NASA Student Launch Preliminary Design Review

Transcription

1 NASA Student Launch Preliminary Design Review Institution: Mailing Address: Project Title: United States Naval Academy Aerospace Engineering Department United States Naval Academy ATTN: NASA Student Launch Capstone 590 Holloway Road Mail Stop 11B Annapolis, MD Maverick Date: 13 JAN 17 Competition: Student Launch Initiative

2 CRITICAL DESIGN REVIEW 13 JAN 2017 UNITED STATES NAVAL ACADEMY ANNAPOLIS, MARYLAND

3 NAVY ROCKETS TEAM MISSION The mission of Navy Rockets is to provide an expansion and application of classroom knowledge through a unique project based engineering opportunity. Navy Rockets also strives to develop members morally and mentally by imbuing them with the highest ideals of engineering leadership and practice. During this year s Student Launch program, Navy Rockets will deliver a rocket and ground support element that incorporates a payload delivery system that meets all required criteria as defined by NASA and Centennial Challenges guidelines. Overall, Navy Rockets is committed to excellence in practice, delivery, and conduct. NAVY ROCKETS CHARTER The vision of Navy Rockets is to: Supplement academic material in both the aerospace and engineering fields Expand each midshipmen s knowledge and experience to become more proficient and wellrounded members of the engineering community Provide leadership opportunities in a technical environment to better serve midshipmen as future leaders in today s Navy As a team we strive to: Seek out projects that can benefit the aerospace community and reinforce our own educational objectives Deliver quality research and products on time, based in sound engineering and business practices, and operate to a level above client expectation As representatives of the armed services we will: Conduct ourselves in a professional manner and bring credit to both the United States Naval Academy and the United States Naval service. We are committed to excellence in practice, delivery, and conduct. 1

4 CONTENTS 1 SUMMARY OF CDR REPORT Team Summary Launch Vehicle Summary ATDLS Summary CHANGES MADE SINCE PROPOSAL Changes made to Vehicle Criteria Changes made to ATDLS Criteria Changes to Project Plan VEHICLE CRITERIA Selection, Design, and Verification of Launch Vehicle Misson Statements, Requirements,Success Criteria Desgin Review at a System Level ROCKET DESIGN Rocket Body Material Selection Fins Nose Cone AVIONICS Altimeter and GPS Recovery Integration Propulsion Tender Descender Landing Legs for ATDLS Onboard computation and telemetry Main Onboard Processor Mobius action camera Raspberry Pi Sense Hat Digi XBee Radio Communication Onboard COmputation and Telemetry Hardware Schematic Onboard Computation And Telemetry Mission Completion Standards

5 5 PERFORMANCE VERIFICATION Risk Identifaction Table Component Testing Ground Ejection Test Avionics Test Materials and Structures Test BUDGET ANALYSIS Budget SUB-SCALE TESTING Sub-Scale testing plan Sbb-Scale Rocket Design Sub Scale Flight Results Sub Scale Flight Data Charts Sub Scale Post Flight Anaylsis Apogee Seperation Main Parachute Deployment Sub Scale Error Analysis Weight Error Human Error SAFETY Saftey Plan Safety Ackowledgement Risk Mitigation Plan Handling Procedures NAR HIigh Power Rocketry Ssafety Code Adherence Hazardous Material Storage Plan SAFETY BRIEF Pre-Launch Breif LEGAL CONSIDERATIONS Rocket Safety Mitigation Plan...59 APPENDICES...64 APPENDIX A: CDR FLIGHT SHEET

6 APPENDIX B: ROCKSIM MOTOR SIMULATION DATA...66 APPENDIX C: USNA WORK BREAKDOWN STRUCTURE...69 APPENDIX D: REQUIREMENTS VERIFICATION...70 APPENDIX E: OPERATIONAL RISK MANAGEMENT...84 APPENDIX F: LEGAL INFORMATION...86 AMATEUR ROCKETRY LEGAL CONSIDERATIONS...92 APPENDIX G: MATERIAL SAFETY DATA SHEET...84 APPENDIX H: STEM OUTREACH ACTIVITES EDUCATIONAL OUTREACH PLAN APPENDIX I: WIND TUNNEL TEST PLAN Introduction: Philosophy of OPERATIONS Participation Flow Diagrams Figure 1-1. Additive Printing Integration Test Flow Injector System Functional Test Criteria for Success Facilities Materials Test Overview Initial Injector Assembly Test APPENDIX J: FULL SCALE SOLIDWORKS BLUEPRINTS LIST OF FIGURES Figure 1: Expanded view of launch vehicle motor centering rings...12 Figure 2: Expanded view of the Maverick Rocket...13 Figure 3: RockSim 2D model used in simulations...14 Figure 4: SolidWorks Full Scale CAD...14 Figure 5: ATDLS Landing Configuration...15 Figure 6: Sub-Scale Solid Works CAD

7 Figure 7: Launch Vehicle Fin Sleeve...13 Figure 8: 2D Schematic of Fins...14 Figure 9: RockSim Stability Simulations...14 Figure 10: Ogive Nose Cone...15 Figure 11: StrattoLogger CF...15 Figure 12: Trackimo TRK 210 GPS...16 Figure 13: Avionics Bay X-Axis...16 Figure 14: Avionics Bay Y-Axis (Flight Orientation)...17 Figure 15: Black Powder casing and connection joint...18 Figure 16: Jolly Logic Chute Release Device...19 Figure 17: Maverick Rocket flight plan...20 Figure 18: Summit Racing Hose Retainer...21 Figure 19: Drift Calculation Results at 30 mph winds...22 Figure 20: Drift Calculation Results, simulation Figure 21: Full Scale simulation flight...23 Figure 22: K1440 RockSim Simulation...24 Figure 23: K660 RockSim Simulation...24 Figure 24: Aerotech K700 RockSim Simulation...25 Figure 25: Tender Descender 3D CAD...26 Figure 26: Tender Descender Top View...27 Figure 27: Tender Descender Side View CAD...27 Figure 28: Aluminum landing leg...28 Figure 29: McMaster Carr Spring Hinge...29 Figure 30: Raspberry Pi 3B Processor...30 Figure 31: ZILU Battery Pack...31 Figure 32: Mobius Wide Angle Action Camera...32 Figure 33: Raspberry Pi SenseHAT...32 Figure 34: XBee Digital Communication Receiver and Transmitter...33 Figure 35: ATDLS Control Avionics Schematic...34 Figure 36: Ultem Fin Can for Sub Scale Flight...44 Figure 37: Fin Can Secured to lower rocket body...45 Figure 38: Upper Section of rocket with fiber glass coupler

8 Figure 39: 18 Inch Ogvie Fiber glass ogive nose cone...46 Figure 40: Full Sub-Scale Rocket in Launch Configuration...46 Figure 41: Altimeter Data from Subscale Launch...47 Figure 42: Upper Section under drogue after apogee separation...48 Figure 43: Lower Section under drogue after apogee separation...49 Figure 44: Lower Section Under main parachute after Jolly Logic deployment...49 Figure 45: Upper Section under main parachute after Tender Descender deployment...50 Figure 46: Successfully separated Tender Descender...50 Figure 47: Ballast used in Sub-Scale flight...51 Figure 48: Elastic Band left on drogue parachute...52 Figure 49: Partially deployed main parachute on upper section...52 LIST OF TABLES Table 2: Material QFD...17 Table 3: Motor Comparison...25 Table 4 Project Risks...36 Table 5: Proposed Income of Maverick Rockets...40 Table 6: Full Scale Maverick Rocket Itemized Budget...42 Table 7: Machining Risk Mitigation...54 LIST OF ABBREVIATIONS AGL...Above Ground Level ATDLS...Autonomous Target Detection Landing System AIAA...American Institute of Aeronautics and Astronautics BSA...Boy Scouts of America CG...Center of Gravity CP...Center of Pressure DARPA...Defense Advanced Research Projects Agency 6

9 FAA...Federal Aviation Administration GSE...Ground Support Equipment GNC...Guidance, Navigation, Control GPS...Global Positioning System ISR...Intelligence, Surveillance, and Reconnaissance MATLAB...Matrix Laboratory MDRA...Maryland Delaware Rocketry Association MESA...Maryland Mathematics Engineering Science Achievement MSL...Mean Sea Level NAR...National Association of Rocketry NASA...National Aeronautics and Space Administration NESA...National Eagle Scout Association PVC...Polyvinyl Chloride QFD...Quality Function Deployment RSO...Range Safety Officer S-glass...Stiff Fiberglass SRQA...Safety, Reliability, and Quality Assurance STEM...Science, Technology, Engineering, and Mathematics TRA...Tripoli Rocketry Association VTC...Video-teleconferencing and communication USLI...University Student Launch Initiative USNA...United States Naval Academy USNA MSTEM...United States Naval Academy Midshipmen Science, Technology, Engineering, and Mathematics 7

10 1 SUMMARY OF CDR REPORT 1.1 TEAM SUMMARY Team Name: Institution: Mailing Address: Navy Rockets United States Naval Academy Aerospace Engineering Department United States Naval Academy ATTN: NASA Student Launch Capstone Mail Stop 11B 590 Holloway Road Annapolis, MD Project Mentors: Robert Utley (NAR Level 3) NAR # 71782, TRA # 6103 President, Maryland Delaware Rocketry Association Trip Barber (NAR Level 3) Former President National Association of Rocketry Project Title: Maverick 1.2 LAUNCH VEHICLE SUMMARY Table 1: Launch Vehicle Dimensions and Characteristics Overall Length Body Tube Inner Diameter Body Tube Outer Diameter Mass Motor Center of Gravity Center of Pressure inches 6.0 inches 6.15 inches lbs Cesaroni K1440 White Longburn (K261-P) inches inches 1.3 ATLDS SUMMARY The Automatic Target Detection and Landing System is designed to control descent and landing of the lower portion on the Maverick Rocket during its descent performing altitude dependent parachute releases 8

11 2 CHANGES MADE SINCE PROPOSAL 2.1 CHANGES MADE TO VEHICLE CRITERIA The following changes have been made to the vehicle since the initial proposal: The Maverick rocket will no longer split into 3 sections at apogee. The Maverick rocket will now separate into two sections at apogee which will descend under drogue parachute independently. At a preprogrammed altitude, the main parachute will release and the target detection sequence will initiate 2.2 CHANGES MADE TO ATDLS CRITERIA The following changes have been made to the ATDLS since the initial proposal: The ATDLS system will no longer require the use of an onboard drone and will now operate under descent of a parachute. The ATDLS will also not be a separate section of the Maverick rocket and instead will be integrated with the upper portion of the rocket. 2.3 CHANGES TO PROJECT PLAN The following changes have been made to the project plan since the initial proposal: No changes have been made to the project plan since the initial proposal. 9

12 3 VEHICLE CRITERIA 3.1 SELECTION, DESIGN, AND VERIFICATION OF LAUNCH VEHICLE MISSION STATEMENT, REQUIREMENTS, AND SUCCESS CRITERIA The mission of the Navy Rockets launch vehicle is to autonomously reach and apogee of 5,280 feet AGL, deploy recovery systems for 2 separate sections of the rocket during descent, use on board camera system to make mid descent course corrections, deploy landing gear, and land on target with a force not to exceed 75 ft-lbs. The mission will be considered a success if the rocket reaches an apogee of 5,280 feet AGL +/- 50 feet, deploys 2 separate recovery systems, lands upright on the target using onboard avionics to make course corrections, and can be ready to launch again in 2 hours DESIGN REVIEW AT SYSTEM LEVEL This year the mission for Navy Rockets is different than years past and thus requires a complete overhaul and new design from last year s rocket. This year s team will incorporate management lessons learned from previous years. This year the rocket team was able to launch Level-1 Kits within two weeks of convening as a team in order to acclimate everyone to working with rockets and meeting our mentor at the Maryland Delaware Rocketry Association (MDRA). The rocket will use a Cesaroni K1440 motor to propel if off the launch stand to apogee. At apogee it will separate deploying the landing legs and exposing the target detection imager. The deployment of the drogue and main parachutes for each section will be controlled using the Jolly Logic Chute Release Device. The avionics will be responsible for processing the imagery and saving the image that successfully detects the targets and it will run through as Raspberry Pi 3B processor. 10

13 4 ROCKET DESIGN 4.1 ROCKET BODY The rocket body will be made from six-inch inner diameter carbon fiber tubing. The outer diameter of the rocket body will be 6.15 inches and will be inches tall when fully assembled and the inner diameter of the rocket body will be 6.00 inches. The avionics housings will be made of 3D printed Ultem. The body sections will each be constructed of the carbon fiber tubing. Any signals needed for data analysis will be propagated via antenna in the fiberglass nose cone, to avoid the Faraday s cage created by the carbon fiber. Post-separation, signal propagation will not be an issue as the ends of each rocket section will be open and have space for antennas to transmit. There will be a bulkhead in the motor section of the body tube to separate the motor section from the other sections of the rocket. The bulkhead in the motor portion of the rocket, and the mounting points for the avionics housings will serve as mounts for the parachute retainers. The bottom section of the body will contain the motor. It will be held in place by a bulkhead at the top and two centering rings that are 0.5 inches thick and attached with epoxy to the body of the launch vehicle. This will allow the motor mount to be removable. The fin sleeve will be constructed of 3D printed Ultem, and will be attached as an external sleeve to the bottom of the rocket, freeing the centering rings from needing to accommodate the fins. The fin sleeve will be bolted into the centering rings through the carbon fiber body. An expanded view can be seen in Figure 1. The bottom ring with the extrusion (1) will have threads (not shown in the figure) that will allow a cap to cover and hold the motor in place once the motor is slid through the center. The ring above, without fin slide holes (2), will be detachable and prevents the fins from sliding out once screwed in. The third ring from the bottom with the fin slots (3) will be attached to the launch vehicle body with epoxy and will be responsible for preventing the motor and fins from falling out of the launch vehicle body. The three bottom rings will be held in place with screws. 11

