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CDR Presentation

February 7, 2012

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• Eric Po Team Leader o Payload Manager o Documentation Manager

• Michael Bo Building Team Manager o Safety Manager

• Sean Ko Outreach o Materials Manager

• Jacob Eo Launch Manager o Budget Manager

• Mike Po Technology Manager o Equipment and Facility Manager

• Michael Go Recovery Manager o Communications Manager

• Brian Go Technical Manager o MSDS Manager

Lake Zurich Rocketry - Team Responsibilities

Lake Zurich High School

CDR – Final Launch Vehicle Dimensions

Length Diameter Span Mass (w/ motor)

108.00 in 6.16 in 15.66 in 401.9591 Oz

Motor CG CP Stability Margin

K1050W 64.8314 in 78.3430 in 2.22

Final Launch Vehicle Dimensions

CDR – LV Key Design Features

System Rationale Characteristics

A - Nose Cone Part of payload - needs to be durable Fiberglass with Ogive design

B - Payload Engineering experimentDesigned to hold all components, deploy easily, able to maneuver, and be durable.

C - Payload Tube Lightweight and durable 6" Carbon Fiber - fiberglass too heavy.

D - Avionics Bay Standard design for redundant ejection charges.Screws attach to payload tube, and shear pins to booster tube for ejection.

E - AV Bay CollarHolds the arming switches - can be easily armed from outside of LV.

2" collar is adequate for arming switches and for vent hole for altimeter.

F - Drogue ChuteDesign to eject with payload and allow LV to descend with wind.

18" Nylon chute that is attached with quick links to eyebolts in bulkplate on Avionics Bay.

G - Main Chute Slows the LV down to safe landing velocity.78" Nylon chute that deploys at 1,000' to reduce impact of winds.

H - Booster TubeNeeds to be lightweight and durable to resist zippers.

6" Carbon Fiber - fiberglass was too heavy for the motor requirement.

I - CradleDesigned to absorb some of the stress on tube from deployment of main.

Connects to the shock cord at the edge of the booster tube.

J - Motor Mount Standard motor mount system for 54 mm motor. Using a K1050W motor from Aerotech

K - FinsAttached to motor tube, and sized to provide stable flight.

Fiberglass fins provide durable system

BA

C

F

E

D

G H

I

K

J

Launch Vehicle Key Design Features

CDR – Final Motor Choice – 1 of 2

Motor Specifications Diameter: 54.0mmLength: 62.7cmTotal Weight: 2203gProp. Weight: 1265gAverage Thrust: 1132.9NMaximum Thrust: 2172.0NTotal impulse: 2426.4NsBurn Time: 2.1s

Thrust Curve

Final Motor Selection - AeroTech K1050W

CDR – Final Motor Choice – 2 of 2

Final Motor Selection - AeroTech K1050W

Motor Subsystem Construction

A - Centering Rings• Made from ¼” birch plywood.• Forward ring is doubled to increase strength for main chute deployment.• Eye bolt is anchored into the forward centering rings for main chute shock

cord anchoring.B - Fins

• Fins extend through the airframe, and are glued to the motor housing.• This increases strength.

C - Motor Tube• Aluminum motor tube that holds the K1050 motor and slides into the kraft

motor housing.• Extends into the motor housing

D - Retention Ring• Holds the K1050 motor into the motor tube

E - Anchor bolts and clips• Used to clip over the retention ring, and holds the motor securely.

A

B

C D

E

CDR – Rocket Flight Stability Margin

Rocket Stability Margin

Length Diameter Span Mass (w/ motor)

108.00 in 6.16 in 15.66 in 401.9591 Oz

Motor CG CP Stability Margin

K1050W 64.8314 in 78.3430 in 2.22

CPCG

As changes to the weight of the rocket occur during construction, this will move the Center of Mass. The team will make these required adjustments to maintain a safe Stability Margin: 

• If the CG moves forward, and increases our stability margin towards being unstable, we will add mass in the motor housing section by adding threaded rod in the pre-drilled holes.

• If the CG moves aft, and decreases the stability margin towards being unstable, we will add mass to the payload section near the AV bay.

