���� +� �"6����+( ��������-�������������������Ball Bearings

$224.50$449.00EA0.51�$ H �������Generator

$64.00$64.00EA1DDD�./.! ����/.������.( B H ��D+�%&�Thermocouple Wire

TotalUnit CostQty unitQtyPart #VendorDescriptionItem

Current Expenditures - Horizontal Stand

Page 18: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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$3,761.95Sub-Total

$500.00Misc. Electrical ComponentsDAQ System

$42.90$1.30pound33Metal Supply6 ft T-BeamT-Beam

$67.60$1.30pound52Metal SupplyC6x13 4ft LongChannel

$1,040.00$1.30pound800Metal SupplyW6x25 12ft LongI-Beam Extrusion

$33.04$33.0416253K65McMaster Top Shaft for Roll Design12" SS Shaft

$49.57$49.5716253K66McMasterShaft for No Roll Design18" SS Shaft

$27.53$27.53159915K276McMasterBall Joint for Torsion Meter1/2" Ball Joint

$180.00$60.003ACC-CB7-10Omega10' MIL/BNC CableAccelerometer Cable

$855.00$285.003ACC793OmegaSingle Axis Accelerometers1 Axis Accelerometers

$258.56$129.2829104T4McMasterCorrosion Resistant Pillow BlockLinear Bearing

$33.76$33.7611610T41McMasterAlloy 6061Alum. Cylinder Stock

$8.76$4.3825709K57McMaster27/64" Outer Ring Taper BearingTaper Bearing Outer

$20.80$10.4025709K18McMaster1" Inner Ring Taper BearingTaper Bearing Inner

$34.08$34.081CJ652-9KMotion Industries2" Lubrication Boot KitU-Boot

$112.59$112.591CJ652BMotion Industries2" 1" Bored JointU-Joint

$7.28$7.28lot of 5192735A240McMasterBall Joint PinClevis Pin

$36.76$18.3828420K63McMasterThread Rod for Ball JointHex body stud

$915.00$305.003LC101-25Omega25lb Tension Compression GaugeS type load cell

$19.36$9.68259915K22McMasterMale Lateral Force Ball JointBall joint

$19.36$9.68259915K482McMasterFemale Lateral Force Ball JointBall joint

TotalUnit CostQty unitQtyPart #VendorDescriptionItem

Estimated Budget - Vertical Test Stand

Page 19: edge.rit.eduedge.rit.edu/content/P07110/public/Deliverables/SD1 Final Review.pdfFailure of U-Joint Bearing Tension (FEA) 38 Failure of U-Joint Bearing Compression (FEA) 115 Failure

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Notable Milestones:

•Finalize Mechanical Design Week 2

•Begin Mechanical Construction Week 5

•Complete Construction of DAQ Week 8

•Test Stand Construction Completion and Testing Week 10