14 Figure 1: Expanded view of launch vehicle motor centering rings The full design of the rocket body was made using SolidWorks to produce CAD drawings that match the dimensions and the scale of the rocket that will be used in the Full Scale. These CAD drawings can be found in Figures

15 Figure 2: Expanded view of the Maverick Rocket 13

16 Figure 3: RockSim 2D model used in simulations Figure 4: SolidWorks Full Scale CAD 14

17 Figure 5: ATDLS Landing Configuration 15

18 Figure 6: Sub-Scale Solid Works CAD MATERIAL SELECTION Carbon fiber was selected for its superior strength, low weight, and high availability to the team. The cost was significantly higher than alternative materials such as fiberglass and cardboard, but the cost difference was not significant enough to push the design out of budget. Carbon fiber s low density allowed a reduction in launch vehicle dimensions and motor size necessary to push the 5280 feet. Carbon fiber will be used throughout the majority of the launch vehicle s body to decrease weight and increase strength. The nose cone will be made of fiberglass, and the avionics bays will be made of 3D printed materials in order to allow signals to pass through these sections. Carbon fiber and fiberglass are common materials used in high power rocketry. A house of quality was used to determine the strengths and weaknesses of using each material. The house of quality uses the Quality Function Deployment System (QFD). The QFD system allows important characteristics of materials to be compared and weighed against each other. The number values correspond to impact as follows: 1. Low importance 2. Medium importance 3. Critical importance 16

19 This weighing system allows important factors to outweigh less desired ones. If the material being judged met the description of the material factor, it was given a positive weight score. If it did not match the description of the material factor, it was given a negative weight score. If the material factor did not stand out as a factor, a negligible score of zero was given. The Material QFD for carbon fiber and fiberglass is shown in Table 2. Table 2: Material QFD Materials Material Factor Weighting Factor Carbon Fiber Fiberglass Low cost High availability Compact rocket size Low weight Easy production High tensile strength High compressive High stiffness High heat resistance High Young's modulus Large motor selection Total

20 4.1.2 FINS The launch vehicle s fins will be additively manufactured from FAA rated Ultem plastic. The benefit of this manufacturing method is that several backup fins can be created and replaced should any of them break. The design is based off of a NACA 0006 airfoil which will provide the necessary correcting force for stable flight. There will be four fins separated at 90 o off the centerline at the base of the launch vehicle. The fin sleeve itself will be assembled as a sleeve to go over the exterior of the carbon fiber body to allow for quick replacement. Fillets will be placed in the areas of highly concentrated stresses to ensure material integrity. The fin sleeve will be secured into the carbon fiber body by using 3 inch galvanized bolts with washers on the exterior and nuts on the inside to secure the fin sleeve in place. The bolts will be arranged in columns of two 45 o off a fin producing an even stress pattern around the circumference of the Maverick rocket. This will allow for a secure fitting and provide the easiest. The length of the fin root is 8 inches long and tapers at a 45 o angle from the top extending out 4 inches to the tip. The tip will maintain the NACA 0006 airfoil but half the dimensions of the root. Success criteria for the fins will depend on their ability to provide a correcting moment for straight flight upward and will be tested in the wind tunnels with a scale model launch vehicle. A schematic of the fin is shown in Figure 7 sketch with dimensions is shown in Figure 8. Figure 7: Launch Vehicle Fin Sleeve 13

21 Figure 8: 2D Schematic of Fins Internally the fins will use a honeycomb support structure. This will significantly reduce the weight of the fin can assembly at the bottom of the rocket. This reduction in weight will yield a greater stability margin for the Maverick rocket. The simulations from RockSim support a stability margin well over the required margin of 2. The maverick rocket will have a stability margin of The results of the RockSim Simulation are reproduced below in Figure 9. Figure 9: RockSim Stability Simulations To help with the complex rendering of the honeycomb internal support system a shop technician will help with the design process and will oversee manufacturing NOSE CONE The nose cone will be made out of fiberglass. This was chosen over Ultem due to the ability to quickly manufacture the nose cone in the event of a damaging anomaly. This allows for electronic signals from the onboard GPS to be sent through the nose cone during descent saving the need to construct a separate antennas bay due to the Faraday s cage caused by the carbon fiber body. It will measure 24 inches tall and will have a diameter of 6 in. The total weight of the nose cone will be lbs. The success of the cone relies on its ability to be structurally sound, lightweight, and cause minimal drag on the launch vehicle overall. An ogive nose cone will be used in the full scale design and can be seen below in Figure

22 Figure 10: Ogive Nose Cone 4.2 AVIONICS ALTIMETER AND GPS The rocket will be using two PerfectFlite StrattoLogger CF as the as the primary altimeters for the two separate sections during flight. For tracking the rocket will be using the Trackimo TRK120 GPS and accompanying software. The two separate sections of the rocket will have redundant systems in order to ensure a safe descent and timely recovery during the mission. The StrattoLogger CF will provide live altitude, velocity, and location data to a computer located at the Navy Rockets ground station. The StrattoLogger CF avionics component is pictured below in Figure 11. Figure 11: StrattoLogger CF The choice to use two separate devices for altimeter and GPS came from safety concerns over the possibility of a premature ignition of the black powder separation charge, similar to the incident that occurred last year with the AIM XTRA 2.0 GPS altimeter combination. Extensive testing will be done on the ground to ensure that the electronics are not prone to interference from ambient radio waves on the launch pad. The Trackimo TRK210 is pictured below in Figure

23 Figure 12: Trackimo TRK 210 GPS All avionics will be kept in an Ultem printed avionics bay. This will allow for one area that contains all the avionics for simplicity during rebuild and repair. This will also allow for a switch in a common location that can turn on all needed avionics once the rocket is safely on the pad. The avionics bay proposed design is seen below in Figures Figure 13: Avionics Bay X-Axis 16

24 6.00 inches 2.00 inches inches Figure 14: Avionics Bay Y-Axis (Flight Orientation) The Ultem avionics bay will act as the anchoring point for the parachute tubular nylon securing point and will house the camera that will work with the ATDLS. The avionics bay will also act as the coupler and will extend 12 into the lower section of the rocket body and 6 into the upper portion of the rocket body. This distance will ensure proper stability during flight. The lower section will be secured into the avionics bay Ultem by using nylon shear screws and the upper section will be bolted in using aluminum bolts to sure that the bay can be taken out quickly and replaced if needed. The middle extrusion, which will be flush with the carbon fiber rocket body, will contain the switches for the avionics. The middle extrusion will be 2 in length, the total length of the avionics bay is 20. This will fulfill the safety requirement and allow the avionics to not be turned on, until they are on the pad and approved by the Range Safety Officer. There will be 4 nylon shear screws 90 o apart around the circumference of the rocket body. The ground separation testing will ensure that the amount of black powder can successfully separate the lower portion of the rocket body at apogee. There will be 1/8 aluminum sheeting protecting the camera and all sensitive avionics from the separation blast as well as 17

25 a Nomex sheet which will allow the camera to remain free of debris that can be caused from the separation charge at apogee RECOVERY INTEGRATION In order to ensure a controlled and accurate descent the recovery equipment must be integrated with the avionics to ensure deployment at the correct height. The Maverick rocket will come down in two separate sections requiring on 60 parachute and one 60 parachute and dual redundant avionic systems to ensure a safe descent. At apogee, the onboard altimeter will send a current to the black power charges at the disconnection joints and send the two sections down from apogee. In order to ensure a clean separation at apogee 1.1 grams of black powder is being used in both charge blocks. To protect the parachutes during the ejection blast, 1 yd 2 of Nomex will be placed in the rocket tube protecting the parachute from the blast. The disconnection joint with black powder charge location is seen below in Figure 15.. Figure 15: Black Powder casing and connection joint At the time of separation a 24 drogue parachute will deploy from both sections to keep them stable and in the proper orientation during descent. With the use of a JollyLogic Chute release device, the main parachute for both sections will be deployed at 700 ft. AGL. The top section, in accordance with the flight plan, will deploy the landing legs at this altitude as well. The JollyLogic Chute Release is seen below in Figure

26 Figure 16: Jolly Logic Chute Release Device The JollyLogic Chute Release device will be set to release the main chute from is packaging at 700 ft. AGL. During the descent phase, real time altitude, location, and velocity will be sent to a laptop at the ground station providing telemetry data from the Trackimo TRK210 GPS system on the Maverick Rocket. The entire flight plan is seen below in Figure 17 with annotations directly below. 19

27 700 ft Figure 17: Maverick Rocket flight plan 1. CP 1, Maverick Launch 2. CP 2, at apogee, separation charge fires 3. CP 3a, the lower section of Maverick will fall under drogue parachute until an altitude of 700 ft. AGL. 4. CP 3b, the main parachute will deploy at an altitude of 700 ft AGL 5. CP 3c, the lower section of the Maverick rocket will land and be tracked via GPS 6. CP 4, at apogee the legs will deploy from the retainers on the lower section, are rotated to their landing position on the upper section, and the drogue parachute will deploy. 7. CP 5, the upper section of Maverick will deploy its parachute at 700 ft AGL and the ATDLS will begin detecting the targets on the ground. 8. CP 6, the upper section main chute will control the descent to 0 ft to perform an upright landing and an image of the different targets will be saved for post mission analysis. At CP4 the 4 the legs will be released from their launch orientation in CP 1. The legs will be held to the side of the body through the use of a Summit Racing Hose Retainer. The hose retainer will fit around the 0.75 landing leg and keep it in the launch configuration. At the time of separation, the leg will be attached to the upper portion of the rocket and will slide out of the retaining rings allowing 20

28 them to expand into their landing configuration. The Summit Racing Hose Retainer is seen below in Figure DRIFT ANALYSIS Figure 18: Summit Racing Hose Retainer During the descent of the rocket, it will be in two parts. Each part will have a 60 parachute and a 24 drogue parachute. The main parachute will be released at 700 ft AGL. The drift due to wind was calculated at several different decent rates and wind speeds. The total drift displacement was calculated using the Visual Drift Distance Calculator mobile app, and RockSim simulations. With a decent rate of 28 ft/s and wind speed of 20 MPH the total drift distance was calculated to be 1026 ft from the launch site. With a decent rate of 28 ft/s and wind speed of 30 MPH the total drift distance was calculated to be 1571 ft from the launch site. With a decent rate of 30 ft/s and wind speed of 20 MPH the total drift distance was calculated to be 978 ft from the launch site. With a decent rate of 30 ft/s and wind speed of 30 MPH the total drift distance was calculated to be 1466 ft from the launch site. Pictures of the analysis can be seen below in Figures

29 Figure 19: Drift Calculation Results at 30 mph winds Figure 20: Drift Calculation Results, simulation 2 22

30 4.3 PROPULSION The launch vehicle will be powered by a commercially available Ammonium-Perchlorate Composite Propellant (APCP) solid rocket motor. The primary goal of motor selection is safely reaching 5,280 ft. AGL apogee. Using a Cesaroni K1440 solid rocket motor the Maverick rocket has reached an altitude of ft in RockSim simulations with no environmental wind. These simulations were run modeling the full weight of the Maverick with the motor and are reproduced in Figure 21. Figure 21: Full Scale simulation flight The graphical representation of the RockSim simulations for different potential motor selections are reproduced below in Figure

31 Figure 22: K1440 RockSim Simulation Figure 23: K660 RockSim Simulation 24

32 Figure 24: Aerotech K700 RockSim Simulation The propulsion assembly must be re-loadable within two hours in accordance with (IAW) NASA USLI project requirements. It will be loaded into the reusable Cesaroni P54-6G motor casing and secured into the motor centering rings seen in Figure 1. The Cesaroni K1440 was chosen due to its ability to allow for a tolerance 8.1% on required apogee. The tolerance is needed because the final weight of the Maverick rocket is designed to be lbs, and having a tolerance allows for changes to the design if needed during the full scale build. The performance characteristics of a Cesaroni K1440 motor compared to other potential motors are given in Table 3. Table 3: Motor Comparison This table is representative of the performance of the rocket in wind speeds of miles per hour which is the average wind speed in Huntsville, AL in the month of April according to weather.com. Using realistic environmental scenarios is important to ensure the highest probability of reaching a maximum apogee of 5280 ft AGL. If the wind is 0 mph on launch day, the Cesaroni K1440 motor will allow the Maverick rocket to reach an apogee of AGL. On launch day the Navy Rockets team will take wind speed measurements and will adjust the ballast accordingly to not exceed the mission apogee. Navy Rockets will not exceed the 10% ballast maximum regulation set forth in the NASA 25