 

We will continue to refine the mass predictions throughout the construction process in order to make adjustments at the appropriate times.

CDR – Thrust to Weight ratio and Rail Exit Velocity

Thrust to Weight Ratio and Rail Exit Velocity

Key Flight Predictions LV Key Flight Predictions Payload

Launch Rail Departure 82.34 ft/s Deployed at Apogee 5321 ft.

Thrust to Weight Ratio 9.2 Weight of Payload 46.00 oz.

Maximum Velocity 647.28 ft/s Range at Deployment 698 feet

Time to Apogee 17.463 sec Descent time <> 180 sec.

Time to Landing 76.245 sec Range at Landing 50 ft.

Maximum Altitude 5321 ft  

CDR – Mass Statement and Mass Margin

Mass Statement and Mass Margin

Subsystem Weights Oz.

Launch Vehicle 145.03Payload 46.00

Avionics Bay 81.02Motor System 83.50

Recovery Systems 43.45Total 401.95

Our mass statement includes some reserves that should account for any additional discrepancies, but the team is confident that there will be no additional weight gain from CDR to the final product.

However, the motor we are using in our design is strong enough to propel an additional 4 ounces to 1 mile high. Therefore, the motor is powerful enough to meet mission altitude requirements with a weight of up to 406 ounces.  

CDR – Recovery systems – 1 of 2

Recovery Systems

Avionics Bay and Recovery Components

Avionics Bay and Recovery Components

Redundant AltimetersDrogue Chute - Payload

Tube

Arming Switches Main Chute - Booster Tube

2 - Forward Eyebolts Main Shock Cord

2 - Aft Eyebolts Drogue Shock Cord

Batteries 4 - Quick Links

2 - Forward Charge cups Shock Cord 'Cradle'

2 - Aft Charge cups 4 - Black Powder Charges

GPS Recovery device Foil Frequency Barrier

Altitude Sensor for verification

Ejection charge terminals

       

We are using a dual event recovery system (DERS). The drogue parachute will be 18 inches in diameter, and will deploy at apogee. The main parachute will be 78 inches in diameter, and will deploy at 1000 feet. This will slow the descent rate to approximately 21.41 ft/sec.

CDR – Recovery System – 2 of 2

Recovery Systems

Compartment Free Volume Charge Size - grams

Payload - Drogue chute 189.04 3 gramsBooster - Main chute 235.62 3 grams

Ejection Charge Sizing

Shear Pins

Shear pins will be used to securely connect all sections that ejection charges will be separating. We will use 1/16” shear pins that require an average of 50 Lbs of force to shear. We are planning on using a minimum of 3 shear pins per section which will then require 150 Lbs. of force to shear, but additional testing is required to make sure this is suitable for the ejection charge sizes we have specified.

Shock Cord Cradle

To prevent a ‘zipper’ to the Booster tube when the Main chute deploys, the team has created a ‘Shock Cord Cradle’ that will reduce some of the stress created on the forward edge of the booster tube

CDR – Kinetic Energy and Wind Drift

Kinetic Energy and Wind Drift

Wind Drift (mph)Range

(ft.)Kinetic Energy at Landing

0 mph 0 ' Booster Tube (main) 53.41 f/lbs

5 mph 239 ' Payload Tube (drogue) 39.21 f/lbs

10 mph 490 ' Independent Payload 18.676 f/lbs

15 mph 690 ' KE=1/2m('v'squared) (1 f/lbs = 1.356 Joules)20 mph 906 '

CDR – Test Plans and Procedures – 1 of 2

Test Plans and Procedures

Test Procedures StatusAltimeter Deployment Test Altimeters are depressurized and then pressurized to test for

proper ejection altitudes of the parachutes Complete

Battery Connection Test The batteries are connected to the various subsystems to test for functionality

Complete

GPS Location Test (Astro) GPS is tested in various locations for verification of accuracy Complete

Altitude Test (Redundant Altimeter)

Redundant Altimeter unit is taken to various heights to test for accuracy

Complete

Ejection Charge Test Ejection charges are ignited in a safe environment to test for proper ejection

Complete

Ejection Test Elements of the launch vehicle are tethered to a zip-line. The ejection charges are then detonated to test for proper separation of elements.