33 USLI Competition. Comparing the motors allowed for a clear choice to be made in favor of the Cesaroni K1440 solid rocket motor due to its desirable performance with the predicted Maverick characteristics and mission parameters. 4.4 TENDER DESCENDER The device, shown in Figures 25-27, holds two D-Rings together with the Coupler Frame and Pin and will be fired to allow for the deployment of the main parachute at the programmed altitude. The inside the Pin Housing is a small black powder charge. This charge is ignited by an electric match controlled by the StrattoLogger Main Chute Leads. Once ignited, it will cause the pin to separate from the frame, allowing the D-Rings to separate. The separation of the D rings allows the weight of the rocket to pull on the shroud lines of the main parachute releasing it from the deployment bag and placing the rocket under a fully deployed main parachute. This device will be tested prior to being used on the sub-scale. The results of these tests are detailed in Figure 25: Tender Descender 3D CAD 26

34 Figure 26: Tender Descender Top View Figure 27: Tender Descender Side View CAD 27

35 4.5 LANDING LEGS FOR ATDLS In order to achieve objective of the NASA USLI the ATDLS will have four deployable aluminum legs that will be attached at a pivot point on the interior of the Maverick rocket. The legs will be 30 long and will be made out of 0.5 diameter tubular aluminum. The aluminum landing leg is pictured below in Figure 28. The diagonal cut at the top of the landing leg allows the leg to sit flush against the rocket body when deployed. The pivot point will be located at the bottom of the diagonal cut on the aluminum landing leg. Figure 28: Aluminum landing leg The hinge will be secured at the top of the distance of the upper section of the Maverick rocket. The launch configuration of the ATDLS landing legs is shown in Figure 2. At CP 4 in Figure 12, the legs will be released from the launch position. Under tension from a McMaster Carr spring hinge, the legs will rotate approximately 30 o to lock into place in the landing configuration. The McMaster Carr spring hinge is located in Figure

36 Figure 29: McMaster Carr Spring Hinge Securing the legs in place will be an aluminum backstop plate that will be secured against the exterior of the rocket body this will ensure that the force of impact on the ground does not cause the aluminum legs to pierce side of the carbon fiber rocket body. Upon full deployment, the top of the landing legs will be pressed against the backstop plate and the constant tension provided by the spring hinges will provide the needed force to secure the legs to the side of the body and maintain them in the landing configuration. The ATDLS will have four landing legs that will support the load of the approximate 8 lb. lander. A four-leg design was chosen because of its ability to provide the most stable configuration in the event that a leg does not deploy or does not properly lock into place at CP 4. In the launch configuration, the legs added drag to the Maverick Rocket. The United States Naval Academy Eiffel wind tunnel will be used to measure the coefficient of drag in full launch configuration. This coefficient of drag will be inputted into RockSim with the Cesaroni K1440 motor to gain a more precise apogee of the Maverick rocket. 29

37 4.6 ONBOARD COMPUTATION AND TELEMETRY Separate from the Recovery Control Avionics, the onboard electronics will include components which will gather precise flight data for telemetry, a radio to transmit status and telemetry information to the ground station, and image processing to identify the ground targets, in order to achieve objective IAW the NASA USLI. These components will run totally separate from the Recovery Control Avionics, although they will be housed in the same Avionics Bay on the rocket MAIN ONBOARD PROCESSOR The Main Processor used for the rocket will be a Raspberry Pi 3B. This will provide for both the image processing and flight data telemetry processing. The Pi 3B is a small profile, 1.2 GHz 64 bit processor with multiple USB and GPIO pins to connect to the needed peripherals such as altimeters, radio transmitters and the camera. It is shown below in Figure 30. Figure 30: Raspberry Pi 3B Processor The Processor will be programmed to do three tasks: Image Processing, Telemetry Data Processing, and Ground Communication Control. Image Processing will involve taking the collected imagery data from the camera and analyzing it in order to identify the three targets during descent. The imagery will be processed in real time using a classifier program which will be trained using imagery collected here on campus. The classifier will be able to filter areas of the image based on their color, and then identify the tarps using data fields such as bit area, side length of groupings, and altitude. The Telemetry Data Processing Function will take raw data collected from a designated Stratologger CF Altimeter and a Raspberry Pi Sense Hat (discussed below), and use this data to calculate a record accurate altitude, velocity, acceleration and orientation. This data will be recorded onboard as well as transmitted to the ground station to be used to verify altitude and flight performance. 30

38 The final function of the Processor will be Ground Communication Control. This will manage communication to the Ground Station to report rocket status and telemetry. It will be connected to the XBee Transmitter. The Raspberry Pi 3B requires a 5V power sources at 1.2A. This will be provided using a ZILU Smart Power Basic 4400mAh external battery. With this power source, the processor can run for approx. 3 hours and 40 minutes. The ZILU is pictured below in Figure 31. Figure 31: ZILU Battery Pack MOBIUS ACTION CAMERA The image data will be collected using a Mobius Wide Angle Lens Action Camera. This is a low profile camera that can provide 1080P video at 30 frames per second or 720P at 60 frames per second. Either of these modes may be used depending on resolution needs and the limited time on view due to descent. The camera has an 820mAh power source capable of recording for 2 hours. It is pictured below in Figure

39 Figure 32: Mobius Wide Angle Action Camera RASPBERRY PI SENSE HAT In addition to a Stratologger CF altimeter, telemetry data will be collected using a Sense HAT. This is a peripheral designed to be used for the Pi 3B. In addition to an LED Matrix and joystick, the Sense HAT includes an accelerometer, gyroscope, barometer, thermometer, and magnetometer. The Main Processor will use gyro, acceleration, and pressure data from the Sense HAT to calculate telemetry information. The Sense HAT is shown below in Figure 33. Figure 33: Raspberry Pi SenseHAT 32

40 4.6.4 DIGI XBEE RADIO COMMUNICATION Radio Communication from Maverick will be done using a Digi XBee ZigBee radio communicator. This will facilitate the transmission of telemetry and status information to the Ground Station. The ZigBee is a small profile radio transmitter that operates in the 2.4 GHz ISM band with a link budget of 110 db. The ZigBee is shown below in Figure 34. Figure 34: XBee Digital Communication Receiver and Transmitter ONBOARD COMPUTATION AND TELEMETRY HARDWARE SCHEMATIC The Data flow between the separate hardware components of the Onboard Electronics is shown in below in Figure 35. This system will facilitate Maverick in completing all imagery and telemetry requirements for our mission. 33

41 Figure 35: ATDLS Control Avionics Schematic ONBOARD COMPUTATION AND TELEMETRY MISSION COMPLETION STANDARDS Due to the complex nature of the Maverick Electronics, the following completion standards have been developed to guide their development to ensure a successful identification of the targets and rocket performance IAW with NASA USLI guidelines. ATDLS Mission Standards 1. Separation of the Maverick rocket body at 5280 ft. AGL 2. Deployment of drogue parachute at time of separation 3. Deployment of main parachute through Jolly Logic Tender Descender at 800 ft. AGL 4. Deployment of four landing legs from the top portion of the rocket during descent 5. Real-time target identification through the Mobius Wide Angle Action Cam and Raspberry-Pi 3B processor 6. Save copies of the identified images allowing for analysis on the ground to be provided in an after action report. 7. Transmission of status and telemetry of rocket through all stages of flight 34

42 These completion standards will be tested extensively on the ground prior to the full assembly of the Maverick Rocket. These tests will be used to ensure proper functioning equipment and the safety of the team and all observers on the ground. 35

43 5 PERFORMANCE VERIFICATION 5.1 RISK IDENTIFACTION TABLE In order to ensure safety and continued reliability of each component on the Maverick rocket, it is required that each be tested extensively. Each of these tests brings a new risk to the project and will require planning and mitigation plans from the safety officer. Table 3 below identifies possible risks that can potentially rise during the testing an integration of the Maverick rocket avionics, propulsion, and recovery systems. Each test will require a safety plan created by the team s safety officer prior to commencing the test. Potential Hazard TIME Project falls behind schedule RESOURCES Sequestration/Government Shutdown Risk Number 2D 2D Mitigation Table 4 Project Risks Team leader hold team to strict adherence of schedule. Be aware of government shutdown timeline. Develop backup funding and resource plan in case our funding and resources are temporarily on hold due to government shutdown. BUDGET Project goes over budget 2E Keep strict track of budget and purchases. Ensure they are closely correlated with project plan and needs. Budget funds are not allocated 2E Seek as many streams of funding as possible so as not to rely on one too much. SAFETY Chemical burns 3D Wear protective equipment when handling materials Injury from power equipment 2E Require training and to work with a partner and wear safety equipment Motors and black powder exploding 1E Only certified people can handle the materials. Checklists will be in place to ensure proper handling and arming. Fire 3C Strict adherence to fire safety procedures. Fire extinguisher present at all times during direct rocket testing and construction. WEATHER High winds 3A Check weather reports before launching. Adjust as necessary. Inclement Weather 3B Monitor weather reports and on-scene situation before determining whether to proceed with launch LAUNCH 36

44 Catastrophic motor failure 1E Ensure safe handling and installing of the motor by certified members Failure to Ignite 4B Ensure that the igniter is installed properly and it has been inspected Overall Ignition system 2E Ensure that the system is functioning and connected properly failure Rocket frame breaks 2E Test the materials strength before launch Fins break 2E Material testing to ensure the strength of the fins; safe handling of launch vehicle when fins are attached. Shear pins do not shear 1E Conduct batch testing Systems do not have 2E Verify battery levels and connections before launch. enough power Failure to seal payload compartment 1D Payload door testing. AVIONICS/RECOVERY Chute fails to open 2D Properly pack chute so that it opens correctly; test different packing methods before final launch. Chute burns 1E Ensure proper placement of protective material and take fire resistance into consideration during chute selection. The Operational Risk Management (ORM) that was used to create this table is defined in Appendix E. The verification plan for entire project s Statement of Work (SOW) can be found in Appendix D. 5.2 COMPONENT TESTING GROUND EJECTION TEST Ground ejection testing will be performed prior to launch. Prior to testing ejection charges in the launch vehicle, ground testing will be performed using an independent article. This test will be used to validate the quantity of black powder used for the size of the section and the number of shear screws. These tests will also be used to demonstrate control of the electric matches which will detonate the ejection charges. To avoid electromagnetic interference (EMI), electronic components will be tested relative to each other prior to interfacing with ejection charges. EMI testing will be repeated once the components are installed in the launch vehicle. The dangerous potential for EMI interference was demonstrated by last year s team when a GPS transmitter induced a current in the electronic match, leading to premature firing of an ejection charge. Our team s ground testing plan will ensure that this risk is mitigated. Once satisfactory testing of the charges, couplers, and avionics are complete, ground testing of ejection charges will be performed on the launch vehicle. 37

45 SEPARATION CHARGE TEST In order to test the separation charge the rocket was taken to a field at the United States Naval Academy and laid on its side. Using the exact quantity of black powder that would be used on the subscale the electric match was rigged on an external switch that allowed the operator to be behind a blast screen. 4 nylon shear screws were inserted 90 o apart around the circumference of the rocket. The switch was connected to a 9 volt battery and the match was ignited. After ignition a successful separation occurred. The blast plate successfully protected the upper portion of the rocket and allowed the blast to occur in the intended direction. This successful test verified the amount of black powder that would be used in the sub-scale and full-scale rocket LEG DEPLOYMENT TESTING To ensure a proper deployment of the legs at apogee the legs will be mounted on the side of the rocket using the McMaster Carr spring hinges. The legs will be fastened to the side of the rocket in the same method that they will be fastened in the full scale rocket. Using the Racing Hose Clamps to secure the legs to the lower section of the rocket the separation charge was fired in the exact fashion that the ground ejection test was fired. The charge will be fired while the rocket is laying on the ground. The added ground friction will ensure that a successful deployment occurs with enough margin to occur during flight of the rocket. In order to validate the test results the test must be completed 3 times without a failure TENDER DESCENDER TESTING The testing over our self-designed tender descender will be conducted at the United States Naval academy aerospace testing facility. The main goal of the testing will be to observe a clean break between the locking mechanisms, allowing for the parachute to deploy, while still staying attached by tethered string. The testing will involve a total of six people. Two members will be holding either ends of the tender by a six foot line. A third member will be holding the igniter switch with a fourth documenting with video and taking notes. Our safety officer will be present to ensure we are adhering to our safety standards and following procedure. Additionally a member of the USNA aerospace department will be present. A successful test would consist of separation of the components. Additionally the two will need to stay tethered together AVIONICS TEST Avionics that will be used to transmit telemetry data from the Maverick rocket will be tested by setting up the ground station laptop to receive real time data in the Navy Rockets cubicle in Rickover Hall. Once the ground station is set up and verified to be working the avionics suites of both the ATDLS and the propulsion section of the Maverick rocket will be driven 3 miles away from the ground station in opposite directions. Through the use of cell phones the team will communicate to ensure that real time data is being sent by both devices. This will have to be performed two times in order to ensure that the 38

46 avionics package can operate well over the required distance of the mission. Once the test is completed the data will be downloaded and compared to the GPS track of the car from a Garmin 3200i for accuracy. It will be necessary to test the avionics in the fiberglass housing that they will reside in for the duration of the mission to ensure that the housing does not interfere with the communication abilities of the avionics suite MATERIALS AND STRUCTURES TEST A scale model of the launch vehicle will be tested on the sting balance in the Eiffel Wind Tunnel in Rickover 035 at varying Reynolds numbers, and angles of attack. To determine the pressure at different vertical locations, the launch vehicle will be manually pitched on the sting balance. Because the speed of the Eiffel Wind Tunnel limits the Reynolds number, the Reynolds numbers will be characteristic of the boost phase of the actual flight of the full-scale launch vehicle, which is where disturbances are most detrimental to stability of the launch vehicle. The Reynolds number will be limited by the maximum velocity generated by the wind tunnel, and the overall size (namely the length and width) of the test section. The goal of the wind tunnel testing will be to model the pressure distribution along the nose cone of the launch vehicle to measure the drag force and the moment forces on the launch vehicle. These values will also be calculated over a time interval of increasing tunnel speed to analyze the dynamic stability. When analyzing the overall stability of the launch vehicle, the forces measured by the sting force balance will be taken into account. The tabulated pressures will be analyzed using MATLAB, and any instability found by the force balance will be further analyzed by the tabulated pressure readings. Both the full-scale launched vehicle and the subscale launch vehicle will be made of the same materials so no changes will have to be done to compensate for skin-friction drag coefficient; carbon fiber body and fiberglass nose cone. Therefore, the significance of the drag calculated by the sting balance will be attributed to profile drag due to that geometry of the launch vehicle and placement of the fins, and not the difference in skin-friction drag due to the material of the launch vehicle. In order to ensure structural integrity of the carbon fiber exterior tubing at apogee the ground ejection test will be performed using the carbon fiber body to observe the reaction of the material under the explosive and violent forces experienced at the time of separation. During ground ejection testing and subscale launch, the fiberglass nose cone will be evaluated for wear and durability. The 3D printed materials are rated for the forces intended during launch, but will also be subjected to ground ejection testing to assure their strength. 39

47 6 BUDGET ANALYSIS 6.1 BUDGET The success of Navy Rockets depends on the ability to build and complete the mission, but relying on that is maintaining a proper budget that will allow for proper purchasing of materials and needed components. Below is the proposed income of the Maverick Rocket team. Table 5: Proposed Income of Maverick Rockets Expected Income, NAVSEA* $9, PEO IWS* $8, Total $17, *Denotes a non-finalized source of income. Maintain a proper budget requires not going over the allotted funds to the team. The Maverick Rocket expected spending is below in Table 6. 40

48 Table 6: Expected Costs of the Maverick Rockets Project Expected Costs, Full Scale $5, Subscale $ Testing and Development $ Support $ Travel $10, Outreach $ Total $17, The itemized full scale rocket budget is broken down below in Table 7. 41

49 Table 6: Full Scale Maverick Rocket Itemized Budget Full Scale Itemized Budget Subsystem Item Unit Cost Quantity Total Cost 6 diameter carbon fiber tube $ $ Resin $ $82.05 Rocket Structure Hardener $ $33.35 Internal Structures and Payload Bay $ N/A $ Miscellaneous Fasteners $50.00 N/A $50.00 AIM XTRA + Base $ $ PerfectFlite Stratologger Altimeter $ $ Iris Ultra 60 Standard Parachute $ $ Rocketman Enterprises Low Porosity Chute $ $ Elliptical Parachute $ $60.00 Avionics and Recovery 6 fiberglass tube $ $ Tubular White Nylon 9/16" $57.50 N/A $34.80 Miscellaneous Fasteners and Components $35.00 N/A $35.00 Steel and Aluminum Framing $ N/A $ Raspberry Pi Avionics Suite $ $ Miscellaneous Fasteners $ N/A $ Propulsion K660 54mm Motor $ $

50 54mm Motor Casing $ $84.69 Total $5,

51 7 SUB-SCALE TESTING 7.1 SUB-SCALE TESTING PLAN The subscale flight had three main objectives. 1. To test the functionality of the fin can in keeping the rocket stable, 2. To test the Tender Descender and its ability to separate the main and drogue parachute at a programmed altitude. 3. To test the performance of the separation charges at apogee. All of these objectives were met for a successful sub-scale launch on 04 DEC 16 at the MDRA Launch Range. Originally the sub-scale test flight was additionally going to test the functionality of the legs but due to the size of the rocket body, the legs were not able to fit with the spring hinges around the exterior of the rocket body. This will be a key test point in the first full-scale test flight 7.2 SUB-SCALE ROCKET DESIGN The rocket that was used in the sub-scale launch was a two section carbon fiber body rocket. The rocket had a fiberglass 18 inch ogive nose cane and an Ultem fin can at the bottom of the rocket. The fin can that was used can be seen below in Figure 36. Figure 36: Ultem Fin Can for Sub Scale Flight The fin can was attached to the body in the same manner that it will be attached in the Full Scale to test for the reliability of the connection under flight loads. The nose cone was also attached in the same fashion that will be used in the full scale this was to test the black powder separation charges to see if 44

52 the calculated amount could separate the nose cone at apogee. The two sections were combined using a fiber glass coupler and nylon shear pins. The fully assembled rocket is seen below in Figures Figure 37: Fin Can Secured to lower rocket body Figure 38: Upper Section of rocket with fiber glass coupler 45

53 Figure 39: 18 Inch Ogvie Fiber glass ogive nose cone Figure 40: Full Sub-Scale Rocket in Launch Configuration 46

54 7.3 SUB SCALE FLIGHT RESULTS The Sub-Scale flight took place on 4 DEC at the Maryland Delaware Rocketry Association launch facilities at Central Sod Farm. The rocket was launched using a K1200 Cesaroni Motor and 1.1 grams of black powder for all separation charges. Full videos of the launch can be seen on the Navy Rocket Team s Facebook page SUB SCALE FLIGHT DATA CHARTS Using the data from the StrattoLogger CF altimeter the following data plots were extrapolated for analysis. The peak altitude reached was 3,342 ft AGL. The following graphs provide altitude vs time, velocity vs time, and acceleration vs time plots that are being used to determine the accuracy of the RockSim simulations for future flights and the error that should be considered in predictions for the full scale. The plots of the flight from the altimeter can be seen in Figure 41. Figure 41: Altimeter Data from Subscale Launch 47

55 7.4 SUB SCALE POST FLIGHT ANAYLSIS APOGEE SEPERATION At apogee the StrattoLogger CF altimeter separated the rocket into two sections successfully and deployed the drogue parachutes that guided the rocket during descent to 700 ft AGL. Figure 42: Upper Section under drogue after apogee separation 48

56 Figure 43: Lower Section under drogue after apogee separation MAIN PARACHUTE DEPLOYMENT The sub-scale launch tested out the two deployment methods. The lower section used a JollyLogic chute release device and the upper section used the custom designed Tender Descender. Both operated successfully during the sub-scale flight. During descent, there was an audible pop, signifying the separation charge going off on the tender descender. The results of the main parachute deployment can be seen below in Figure Figure 44: Lower Section Under main parachute after Jolly Logic deployment 49

57 Figure 45: Upper Section under main parachute after Tender Descender deployment 7.5 SUB SCALE ERROR ANALYSIS Figure 46: Successfully separated Tender Descender WEIGHT ERROR The initial projected weights and simulations of the sub-scale rocket were off due to last minute design changes which required shortening the rocket reducing the weight. This reduction of weight and length was never factored into RockSim as a result the stability margin was below the required 2 when the 50

58 rocket was first assembled. To remediate this, ballast was stored in the nose cone. When the ballast was in place the stability margin returned to The ballast that was used was within the NASA USLI requirement of less than 10% of the overall rocket weight when fully assembled. The ballast that was used can be seen in Figure 47. Figure 47: Ballast used in Sub-Scale flight HUMAN ERROR The largest error in the sub-scale flight was human error. In the upper section the parachute deployment required the drogue chute to pull the main parachute out of the deployment bag once the tender descender fired allowing the drogue to pull the parachute out. While the tender descender did set the charge off allowing the drogue chute to pull the main parachute out of the deployment bag, it was unable to because the elastic band securing the drogue parachute during transport was never taken off. This prevented wind from filling the parachute and completing the mission. The secured drogue parachute can be seen below in Figure

59 Figure 48: Elastic Band left on drogue parachute However due to a successful operation of the Tender Descender the main parachute was almost deployed based off of aerodynamic forces alone. The partially deployed main parachute can be seen in Figure 49. Figure 49: Partially deployed main parachute on upper section 52

60 The human error was isolated to a single event in the sub-scale and to ensure that is does not occur anymore a more thorough step by step launch day procedure has been put into place to ensure that this does not happen in future launches. Overall the launch was a success and allowed the team to verify the performance of the StrattoLogger CF, JollyLogic, and the custom built Tender Descender. These components will be vital to the success of the full scale design. 53

61 7 SAFETY 7.1 SAFETY PLAN SAFETY ACKNOWLEDGEMENT Navy Rockets acknowledges the inherent danger in rocket work and that careful steps must be taken to minimize the risk of mishap or injury. The team has developed safety plans to ensure the team, the project, and the equipment are not harmed during the course of the project. Each member of Navy Rockets is committed to maintaining a safe environment in attempt to prevent any damage or injury that may occur before or during the competition. A signed statement of this acknowledgement is included in Appendix B RISK MITIGATION PLAN Although the team places a high priority on safety, some activities and work can still be dangerous to the team and equipment. Some of the major hazards that might occur during this project can be found in Table 8. The graphics for the safety scaling can be found in this appendix as well. Table 7: Machining Risk Mitigation Hazard Risk number Mitigation Machine usage 2E Everyone will be qualified to use the equipment and will work with a partner Chemical spills 3D PPE will be used when working with chemicals Unexpected explosion of motor or black powder 1E Only certified team members will handle explosives and they will be stored properly Misfire of the motor or black powder while testing 1E Once the area is safe the materials will be disarmed Improper flight of the rocket 2D Obey the RSO and all NAR distances rules The fabrication of the rocket will occur in the Rickover Hall Machine Shop at the United States Naval Academy. The shop has a dedicated staff of experts in the fields of metalwork, composite materials, and woodworking. This staff will help teach the members of Navy Rockets how to safely operate equipment while under their supervision. The Machine Shop will also teach building techniques that the team will be able to use during the production of the rocket. All after-hours work in the shop requires notification at least one day in advance. The Machine Shop requires that all team members have a partner when working after hours. Also, the team limited to the use of hand tools when the shop staff is not present. 54

62 During the competition, the team will be required to complete testing on the rocket, its systems, and the payload in order to confirm the project has attained the desired results. Each test, modification, and launch will be properly documented. Each event will also be preceded by a safety brief in order to properly identify and discuss new and persisting hazards HANDLING PROCEDURES The National Association of Rocketry (NAR) and the Tripoli Rocketry Association (TRA) have developed their own safety codes. These codes, included in 7.1.4, give an outline of procedures that have been established to keep the launches safe for all involved. All members will adhere to the rules and regulations that NAR and TRA have established for high power rocketry. On launch day, the Range Safety Officer (RSO) will make a final inspection of the rocket to ensure it is safe. All members will comply with any RSO decision. The handling of hazardous material will only be done by persons qualified to use that material. The level-one rocket motors will be handled by the team members that are certified during sub-scale testing. The purchase, storage, and transportation of higher level rocket motors will be done by the team s MDRA mentor. This mentor will observe all team launches in order to share their knowledge and ensure materials are handled properly. Many of the materials used during the competition have hazards associated with them. A list of potential material hazards can be found in Appendix F. Paper copies of all of the hazard information will be kept in the design room for reference by all members. Additionally, members of the team will be briefed by the Safety Officer on all material hazards of a specific substance before the substance is used on any part of the project NAR HIGH POWER ROCKETRY SAFETY CODE ADHERENCE 1. Certification. The Navy Rockets Team will only use motors that are permitted by the NASA Student Launch Competition. 2. Materials. The safety officer will ensure that only lightweight materials and ductile metals will be used for the construction of the rocket. 3. Motors. The safety officer, as well as the group mentor, will ensure that only certified, commercially made rocket motors are used, and will not tamper with these motors or use them for any purposes except those recommended by the manufacturer. The safety officer, as well as all group members acting as safety observers, will keep smoking, open flames, and heat sources at least 25 feet away from these motors. 4. Ignition System. The ignition system will be conducted by the RSO. 5. Misfires. Misfires will be handled according to qualified RSO instruction, and a minimum of 60 seconds will be waited until any individual approaches the rocket. 55