Complete

RockSim Verification Test Data from subscale launch vehicle and from RockSim are compared to test the validity of RockSim

Complete

Altitude Test (Ejection Altimeters)

Altimeters are pressurized to various altitudes to test the accuracy of flight data

Complete

Subscale Launch Measurements of stability and strength were taken from the subscale flight to verify the integrity of the launch vehicle’s design

Complete

Parachute Drop Tests Both the drogue parachute and the main parachute are dropped from various heights to test for parachute functionality

Complete

Altimeter Continuity Test The continuity of the altimeter terminals are tested to verify proper wire connections

Complete

Integration Test The payload fits into the payload bay as designed Planned

CDR – Tests and Procedures – 2 of 2

Test Plans and Procedures

Balloon testing • Para-wing construction and design• Release mechanism

Static Line testing• Ejection charges• Shear pins• Recovery systems

 Full-scale launch vehicle test flight(s)

• RC signal strength• Telemetry• Checklists• Component Integration

Additional Testing Planned:

CDR – Scale model test flight - 1 of 4

Scale Model Test Flight

Launch Details Launch Date: January 14, 2012 Launch Location: Richard Bong State Recreation Area

• GPS coordinates:  Lat: 42 Deg, 37 Min, 44.06 Sec N  Long: 88 Deg, 10 Min, 17.83 Sec W

 Launch Conditions:

• 17 degrees• partly cloudy• 3-5 mph from NW• launch at 10:45 AM CST

Launch Objectives:

•Verify flight predictions from RockSim.

• Test a dual event recovery system with redundant altimeters.

• Use checklists for prep, launch, flight, recovery, and analysis.

• Verify that payload signal strength was adequate for RC control.

• Verify that our GPS system worked correctly.

• Determine if our construction techniques were suitable to meet SLI requirements.

• Collect data for analysis.

CDR – Scale model test flight - 2 of 4

Scale Model Test Flight

Length Diameter Span Diameter

71.875 In. 4.000 In. 12.50 In.

Mass Motor Total Impulse

150.5746 Oz. J290 683.6 Ns

CG CP Stability Margin

42.7940 In. 54.2388 In. 2.86

Scale model was built at 2/3 scale of Full Size

  RockSim Prediction Actual Flight

Apogee Altitude 2968.66 Ft. 2989.00 Ft.

Time to Apogee 13.90 sec. 13.5 sec.

CDR – Scale Model Flight Test – 3 of 4

Scale Model Test Flight

Flight and Recovery Observations:• Launch was straight and smooth with no

indications of any issues.• Drogue deployed at apogee• Main chute did not deploy• Landing without main deployed caused the

damage to the airframe. We calculated the Kinetic Energy of the landing without the main chute deployed to be 1284.32 ft/lbs.

Data Analysis:• RockSim was verified on apogee altitude and

time to apogee.• We had good signal connection with the RC

components from the ground.• We were at a maximum of 3,027 feet from

transmitter to receiver.• Both altimeters worked for the redundant

charges.• The Garmin Astro worked perfectly, and gave us

accurate recovery data.

CDR – Scale Model Flight Test – 4 of 4

Scale Model Test Flight

Apogee: PWRLOSS Ground Elevation: 631' MSL Main Setting: 700' AGL Drogue At: 13.80 Seconds Apogee: 2980 Ft.

On-board Altimeter Data

Data Analysis and Conclusions 

By looking at the flight data and observations, the following conclusions can be made:

•  Apogee was reached in 13.85 Sec.• Apogee altitude was approximately 2982 Ft. – verifying our RockSim prediction.• We encountered a power loss just after the drogue ejection charge fired.• RC Signal Strength was strong.• GPS was accurate• Flight was stable• Modifications need to be made for full size rocket.