63 6. Launch Safety. The qualified RSO will have the final call pertaining to launch safety, with strict adherence to NAR code. 7. Launcher. The launcher will be provided by the NASA Student Launch Competition, and the safety officer will check for adherence to NAR code thereafter. 8. Size. The safety officer and propulsion officer will ensure that the rocket will both: not contain a motor that totals more than 40,960 N-sec (9208 pound-seconds) of total impulse; and that the rocket will not weigh more at liftoff than one-third of the certified average thrust of the rocket motor ignited at launch. 9. Flight Safety. The RSO on the day of the launch will ensure adherence to the NAR flight safety code requirements. 10. Launch Site. The launch site will be determined by the NASA Student Launch Competition. 11. Launcher Location. The launcher location will be determined by the NASA Student Launch Competition. 12. Recovery System. The safety officer will ensure that: all parts of the rocket will use a parachute recovery systems so that all parts of the rocket return safely and undamaged and can be flown again; as well as that only flame-resistant or fireproof recovery system waddings will be used. 13. Recovery Safety. The safety officer will ensure adherence to the NAR recovery safety code requirements HAZARDOUS MATERIAL STORAGE PLAN Black Powder: Black powder will be handled and stored according to BATFE requirements, outlined in the Federal Explosives Law and Regulations handbook. PPE such as eye protection, and rubber gloves will be worn when handling the black powder as well. Ignition systems, being another hazardous material, will not be handled by Navy Rocket Team personnel, as that will be the responsibility of the RSO. Avionics: Avionics hardware can potentially be a hazard to the flammable rocket motors when emitting radio frequencies. Therefore the safety officer will ensure that the avionics equipment is only on and functioning when not in danger of affecting the other hazardous materials. High Powered Motor: Rocket motors are stored in a fireproof locker in the Astronautics Engineering lab decks within Rickover Hall, at the United States Naval Academy. NAR level 3 qualified lab technicians will handle 56

64 any and all motors, when transporting them to and from the competition. They will also handle the shipping, receiving, and transfer to storage of the motors for the Navy Rockets Team. The motors will be transported in a sealed fireproof container, which only the qualified lab technician will have access to. The container will be placed away from excess heat sources as well as other flammable materials (minimum of 25 ft.), within the government van that will be used to transport materials to the competition. 7.2 SAFETY BRIEF In order to guarantee that Navy Rockets will be safe during this competition, a briefing has been developed to keep the team aware of possible dangers. Before any construction or material handling, a safety brief will discuss required precautions. The material hazards and the possible risks and mitigations can be found in Appendices F and C, respectively, and will be referenced as required. The following brief will be issued before the commencement of any building or launch in the yearlong project: 1. Shop Safety a. Wear personal protective equipment while working: i. Ear plugs ii. Gloves (as appropriate) iii. Hard hats iv. Safety glasses b. Always work with a partner 2. Accident Avoidance a. Always read and understand warnings about equipment or material that is being used. b. Call a training timeout if an environment appears unsafe. 3. Launch Day Safety a. The RSO has the final word on the safety of the rocket. b. All launch instructions must be followed and the team needs to be alert while arming the systems. 57

65 4. Materials c. All laws and regulations must be followed. a. Only qualified personnel will handle dangerous materials. (i.e. Black powder, high powered rocket motors, and igniter wires) PRE-LAUNCH BRIEF Before any rocket launch, Navy Rockets will carry out a Pre-Launch Brief. This brief will be issued by the Safety Officer and will discuss the flight plan and any concerns that may arise that day. The Pre-Launch Brief is below: 1. Launch Overview 2. Weather a. Motor selection b. Goals c. Test Reasons and predicted outcomes d. Avionics test a. Launch concerns 3. Rocket Performance a. Weight b. Altitude 4. Flight Conduct 5. Safety a. Initial Stage Separation i. Stage Chute Deployment ii. Tracking b. Secondary Stage Separation i. Stage Drogue Chute Deployment c. ATDLS Initialization and Deployment a. ORM considerations b. Safety concerns 6. Emergencies 7. RSO a. General Emergencies b. Hazards and Mitigation a. Rules 58

66 b. Launch check 7.3 LEGAL CONSIDERATIONS The Navy Rockets team acknowledges the laws governing the use of high power rockets. This includes the FAA regulation on airspace, the Federal Aviation Regulation 14 CFR: Subchapter F: Part 101: Sub-part C, the Code of Federal Regulation 27 Part 55, and the code for the use of low- explosives: NFPA 1127 Code for High Power Model Rocketry. This information can be found in Appendix E. All flight testing for the project will be done with MDRA at their launch sites. MDRA has a FAA flight waiver for the necessary one mile altitude for every weekend of the year. This provides Navy Rockets with the launch capability needed to complete testing on both sub-scale and full-scale launches. MDRA has the intention to have zero injuries during any launch, and the group has multiple qualified Range Safety Officers that ensure everyone is adhering to the rules. 7.4 ROCKET SAFETY MITIGATION PLAN Potential Hazard Risk # Hazard Mechanism Mitigation Plan GENERAL SAFETY RISKS Chemical burns 2D 1. Exposure to corrosive or otherwise dangerous material. Wear protective equipment when handling any potentially corrosive or caustic materials 2. Damage to or failure of batteries or other components. Injury from power equipment 2C 1. Failure to practice proper machine safety habits. 2. Lack of familiarization with applicable equipment. Require training and to work with a partner and wear safety equipment before operating any power machinery. Inexperienced personnel will not operate power machinery without supervision. Motors and black powder exploding prematurely. 1D 1. Improper handling of motors. 2. Improper handling of black power. Strict adherence to safe storage and handling procedure. Motor handling only permitted by designated personnel. 3. Premature activation of charges. 59

67 Fire 1C 1. Improper handling of combustibles. 2. Wiring concern. Strict adherence to fire safety procedures. Fire extinguisher present at all times during direct rocket testing and construction. 3. Inadvertent ignition of explosives/motor. Electrical Injury or damage. 1E 1. Faulty wiring. 2. Contact with high voltage source. 3. Failure to respect electrical safety procedures. Electrical injury risk minimized by low voltages of the launch vehicle electrical systems. Wiring concerns handled in later sections. Any contact with higher voltage machinery will only be done by trained or certified personnel and not by inexperienced team members. WEATHER High winds, leading to offcourse flight or damage due to shear. 3A 1. Choice of launch site / date. Local weather reports are to be consulted before any launch. Final determination on launch will be made onsite. Drift from mild to moderate wind speed mitigated by use of drogue chutes. Inclement Weather (Rain, Snow, etc.) 3B 1. Choice of launch site / date. 2. Global weather patterns. Monitor weather reports and on-scene situation before determining whether to proceed with launch. In the event of lightning any test launches will be immediately scrubbed until weather conditions improve. High Humidity or extreme temperature 3D 1. Choice of launch site / date. 2. Storage of components in locations without climate control. All anticipated tests and launches will occur at latitudes and during seasons where temperature and humidity cannot be expected to reach dangerous levels. In the event that high temperature and humidity is expected, launch decision will be made on a case-by-case basis. Components and launch vehicle are kept in climate controlled conditions at room temperature when not in launch. Low Cloud Floor / Fog 3C 1. Choice of launch site / date. 2. Initial Launch altitude. During inclement or low visibility weather events, launch determination will be made on a case-by-case basis. If a launch does occur, use of GPS capable devices in both the payload and avionics section will enable 60

68 safe recovery of the rocket in the event that visibility is lost at any point. Propulsion Motor ignites prematurely. 1D 1. Premature initiation of connectors. 2. Inadvertent activation of launch by unwitting personnel. Motor ignition is delayed. 2D 1. Motor design problems. 2. Faulty connections. Motor does not ignite. 2D 1. Motor design problems. 2. Faulty connections. Launch vehicle does not reach stable velocity before exiting the launch rail. Structures 1D 1. Insufficient impulse production by motor. 2. Motor does not fully ignite. MODERATE DIFFICULT DIFFICULT EASY Ensure that electronic matches are not energized prior to launch. Protect E-matches from EMF during insertion. Only allow necessary persons near launch vehicle during and following igniter insertion. Ensure stand-off time for approaching launch vehicle if ignition does not occur immediately before establishing a failed ignition. Enforce stand-off time for approaching launch vehicle if ignition is not achieved. Ensure E-matches are deenergized prior to approaching launch vehicle. E- matches checked for continuity prior to insertion. Ensure insertion method reliably reaches the ignition pellet at the top of the motor. Substantial factor of safety in design for expected launch rail exit velocity compared to necessary stable velocity, given vehicle characteristics, motor thrust profile, and launch rail length. Fin failure leading to loss of rocket stability and entire rocket failure 2C 1. Overweight rocket. 2. Insufficiently strong material choice for fins. 3. Launch forces far exceeding design values. MODERATE Fins will be made of 3D printed Ultem and tested for correcting moments and fin flutter to ensure a sufficient factor of safety. Epoxy maximum tensile strength is 7,600 psi, while maximum operating temperature is 225F. Exceeding this value could lead to motor mount failure. Force from parachute ejection causing the eye screw/bulkhead failure 2C 2C 1. Insufficient accounting of the forces rocket is subject to. 2. Occurrence of fire or ignition in vicinity may damage components. 1. Parachute forces far exceeding expected design values. MODERATE MODERATE Design with a sufficient factor of safety using given strength values and test a full scale of the design that includes construction and launch of the rocket. The epoxy failure parameters are considered to be the limiting factor for structural concerns. Components will undergo full investigation and/or replacement if they have been subject inadvertently to high temperature or pressure. Epoxy will not be used on the motor section, only bolts and hardware. The forces of recovery will be measured and calculated to ensure a viable factor of safety. If needed due to safety concerns following initial 61

69 testing, a thickened bulkhead with more contact points for the screws will be implemented. The maximum internal pressure is 170 psi. Exceeding this could cause an explosive structural failure. 1D 1. Incorrect accounting of the forces rocket is subject to. 2. Grossly underestimating system design. MODERATE Ensure in the rocket design that the sections are free of obstructions that could prevent the sections from separating causing overpressure failure. Each section will be tested for fit and friction in ease of sliding. A safety factor of at least 4 will be used as the required pressure for stage ejection. Shear pins do not shear 2D 1. Improper choice in shear pins. Hinges on legs cause body tube to fail. 3D 1. Mounting bracket causes focused amount of force on tube. Tender descender fails. 1E 1. Bracket on descender breaks/shears off. Avionics/Recovery Parachutes don't deploy 1C 1. Improperly packed parachutes. 2. Error with blast charge or avionics. Holes or Tears in Parachute 1D 1. Improper handling. 2. Wear from repeated use. Blast charge fails to fire 2D 1. Poorly packed black powder. 2. Incorrect connection between charge and powder. EASY EASY MODERATE MODERATE EASY MODERATE Batch testing of shear pins to be conducted before implementation in any rocket design. Multiple drop tests will be done on legs and mounting brackets with more force than the tube will undergo. Since rocket will be on the ground when the bracket would fail, no concern exists except for the rocket itself. The descender will be made of machined aluminum. Tensile and pull tests will be performed, including jerk tests where all the force is exerted in a short amount of time to ensure the bracket will be strong enough. Study results from ground ejection and subscale tests to ensure proper ejection which leads to parachute deployment to determine what parts of the process can be improved. Ensure that parachutes are correctly loaded and secured. Other failure modes are addressed below. Parachutes are inspected closely before packing for any evidence of damage. Charges and all wiring for the charges will be tested beforehand and the security officer will conduct a final check before launch to ensure the system is correctly installed. Use of redundant charges to ensure Ejection charges do not separate launch vehicle sections Improper wiring causing shorts or opens in the line, which could lead to premature or failed ignition of charges. 2C 1C 1. Insufficient amount of black powder Contact between wires. 2. Poorly attached or connected wires. DIFFICULT MODERATE The use of redundant ejection charges is intended to mitigate the chance of any specific charge failing to achieve its task. Each charge is capable of separating the launch vehicle sections. Black powder Twist and solder all wiring to each connector in order to reduce the chance of shorting out. Electrical wiring schematic streamlined to minimize the number of required components, connections, and switches. 62

70 Insufficient battery voltage or current for avionics. Altimeter fails to activate during a flight. Altimeters recording inaccurate results. Altimeters chute deployment can occur at an incorrect altitude. Tender descender fails to separate. 2C 3C 3C 4D 1D 1. Reuse of batteries. 2. Failure to inspect battery voltages. 1. Disconnect or loss of battery power. 2. Faulty or damaged altimeter. 1. Damaged components. 2. Pressure variation within the avionics bay. 1. Damaged components. 2. Programming/User Error 1. Power charge in descender is not strong enough. 2. Electric match does not ignite powder charge. EASY MODERATE DIFFICULT DIFFICULT DIFFICULT Use of separate, easily removable 9V batteries for each electronic component. Batteries are to be swapped out and replaced with fresh ones before every flight or test flight. Each altimeter is tested thoroughly to ensure functionality before use in test or official launches. Use of redundant altimeters will allow for normal flight and recovery in the event that one altimeter fails. Audible indicators show that an altimeter has powered on before a flight commence. Each altimeter is cross-referenced with the other altimeters to ensure consistency. Due to the use of two separate brands of altimeter, the possibility of identical, yet inaccurate readout is considered negligible. Altimeters are set to deploy the drogue chute at apogee, whose altitude will depend on the performance of the rocket. Main chute deployment is achieved with redundant altimeters. 500ft main chute deployment selected to ensure that variation by a few feet in either direction will not compromise the integrity of the rocket landing. Multiple tests will be conducted on descender charge itself to determine the proper amount of powder to use, and a factor of safety of 2 will be used. Subscale and full scale launches will both incorporate descenders to ensure their functionality. 63

71 APPENDIX A: CDR FLIGHT SHEET APPENDICES All data is from simulations using the leading design at the time of submission 13 JAN

72 65

73 APPENDIX B: ROCKSIM MOTOR SIMULATION DATA K660 Thrust Curve 66

74 K1220 Thrust Curve K1440 Thrust Curve 67

75 Full scale motor performance comparison 68

76 APPENDIX C: USNA WORK BREAKDOWN STRUCTURE 69

77 APPENDIX D: REQUIREMENTS VERIFICATION Requirement Description and Design Features Verification Plan 1 Vehicle Requirements 1.1 Must deliver payload to an apogee of 5280 ft AGL Design and testing of full scale 1.2 Must carry one barometric altimeter Include in design of Avionics Bay The official scoring altimeter shall report the official competition altitude via a series of beeps to be checked after the competition flight. Team lead verification of altimeter performance Teams may have more than one altimeter if required Team leader purchase needed avionics for design NASA will mark altimeter at LRR Team leader will ensure reviewing official marks altimeter NASA will obtain altitude by listening to audible beeps after launch Team lead will take altimeter to NASA official All electronics must be capable of being turned off Team lead will verify will avionics lead prior to CDR that avionics suite is in compliance Warrant a score of 0 Team lead will ensure design is not in violation of following restrictions Marked altimeter cannot become broken or damaged Team does not report to NASA following launch Altimeter reports an apogee over 5,600 ft Avionics lead will ensure avionics work after full scale test to ensure reliability Team lead will ensure the altimeter is taken to NASA Propulsion lead will ensure that proper tests are preformed to ensure proper altitude The rocket is not flown at competition Team will perform all required launches to ensure eligibility at competition 1.3 Avionics will be powered by commercially available batteries Team lead will ensure the design uses COTS batteries 70

78 1.4 Full scale rocket will be designed to be recoverable and reusable again in the same day Team lead will test reusability of rocket art full scale test to ensure compliance with NASA regulations 1.5 Maximum of 4 independent sections on full scale design Team lead will verify design before fabrication 1.6 Team lead will verify design before The launch vehicle shall be limited to a single stage fabrication 1.7 The launch vehicle shall be capable of being prepared for flight at the launch site within 4 hours The team will do a practice launch day scenario to ensure preparation 1.8 The launch vehicle shall be capable of remaining in a launch ready configuration for a minimum of 1 hour The team will do a practice launch day scenario to ensure preparation 1.9 The launch vehicle shall be capable of being launched by a standard 12 volt direct current The team will do all full scale practice launches with a 12 volt DC power source to ensure compliance 1.10 The launch vehicle shall require no external circuitry or special ground support equipment to initiate launch The team will perform all test launches in competition configuration to ensure compliance 1.11 The launch vehicle shall use a commercially available solid motor propulsion system using ammonium perchlorate composite propellant (APCP) which is approved and certified by the National Association of Rocketry (NAR), Tripoli Rocketry Association (TRA), and/or the Canadian Association of Rocketry (CAR). Team lead will verify design before fabrication Final motor choices must be made by the Critical Design Review (CDR). Team lead will verify design and motor selection prior to fabrication Any motor changes must be approved by NASA after CDR and must be cleared by the RSO Team lead will notify NASA immediately upon a potential motor change 1.12 Pressure vessels will meet the following criteria Team lead will verify design before 71

79 The minimum factor of safety (Burst or Ultimate pressure versus Max Expected Operating Pressure) shall be 4:1 with supporting design documentation included in all milestone reviews. Team lead will verify design before fabrication The low-cycle fatigue life shall be a minimum of 4:1. Team lead will verify design before fabrication Each pressure vessel shall include a solenoid pressure relief valve that sees the full pressure of the tank Team lead will verify design before fabrication Full pedigree of the tank shall be described, including the application for which the tank was designed, and the history of the tank, including the number of pressure cycles put on the tank, by whom, and when. Team lead will verify design before fabrication 1.13 Total impulse shall not exceed 5,120 seconds 1.14 Launch vehicle shall have a minimum static stability of 2.0 prior to launch rail exit Team lead will verify design before fabrication Team lead will verify design before fabrication 1.15 The launch vehicle shall have a rail velocity of 52 fps Team lead will ensure compliance through RockSIm calculations 1.16 All teams will launch and recover a subscale model prior to CDR Team lead will ensure a subscale launch has occurred prior to 30 NOV The subscale model should resemble and perform as similarly as possible to the full-scale model, however, the full-scale shall not be used as the subscale model. Sub scale test will be designed to mimic full scale. This will be verified by the team lead The subscale model shall carry an altimeter capable of reporting the model s apogee altitude Sub scale test will be designed to mimic full scale. This will be verified by the team lead 72

80 1.17 All teams shall successfully launch and recover their full-scale rocket prior to FRR in its final flight configuration. The rocket flown at FRR must be the same rocket to be flown on launch day. The purpose of the full-scale demonstration flight is to demonstrate the launch vehicle s stability, structural integrity, recovery systems, and the team s ability to prepare the launch vehicle for flight. A successful flight is defined as a launch in which all hardware is functioning properly (i.e. drogue chute at apogee, main chute at a lower altitude, functioning tracking devices, etc.). The following criteria must be met during the full scale demonstration flight: Team lead will ensure compliance in design The vehicle and recovery system shall have functioned as designed. Team lead will ensure successful compliance in subscale test plan The payload does not have to be flown during the full-scale test flight. The following requirements still apply: Testing of subscale and full scale rocket If the payload is not flown, mass simulators shall be used to simulate the payload mass Testing of subscale and full scale rocket The mass simulators shall be located in the same approximate location on the rocket as the missing payload mass. Testing of subscale and full scale rocket If the payload changes the external surfaces of the rocket (such Testing of subscale and full scale rocket in as with camera housings or external probes) or manages the compliance with NASA regulations total energy of the vehicle, those systems shall be active during the full-scale demonstration flight The full-scale motor does not have to be flown during the fullscale test flight. However, it is recommended that the full-scale motor be used to demonstrate full flight readiness and altitude verification. If the full-scale motor is not flown during the full- The full scale motor will be planned to be flown in the full scale test flights. The vehicle shall be flown in its fully ballasted configuration during the full-scale test flight. Fully ballasted refers to the same Testing of subscale and full scale rocket amount of ballast that will be flown during the launch day flight. 73

81 After successfully completing the full-scale demonstration flight, the launch vehicle or any of its components shall not be modified All changes after full scale tests will be without the concurrence of the NASA Range Safety Officer immediately forwarded to NASA RSO (RSO) Full scale flights must be completed by the start of FRRs (March Testing of subscale and full scale rocket 6th, 2016). If the Student Launch office determines that a reflight is necessary, than an extension to March 24th, 2016 will be compliance with proper scheduling to ensure granted. This extension is only valid for re-flights; not first time 1.18 Any structural protuberance on the rocket shall be located aft of the burnout center of gravity. Team lead shall verify design prior to fabrication 1.19 Vehicle Prohibitions Team lead shall verify design prior to fabrication The launch vehicle shall not utilize forward canards. Team lead shall verify design prior to fabrication The launch vehicle shall not utilize forward firing motors. Team lead shall verify design prior to fabrication The launch vehicle shall not utilize motors that expel titanium sponges (Sparky, Skidmark, MetalStorm, etc.) Team lead shall verify design prior to fabrication The launch vehicle shall not utilize hybrid motors. Team lead shall verify design prior to fabrication The launch vehicle shall not utilize a cluster of motors. Team lead shall verify design prior to fabrication The launch vehicle shall not utilize friction fitting for motors Team lead shall verify design prior to fabrication 74

82 The launch vehicle shall not exceed Mach 1 at any point during flight. Team lead shall verify design prior to fabrication Vehicle ballast shall not exceed 10% of the total weight of the rocket. Team lead shall verify design prior to fabrication 2 RECOVERY SYSTEM REQUIREMENTS 2.1 The launch vehicle shall stage the deployment of its recovery devices, where a drogue parachute is deployed at apogee and a Recovery lead will ensure that recovery main parachute is deployed at a much lower altitude. Tumble sequence is in full compliance with NASA recovery or streamer recovery from apogee to main parachute regulations deployment is also permissible, provided that kinetic energy during drogue-stage descent is reasonable, as deemed by the Range Safety Officer. 2.2 Each team must perform a successful ground ejection test for both the drogue and main parachutes. This must be done prior to the initial subscale and full scale launches... A sub scale test plan will be written and executed prior to full scale integration 2.3 Drop tests using the ATDLS will be used At landing, each independent sections of the launch vehicle shall to verify compliance with NASA regulation have a maximum kinetic energy of 75 ft-lbf. 2.4 The recovery system electrical circuits shall be completely independent of any payload electrical circuits Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead 2.5 The recovery system shall contain redundant, commercially available altimeters. The term altimeters includes both simple altimeters and more sophisticated flight computers. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead 75

83 2.6 Motor ejection is not a permissible form of primary or secondary deployment. Team lead will verify design prior to full scale test 2.7 Each altimeter shall be armed by a dedicated arming switch that is accessible from the exterior of the rocket airframe when the rocket is in the launch configuration on the launch pad. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead 2.8 Each altimeter shall have a dedicated power supply. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead 2.9 Each arming switch shall be capable of being locked in the ON position for launch. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead 2.10 Removable shear pins shall be used for both the main parachute Structures lead will verify design is in full compartment and the drogue parachute compartment. compliance with NASA regulation prior to fabrication 2.11 An electronic tracking device shall be installed in the launch vehicle and shall transmit the position of the tethered vehicle or any independent section to a ground receiver. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead Any rocket section, or payload component, which lands untethered to the launch vehicle, shall also carry an active electronic tracking device. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead The electronic tracking device shall be fully functional during the official flight on launch day Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead 2.12 The recovery system electronics shall not be adversely affected by any other on-board electronic devices during flight (from launch until landing). Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead The recovery system altimeters shall be physically located in a separate compartment within the vehicle from any other radio frequency transmitting device and/or magnetic wave producing device. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead 76

84 The recovery system electronics shall be shielded from all onboard transmitting devices, to avoid inadvertent excitation of the recovery system electronics. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead The recovery system electronics shall be shielded from all Avionics lead will ensure design is in full onboard devices which may generate magnetic waves (such as compliance with NASA regulations and generators, solenoid valves, and Tesla coils) to avoid inadvertent will be verified by team lead excitation of the recovery system The recovery system electronics shall be shielded from any other onboard devices which may adversely affect the proper operation of the recovery system electronics. Avionics lead will ensure design is in full compliance with NASA regulations and will be verified by team lead 3 EXPERIMENT REQUIREMENTS Each team shall choose one design experiment option from the following list. Team lead will ensure a mission is chosen prior to submitting the RFP to NASA Additional experiments (limit of 1) are encouraged, and may be flown, but they will not contribute to scoring. If time allows the team lead will consult the team about incorporating an additional mission on the rocket If the team chooses to fly additional experiments, they shall provide the appropriate documentation in all design reports so experiments may be reviewed for flight safety. If applicable the team lead will oversee the documentation process for additional experiment Teams shall design an onboard camera system capable of Avionics lead will design avionics suite in identifying and differentiating between 3 randomly placed targets compliance with mission requirements Each target shall be represented by a different colored ground tarp located on the field. Team avionics lead will use provided samples to ensure proper programming for mission completion 77

85 Target samples shall be provided to teams upon acceptance and Team lead will provide proper mailing prior to PDR. address to NASA All targets shall be approximately 40 X40 in size Avionics lead will ensure any ground testing is performed with proper sized samples to ensure quality of test results The three targets will be adjacent to each other, and that group shall be within 300 ft. of the launch pads After identifying and differentiating between the three targets, the launch vehicle section housing the cameras shall land upright, and provide proof of a successful controlled landing. Full scale launch test will replicate launch day scenario to ensure mission completion at competition and preparedness Avionics lead will design avionics suite in compliance with mission requirements Data from the camera system shall be analyzed in real time by a Avionics lead will design avionics suite in custom designed on-board software package that shall identify compliance with mission requirements and differentiate between the three targets. 4 SAFETY REQUIREMENTS 4.1 Each team shall use a launch and safety checklist. The final checklists shall be included in the FRR report and used during the Launch Readiness Review (LRR) and any launch day operations. Team lead will verify all documentation prior to submission 4.2 Each team must identify a student safety officer who shall be responsible for all items in section 4.3. Team lead will appoint a safety officer prior to RFP 4.3 The role and responsibilities of each safety officer shall include, but not limited to: Team Safety Officer will ensure all roles and responsibilities are being accomplished Monitor team activities with an emphasis on Safety during: Team lead will monitor safety enforcement efforts 78

86 Design of vehicle and launcher Team safety lead will approve design from a safety perspective prior to fabrication Construction of vehicle and launcher Team safety lead will approve design from a safety perspective prior to fabrication Assembly of vehicle and launcher Team safety lead will approve design from a safety perspective prior to fabrication Ground testing of vehicle and launcher Team safety lead will approve design from a safety perspective prior to fabrication Sub-scale launch test(s) Team safety lead will approve test plan from a safety perspective prior to fabrication Full-scale launch test(s) Team safety lead will approve test plan from a safety perspective prior to fabrication Launch day Team safety lead will attend all safety briefs and brief the team prior to any action on an active launch range Recovery activities Team safety lead will approve all recovery tests and designs prior to integration Educational Engagement Activities Team safety lead will ensure the safety of guests of the rocket team at all outreach events. Will report directly to team lead Implement procedures developed by the team for construction, assembly, launch, and recovery activities Team safety lead will brief team lead on procedures for the team to follow and ensure their obedience to established procedures 79