CDR – Tests of Recovery system

Testing of Recovery System

Tests of the Recovery system include:

• Static Line testing

• Test flights

• Parachute deployment

• Weather Balloon drop testing

• RockSim predictions

• Vacuum test for altimeters

• Force test for harnesses

• Construction testing

Ejection charge test on a static line

CDR – Payload Design – 1 of 5

Payload Design

Payload Objectives 

• Direct the payload to a specific landing location• Gain telemetry from our payload such as speed, GPS coordinates, and altitude• Land the payload SAFELY• Gain video telemetry to accurately direct the payload Payload Success Criteria 

To have a successful payload, our team has brainstormed a list of requirements that our payload shall meet. They are:

• Land the payload within 50 feet of a designated location• Land the payload SAFELY• Gaining information from the payload during the payload’s flight

CDR – Payload Design – 2 of 5

Payload Design

Payload Systems:

• RC controlled fan – to provide the payload with controlled movement• RC controlled directional fins – to change the course of the payload• Video camera – to help the pilot guide the payload• Telemetry system – to help collect data to analysis the descent• GPS locator – to assist in the recovery of the payload should it go off course• Para-Wing Chute – provides a slow descent with forward velocity• Payload release mechanism – for safety – remotely controlled release of the payload when the RSO gives approval.

CDR – Payload Design – 3 of 5

Payload Design

Payload Release Mechanism Payload Electronics

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R/C Signal ComponentsComponent Function

HiTec Optic 2.4

Transmits the commands for

movinig the fins and power to the

fan

HiTec- Optima 9

Receives the fan and fin movement information from the tramsmitter

HiTec-HS-45HB

Moves the directional fins per

the signal received

Telemetry ComponentsComponent Function

HTSS-Blue

transmits the telemetry data to the HTS-Navi-

USB

HTS-GPS

Calculates GPS and altitude

information every second

HTS-Navi-USB

Enters the telemetry data into grounnd based laptop

Additional Payload Components

Component Function

WiVid L-5801-BTransmits positioning video to Payload Pilot

Garmin Astro 220Assists in recovery of Payload - back up for

GPS data

E-Flite 300 EFLM1150

Adjustable speed fan for forward movement

E-Flite 300 EFLM1150

powers all of the R/C controls on the Payload

Horizon R/C landing gear

Moves the camera to the desired view point

for pilot control

LOC Precision / Custom-made

Custom vents to propel the Payload forward

Custom MadeAdjusts the air flow to turn the Payload on

descent

CDR – Payload Design – 4 of 5

Payload Design - Electronics

CDR – Payload Design – 5 of 5

Payload Design – Para-wing

Para-wing System:

• A gliding parachute

• Reduces descent rate

• Propels payload with forward velocity

• Will be deployed when the release mechanism is activated.

• Testing to begin in February from balloon drop tests.

• Construction assistance is being offered by Top-flight.

• Details on the design can be found in Apogee Components Technical Publication #7.

CDR – Payload Integration and Interfaces

Payload Integration and Interfaces

Payload Integration:

• Payload Containment Tube is attached to the nose cone.

• The tube is divided into different levels, with each level holding payload components.

• GPS tracking unit• RC batteries and Servos• Telemetry components• Fan and directional fins• Wireless Video camera with

retractable arm• Para-wing cup with release charge

• The Payload Containment Tube slides inside the payload airframe tube.

• At the end of the Payload Containment Tube is the Para-wing cup, which also houses the Release Ejection Charge.

• The entire payload system is secured to the payload airframe tube with shear pins.

Payload Interfaces:

• RC Interface• Control of fan• Control of directional fins• Activate release ejection charge• Telemetry Interface

• GPS Interface• Garmin Astro

• Video Interface• To monitor on ground

AV Bay Interfaces:

• Altimeters• Redundant altimeters activate DERS

ejection charges

• GPS • Garmin Astro

CDR – Status of Requirement Verifications – 1 of 2

Status of Verifications – Launch Vehicle

Requirement Design Element Verification5,280 feet AGL Motor K1050W RockSim analysis and LV test 1Maximum total impulse of 2,560 Nsec (K) Motor K1050W Aerotech testing resultsRemain subsonic Maximum Velocity = .60488 mach RockSim and LV test 1All sections to have GPS tracking device Garmin Astro in payload and AV Bay Completed – flight testMust be have a stabilty margin of between 2.0 and 2.50 (RockSim)