87 4.3.3 Manage and maintain current revisions of the team s hazard analyses, failure modes analyses, procedures, and MSDS/chemical inventory data Assist in the writing and development of the team s hazard analyses, failure modes analyses, and procedures. Team safety lead will put all testing plans in the rocket team Safety and prevention binder which will travel to all tests and launch week with the team Team safety officer will ensure that all actions are safe before they are initiated. Will report to team lead if situation becomes unsafe 4.4 Each team shall identify a mentor. A mentor is defined as an adult who is included as a team member, who will be supporting The team mentor will be chosen by PDR the team (or multiple teams) throughout the project year, and and will assist in the project by offering may or may not be affiliated with the school, institution, or guidance and recommendations IAW 5.1 organization. The mentor shall maintain a current certification, and be in good standing, through the National Association of Rocketry (NAR) or Tripoli Rocketry Association (TRA) for the motor impulse of the launch vehicle, and the rocketeer shall have flown and successfully recovered (using electronic, staged recovery) a minimum of 2 flights in this or a higher impulse class, prior to PDR. The mentor is designated as the individual owner of the rocket for liability purposes and must travel with the team to launch week. One travel stipend will be provided per mentor regardless of the number of teams he or she supports. The stipend will only be provided if the team passes FRR and the team and mentor attends launch week in April. 4.5 During test flights, teams shall abide by the rules and guidance of the local rocketry club s RSO. The allowance of certain vehicle configurations and/or payloads at the NASA Student Launch Initiative does not give explicit or implicit authority for teams to fly those certain vehicle configurations and/or payloads at other club launches. Teams should communicate their intentions to the local club s President or Prefect and RSO before attending any NAR or TRA launch. Team lead will be responsible for coordinating with MDRA to ensure all procedures are being followed at each test flight 4.6 Teams shall abide by all rules set forth by the FAA Team lead and safety officer will work together to ensure all legal requirements and documentation are followed and filled out 80

88 5 GENERAL REQUIREMENTS 5.1 Students on the team shall do 100% of the project, including design, construction, written reports, presentations, and flight preparation with the exception of assembling the motors and handling black powder or any variant of ejection charges, or preparing and installing electric matches (to be done by the team s mentor). Team leader will develop a WBS to keep all team members on track to complete the project on team and to all mission requirements 5.2 The team shall provide and maintain a project plan to include, but not limited to the following items: project milestones, budget and community support, checklists, personnel assigned, educational engagement events, and risks and mitigations. The team lead will share the WBS with NASA and the team to ensure everyone is knowledgeable about the major milestones for the yearlong project 5.3 Foreign National (FN) team members shall be identified by the Preliminary Design Review (PDR) and may or may not have access to certain activities during launch week due to security restrictions. In addition, FN s may be separated from their team during these activities. All FNs will be identified to the team lead at the time of sign-ups and will be forwarded to NASA IAW regulation 5.4 The team shall identify all team members attending launch week activities by the Critical Design Review (CDR). Team members The team mentor will be chosen by PDR shall include: and will assist in the project by offering guidance and recommendations IAW Students actively engaged in the project throughout the entire year. One mentor (see requirement 4.4). No more than two adult educators. Team lead will ensure everyone involved knows the project requirements and can be a full participant in the yearlong project The mentor for the team will named prior to PDR and approved through the required channels in the University Team lead will ensure that adult educators are documented IAW NASA regulations 81

89 5.5 The team shall engage a minimum of 200 participants in educational, hands-on science, technology, engineering, and mathematics (STEM) activities, as defined in the Educational Engagement Activity Report, by FRR. An educational engagement activity report shall be completed and submitted within two weeks after completion of an event. A sample of the educational engagement activity report can be found on page 28 of the handbook. Team STEM lead will ensure that all outreach requirements are met and will present a plan to the team lead on a plan for completion 5.6 The team shall develop and host a Web site for project documentation. Team website lead will ensure the website is launched and bug free prior to 31 OCT 5.7 Teams shall post, and make available for download, the required deliverables to the team Web site by the due dates specified in the project timeline. Team lead will ensure all website requirements are met prior to allowing outside access to the website 5.8 All deliverables must be in PDF format. Team lead will handle all deliverables and will ensure that they are in PDF format prior to submission 5.9 In every report, teams shall provide a table of contents including major sections and their respective subsections. Team lead will review documentation for completion requirements prior submission for grading 5.10 In every report, the team shall include the page number at the bottom of the page. Team lead will review documentation for completion requirements prior submission for grading 5.11 The team shall provide any computer equipment necessary to perform a video teleconference with the review board. This includes, but not limited to, a computer system, video camera, speaker telephone, and a broadband Internet connection. If possible, the team shall refrain from use of cellular phones as a means of speakerphone capability Team lead will work with the AV department to ensure NLT 1 week prior to teleconference that all equipment is reserved to allow smooth communication between parties during review sessions 5.12 All teams will be required to use the launch pads provided by Student Launch s launch service provider. No custom pads will be permitted on the launch field. Launch services will have 8 ft rails, and 8 and 12 ft rails available for use. Team propulsion lead will ensure that the launch pad is provided by the launch service provider and no custom pads are being used 82

90 5.13 Teams must implement the Architectural and Transportation Barriers Compliance Board Electronic and Information Technology (EIT) Accessibility Standards (36 CFR Part 1194) Subpart B-Technical Standards ( Software applications and operating systems Web-based intranet and Internet information and applications. Team lead will ensure team is in full compliance with government and NASA regulations at all times during the project 83

91 APPENDIX E: OPERATIONAL RISK MANAGEMENT 84

92 85

93 APPENDIX F: LEGAL INFORMATION 86

94 87

95 88

96 89

97 90

98 91

99 AMATEUR ROCKETRY LEGAL CONSIDERATIONS Applicability. (a) This subpart applies to operating unmanned rockets. However, a person operating an unmanned rocket within a restricted area must comply with (b) (7) (ii) and with any additional limitations imposed by the using or controlling agency. (b) A person operating an unmanned rocket other than an amateur rocket as defined in 1.1 of this chapter must comply with 14 CFR Chapter III Definitions. The following definitions apply to this subpart: (A) Class 1 Model Rocket means an amateur rocket that: (1) uses no more than 125 grams (4.4 ounces) of propellant; (2) Uses a slow-burning propellant; (3) Is made of paper, wood, or breakable plastic; (4) Contains no substantial metal parts; and (5) Weighs no more than 1,500 grams (53 ounces), including the propellant. (b) Class 2 High-Power Rocket means an amateur rocket other than a model rocket that is propelled by a motor or motors having a combined total impulse of 40,960 Newton-seconds (9,208 pound-seconds) or less. (c) Class 3 Advanced High-Power Rocket means an amateur rocket other than a model rocket or high-power rocket General operating limitations. (a) You must operate an amateur rocket in such a manner that it: (1) Is launched on a suborbital trajectory; (2) When launched, must not cross into the territory of a foreign country unless an agreement is in place between the United States and the country of concern; (3) Is unmanned; and (4) Does not create a hazard to persons, property, or other aircraft. 92

100 (b) The FAA may specify additional operating limitations necessary to ensure that air traffic is not adversely affected, and public safety is not jeopardized. 93

101 Operating limitations for Class 2-High Power Rockets and Class 3-Advanced High Power Rockets. When operating Class 2-High Power Rockets or Class 3-Advanced High Power Rockets, you must comply with the General Operating Limitations of In addition, you must not operate Class 2-High Power Rockets or Class 3-Advanced High Power Rockets (a) At any altitude where clouds or obscuring phenomena of more than five-tenths coverage prevails; (b) At any altitude where the horizontal visibility is less than five miles; (c) Into any cloud; (d) Between sunset and sunrise without prior authorization from the FAA; (e) ) Within 9.26 kilometers (5 nautical miles) of any airport boundary without prior authorization from the FAA; (f) In controlled airspace without prior authorization from the FAA; (g) Unless you observe the greater of the following separation distances from any person or property that is not associated with the operations: (1) Not less than one-quarter the maximum expected altitude; (2) 457 meters (1,500 feet.); (h) Unless a person at least eighteen years old is present, is charged with ensuring the safety of the operation, and has final approval authority for initiating high-power rocket flight; and (i) Unless reasonable precautions are provided to report and control a fire caused by rocket activities ATC notification for all launches. No person may operate an unmanned rocket other than a Class 1 Model Rocket unless that person gives the following information to the FAA ATC facility nearest to the place of intended operation no less than 24 hours before and no more than three days before beginning the operation: 94

102 (a) The name and address of the operator; except when there are multiple participants at a single event, the name and address of the person so designated as the event launch coordinator, whose duties include coordination of the required launch data estimates and coordinating the launch event; (b) Date and time the activity will begin; (c) ) Radius of the affected area on the ground in nautical miles; (d) Location of the center of the affected area in latitude and longitude coordinates; (e) Highest affected altitude; (f) Duration of the activity; 95

103 (g) Any other pertinent information requested by the ATC facility Information requirements. (a) Class 2 High-Power Rockets. When a Class 2 High-Power Rocket requires a certificate of waiver or authorization, the person planning the operation must provide the information below on each type of rocket to the FAA at least 45 days before the proposed operation. The FAA may request additional information if necessary to ensure the proposed operations can be safely conducted. The information shall include for each type of Class 2 rocket expected to be flown: (1) Estimated number of rockets, (2) Type of propulsion (liquid or solid), fuel(s) and oxidizer(s), (3) Description of the launcher(s) planned to be used, including any airborne platform(s), (4) Description of recovery system, (5) Highest altitude, above ground level, expected to be reached, (6) Launch site latitude, longitude, and elevation, and (7) Any additional safety procedures that will be followed. (b) Class 3 Advanced High-Power Rockets. When a Class 3 Advanced High-Power Rocket requires a certificate of waiver or authorization the person planning the operation must provide the information below for each type of rocket to the FAA at least 45 days before the proposed operation. The FAA may request additional information if necessary to ensure the proposed operations can be safely conducted. The information shall include for each type of Class 3 rocket expected to be flown: (1) The information requirements of paragraph (a) of this section, (2) Maximum possible range, (3) The dynamic stability characteristics for the entire flight profile, (4) A description of all major rocket systems, including structural, pneumatic, propellant, propulsion, ignition, electrical, avionics, recovery, wind-weighting, flight control, and tracking, (5) A description of other support equipment necessary for a safe operation, (6) The planned flight profile and sequence of events, (7) All nominal impact areas, including those for any spent motors and other discarded hardware, within three standard deviations of the mean impact point, (8) Launch commits criteria, (9) Countdown procedures, and (10) Mishap procedures 77

104 User Certification NFPA Code 1127 and the safety codes of both the NAR and TRA require that high power motors be sold to or possessed by only a certified user. This certification may be granted by a nationally recognized organization to people who demonstrate competence and knowledge in handling, storing, and using such motors. Currently only the NAR and TRA offer this certification service. Each organization has slightly different standards and procedures for granting this certification, but each recognizes certifications granted by the other. Certified users must be age 18 or older. Explosives Permits Hobby rocket motors (including high power) no longer require a Federal explosives permit to sell, purchase, store, or fly. Certain types of igniters, and cans or other bulk amounts of black powder do require such permits. Under the Organized Crime Control Act of 1970 (Public Law ). A Federal Low Explosives User Permit (LEUP) from the Bureau of Alcohol, Tobacco, and Firearms (BATF) is required to purchase these items outside one s home state, or to transport them across state lines. These items, once bought under an LEUP, must thereafter be stored in a magazine that is under the control of an LEUP holder. A Type 3 portable magazine or Type 4 indoor magazine (described under NFPA Code 495) is required, and it can be located in an attached garage. BATF must inspect such magazines. Federal permits can be obtained from the BATF using their Form / , available from the ATF Distribution Center, 7943 Angus CT., Springfield, VA These are issued only to U.S. citizens, age 18 and older, who have no record of conviction of felonies and who pass a background check conducted by the BATF. This check includes a personal interview by a BATF agent. Launch Site Requirements The first requirement for any launch site is permission of the owner to use it for flying rockets! Use of land even public property without permission is usually illegal and always a bad way for a NAR member to demonstrate responsible citizenship. The NAR will issue site owner insurance to chartered sections to cover landowners against liability for rocket-flying accidents on their property such insurance is normally required. 78