Stability margin - 2.22 RockSim analysis and inspection

Must have at least 1 sub-scale test flight Scheduled for 1-14-2012 Completed 1-14-2012Must have at least 1 test flight of full-scale LV Scheduled for 3-17-2012 Scheduled for 3-17-2012LV must meet flight review by RSO Pending approval Inspection by RSOReady to launch within 2 hours of waiver Pending test flights TestingReady mode for one hour Electronics tested to achieve TestingUtilize Launch and Safety checklist Completed - see PDR Inspection and analysisDERS - Drogue and Main chutes Completed in design Inspection and TestingSeparate Arming Switches - no higher than 6' Completed in design Inspection and testingRedundant Altimeter Systems Completed in design Testing

Electronics protected from freq. interferenceCompleted in design - a foil barrier on surface of forward bulkplate

Analysis and testing

Removable Shear pins Completed in design Included in design and testedNo more than 75 ft/lbs of KE per section Maximum KE = 53.41 ft/lbs RockSim analysis and LV Test

All sections within 2,500 feet of launch pad Maximum Range = 906' with 20 mph winds RockSim analysisUtilize Recovery checklist Completed - see PDR Inspection and AnalysisReady for re-launch in same day - no repairs Pending test flights TestingCollect experiment data for analysis Telemetry data being stored on laptop TestingMust have flown and recovered a min of 15 flights at K Class or greater

Both Mentors have achieved this Completed

CDR – Status of Verifications – 2 of 2

Test Procedures StatusDrop Test The payload is dropped from a helium balloon at 250 feet to

test for accuracy of steering and structural integrityPlanned

Battery Connection Test The batteries are connected to the various subsystems to test for functionality

Complete

GPS Location Test (GPS Unit) GPS is tested in various locations for verification of accuracy

Complete

Altitude Test (GPS Unit) GPS unit is taken to various heights to test for accuracy Planned

Speed Test (GPS Unit) GPS unit is moved at various speeds for verification of accuracy

Planned

Flight Path Test (GPS Unit) GPS unit’s flight path is tested during the drop test to verify accuracy

Planned

GPS Location Test (Garmin Astro)

GPS is tested in various locations for verification of accuracy

Complete

Altitude Test (Altimeter) Altimeter is taken to various heights to test for accuracy Complete

R/C Transmitter and Receiver Operating Distance Test

R/C Transmitter and Receiver are taken to their furthest operating distance to verify that the will operate at over 1 mile

Complete

Thrust Test The payload is placed on a scale and has its thrust steadily increased to verify that it can propel the payload in flight

Complete

Wiring Test The subsystems are connected to corresponding wire connections to test if each responds accordingly

Complete

Stress Test The payload is run for an hour to verify that it can withstand the stresses of flight

Complete

Camera Test Camera images are compared to known ground features to ensure that the camera is functioning

Planned

Final Test The completed payload is tested for functionality Planned

Status of Verifications - Payload

CDR – PDR Action Items

PDR Action Items

Action Item and Resolution:

• Calculate the KE for each section of the vehicle.

• Added to CDR – page 44

• Implement a remote controlled release mechanism for any UAV. This will be activated when approval is given by the RSO.

• Added to payload design and included in CDR – page 74

• Team should research any pertinent FAA regulations concerning RC operations above 400-500 feet. If a waiver is needed, the team should look into filing one.

• The team identified the FAA document regarding this – AC 91-57.• Our research indicates that this Advisory Circular is only intended to prevent

collisions between RC controlled models, and aircraft. There is no mention of frequency interference as a concern.

• We believe that the FAA waiver that NASA SLI has in place for the Huntsville launch will cover any RC activity over 400’ and under the waiver ceiling.

• As a feedback item, the team was asked to prepare more information regarding the design and use of our Para-wing.

• We added a lengthy section on the Para-wing to the CDR – see page 76

• As a feedback item, the team was asked to specify a larger size shock cord, and also to use a stronger glue than 5 minute epoxy.

• Both items have been resolved.

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