105 The NAR safety codes and NFPA Codes establish some minimum requirements for the size and surroundings of launch sites. Model rocket launch sites must have minimum dimensions which depend on the rocket s motor power as specified in Rule 7 of the model rocket safety code and its accompanying table. The site within these dimensions must be free of tall trees, power lines, buildings, and dry brush and grass. The launcher can be anywhere on this site, and the site can include roads. Site dimensions are not tied to the expected altitude of the rockets flights. According to the high-power safety code, high-power rocket launch sites must be free of these same obstructions, and within them the launcher must be located at least 1500 feet from any occupied building and at least one quarter of the expected altitude from any boundary of the site. NFPA Code 1127 establishes further requirements for the high-power site: it must contain no occupied buildings, or highways on which traffic exceeds 10 vehicles per hour; and the site must have a minimum dimension no less than either half the maximum expected rocket altitude or 1500 feet, whichever is greater or it must comply with a table of minimum site dimensions from NFPA 1127 and the high power safety code. While model rocketry and high power rocketry, when conducted in accordance with the NAR Safety Codes, are legal activities in all 50 states, some states impose specific restrictions on the activity (California being the worst example of this) and many local jurisdictions require some form of either notification or prior approval of the fire marshal. It is prudent and highly recommended that before you commit to a launch site you meet with the fire marshal having jurisdiction over the site to make him aware of what you plan to do there and build a relationship 79

106 with him just as you did with the land owner. The fact that NAR rocketry is recognized and its safety and launch site requirements are codified in Codes 1122 (Model Rockets) and 1127 (High Power Rockets) by the National Fire Protection Association will be a very powerful part of your discussion with any fire marshal. Airspace Clearance The Federal Aviation Administration (FAA) has jurisdiction over the airspace of the U.S. and whatever flies in it. Their regulations concerning who may use it and under what conditions are known as the Federal Aviation Regulations (FAR) which are also called Title 14 of the Code of Federal Regulations (14 CFR). Chapter 1, Subchapter F, Part 101 of these regulations (14 CFR 101.1) specifically exempts model rockets that weigh 16 ounces or less and have 4 ounces or less of propellant from FAA regulation as long as they are operated in a manner that does not create a hazard to persons, property, or other aircraft. When operated in this safe manner, model rockets may be flown in any airspace, at any time, and at any distance from an airport without prior FAA approval. Rockets larger than these specific limits i.e. all high-power rockets are referred to as unmanned rockets by the FARs and are subject to very specific regulations. Such rockets may not be flown in controlled airspace (which is extensive in the U.S. even at low altitudes and includes all airspace above 14,500 feet), within 5 miles of the boundary of any airport, into cloud cover greater than 50% or visibility less than 5 miles, within 1500 feet of any person or property not associated with the operation, or between sunset and sunrise. Both NFPA Code 1127 and the NAR high-power safety code require compliance with all FAA regulations. Deviation from these FAR limits for unmanned rockets requires either notification of or granting of a waiver by the FAA. Such a waiver grants permission to fly but does not guarantee exclusive use of the airspace. The information required from the flier by the FAA is detailed in section S of the FAR (14 CFR ). If the rockets are no more than 1500 grams with no more than 125 grams of propellant, no notification of or authorization by the FAA is required. Larger rockets require a specific positive response from the FAA Regional Office granting a waiver before flying may be conducted; and the waiver will require that you notify a specific FAA contact to activate a Notice to Airmen 24 hours prior to launch. The waiver is requested using FAA Form , available from any FAA office or the FAA website. This form must be submitted in triplicate to the nearest FAA Regional Office 30 days or more in 80

107 advance of the launch, and it is advisable to include supplemental information with it, including copies of the Sectional Aeronautical Chart with the launch site marked on it and copies of the high-power safety code. The FAA charges no fee. Ignition Safety The NAR safety codes and the NFPA Codes both require that rockets be launched from a distance by an electrical system that meets specific design requirements. Ignition of motors by a fuse lit by a hand- held flame is prohibited, and in fact both NFPA Codes prohibit the sale or use of such fuses. All persons in the launch area are required to be aware of each launch in advance (this means a PA system or other loud signal, especially for high-power ranges), and all (including photographers) must be a specified minimum distance from the pad prior to launch. This safe distance depends on the power of the motors in the rocket; the rules are different for model rockets and high-power rockets. Both the field size and the pad layout at a rocket range particularly a high-power range must take into account and support the size of the rockets that will be allowed to fly on the range. For model rockets, the safe distance depends on the total power of all motors being ignited on the pad: 15 feet for 30 N-sec or less and 30 feet for more than 30 N-sec. For high-power rockets, the distance depends on the total power of all motors in the rocket, regardless of how many are being ignited on the pad, and on whether the rocket is complex, i.e. multistage or propelled by a cluster of motors. The distance can range from 50 feet for a rocket with a single H motor to 2000 feet for a complex rocket in the O power class. These distances are specified in a table in NFPA Code 1127 and the NAR high-power safety code. Motor Certification Both NAR safety codes and both NFPA Codes require that fliers use only certified motors. This certification requires passing a rigorous static testing program specified in the NFPA Codes. The NAR safety codes and insurance require that NAR members use only NAR certified motors; and since the NAR currently has a reciprocity agreement with TRA on motor certification, this means that TRA- certified motors also have NAR certification. The NFPA Codes recognize certifications granted by any approved testing laboratory or national user organization, but only the NAR and TRA can provide this service in most parts of the country. The California Fire Marshal has his own testing program for motors in that state. Motors made by private individuals or by companies without proper explosives licenses, and motors not formally classified for shipment by the U.S. Department of Transportation, are not eligible for NAR certification and may not be used on an NAR range. 81

108 Shipping of Motors Sport rocket motors generally contain highly flammable substances such as black powder or ammonium perchlorate, and are therefore considered to be hazardous materials or explosives for shipment purposes by the U.S. Department of Transportation (DOT). There are extensive regulations concerning shipment in the DOT s section of the CFR Title 49, Parts These regulations cover packaging, labeling, and the safety testing and classification that is required prior to shipment. These regulations are of great concern to manufacturers and dealers, and there are severe penalties for non-compliance. Basically, it is illegal to send rocket motors by UPS, mail, Federal Express, or any other common carrier or to carry them onto an airliner except under exact compliance with these regulations. The reality of these regulations, and the shippers company regulations, is that it is virtually impossible for a private individual to legally ship a rocket motor of any size. Transportation of motors on airlines is very difficult to do legally and should be avoided if at all possible. It takes weeks of advance effort with the airline, and in the post-september 11 world is probably not even worth attempting. Insurance Most property owners, whether government bodies or private owners, will demand the protection of liability insurance as a precondition to granting permission to fly sport rockets on their property. The NAR offers such insurance to individual fliers, to chartered NAR sections, and to flying site owners. Individual insurance is automatic for all NAR members. It covers only the insured individual, not the section or the site owner. Under the current underwriter this insurance runs for a 12 month period, coincident with NAR membership. Sections are insured as a group for a year; remember that section insurance is coincident with the section charter and expires on April 4 each year. Site owner insurance is available to all active sections for free. Each site owner insurance certificate covers only a single site (launch 82

109 field or meeting room). NAR insurance covers only activities that are conducted in accordance with the NAR safety code using NAR-certified motors. It provides $2 -million aggregate liability coverage for damages from bodily injury or property damage claims resulting from sport rocket activities such as launches, meetings, or classes and $1 million coverage for fire damage to the launch site. It is primary above any other insurance you may have. References NFPA Code 495, Explosives Materials Code, National Fire Protection Association, 1 Batterymarch Park, Quincy, MA NFPA Code 1122, Code for Model Rocketry. NFPA Code 1127, Code for High Power Rocketry. Code of Federal Regulations, Title 14, Part 101, Federal Aviation Regulations by the FAA for unmanned rockets. Code of Federal Regulation, Title 16, Part (a)(8), Consumer Product Safety Commission exemption for model rockets. Code of Federal Regulations, Title 27, Part 55, Bureau of Alcohol, Tobacco, and Firearms regulations. Code of Federal Regulations, Title 49, Parts , Department of Transportation hazardous material shipping regulations. Model Rocket Safety Code, National Association of Rocketry. High Power Rocketry Safety Code, National Association of Rocketry. 83

110 APPENDIX G: MATERIAL SAFETY DATA SHEET 84

111 85

112 86

113 87

114 88

115 89

116 90

117 91

118 92

119 93

120 94

121 95

122 96

123 97

124 98

125 99

126 100

127 101

128 102

129 103

130 104

131 105

132 106

133 107

134 108

135 109

136 110

137 111

138 112

139 113

140 114

141 115

142 116

143 117

144 118

145 119

146 120

147 121

148 APPENDIX H: STEM OUTREACH ACTIVITES EDUCATIONAL OUTREACH PLAN Navy Rockets plans to continue to involve itself in the community through educational outreach events. The main targets of the outreach events will be primary and secondary school students interested in the areas of Science, Technology, and Mathematics (STEM). In general, participation in the events will be supplementary to the overall goal of the event. All STEM events involve the rotation students through a variety of engineering and technology disciplines. Navy Rockets provides opportunities for under- represented populations to experience design and engineering processes. This will all be done outside of a classroom setting through selected STEM events where participants are engaged and actively learning. As noted on the USNA Stem website, the USNA STEM Center is focused on addressing an urgent national need for more young people to pursue careers in science, technology, engineering and mathematics. USNA faculty and midshipmen provide STEM outreach to local and national communities to engage and influence students and teachers. Navy Rockets will supplement the mission of the STEM Program by fulfilling its own requirements. The shared goals of the USNA STEM program and Navy Rockets include the following: Outreach with local communities to influence students and teachers to increase focus toward STEM-related studies and activities. Allow Navy Rocket participants to be intellectually challenged by creating programs for Midshipmen, and other program participants that will facilitate problem solving and critical thinking while still developing a basic technical sense of the projects. Create an interest in the aerospace community specifically, and all aspects of systems engineering that it entails. Through hands on utilization of technology and computer programs, Navy Rockets hopes to foster interest in the future of aerospace engineering and space flight. Some events that we will be participating in include: Navy Rockets plans to be involved in unique STEM events where a variety of populations are targeted. There are four types of events that Navy Rockets plans on doing. All four events involve direct interaction with the participants. The four types include: Direct Educational interaction involving Aerospace Engineering and STEM topics Direct Outreach interaction involving Aerospace engineering and STEM topics Indirect Educational interaction involving Aerospace engineering and STEM topics Indirect Outreach involving Aerospace engineering and STEM topics Navy Rockets plans on impacting the multiple STEM events listed below. The events are not a 122

149 comprehensive list of the events the team members attend, but they are a list of the major events that are scheduled. 1. MESA DAY Done in collaboration with Maryland Mathematics Engineering Science Achievement (MESA), MESA day is one of the primary recurring USNA STEM events that Navy Rockets plans on doing. MESA day is a full day of involved activities that keep elementary students from local counties and Baltimore City involved and interested in STEM related activities. Along with a plethora of age-appropriate interactive activities in different STEM areas, groups are encouraged to participate in a mini engineering design competition. Navy Rockets involvement in MESA day would consist of creating aerospace specific activities that will keep the students engaged and attentive. MESA day occurs monthly. 2. Mini-STEM At the Naval Academy, high schools from around the country have students come visit USNA for an overnight visit or a long weekend. This is known as a Candidate Visit Weekend. During these candidate visits, the students tour the technical majors, but more importantly, spend time engaged in interactive science and engineering activities. Navy Rockets plans to bolster the candidate s visits with helpful science and engineering activities. Navy Rockets has the ability to conduct wind tunnel experiments, load cell experiments, and much more with the mini- STEM groups. Candidate visits are held a handful of times during a semester, so there are an abundance of mini-stem opportunities for Navy Rockets to pick up on 3. Girls-Only STEM Day Part of the Girls Exploring Technology through Innovative Topics (GET IT and go) Program, the girls-only STEM day focuses on engineering design and development through a comprehensive competition. The goal is to encourage female participation in STEM programs and studies because females are under-represented in STEM communities. At the competition, female students will have the opportunity to compete, and to attend workshops and meet female professors. 123

150 APPENDIX I: WIND TUNNEL TEST PLAN USNA ROCKET PROPULSION PROGRAM FUNCTIONAL TEST PLAN USNA-TP-R October 2016 Approvals Project Engineer Date 124

151 REVISION LETTER RECORD OF CHANGES DATE TITLE OR BRIEF DESCRIPTION ENTERED BY A 25 OCT 16 Draft LA 125

152 Introduction: This Functional Test Plan describes the procedures used to operate the flow aerodynamic force test being performed on the NASA Student Launch (USLI) sub-scale rocket in the Open Circuit Wind Tunnel. Pressure Variation on Symmetric rockets: The purpose of this experiment is to test a sub-scale model rocket at multiple incidence angle with varying Reynolds numbers. This test will allow Navy Rockets to determine the aerodynamic forces present on the rocket throughout the flight along with proving our use of outboard legs, for landing is still aerodynamically sound. Knowledge of the forces during flight will give way to more accurate analysis of rocket flight path trajectory, especially in comparison to rocket trajectory simulation software. This work will be presented to complement the Navy Rocket research and development as a part of the USLI competition Philosophy of OPERATIONS The scale model testing will take place inside the Open Circuit Wind Tunnel in Rickover Hall. It will be mounted to the sting balance, with pressure ports longitudinally along the rockets nose cone. The model will be designed in SolidWorks and 3D printed to match the sub scale parameters. The pressure ports will be 3D printed into the scale model. The model will be run at varying Reynolds numbers. The incidence angle of the scale model will change but the free-stream flow will not Participation Personnel responsible for the operations are listed in Table Flow Diagrams The Additive Printing integration and test flow is shown in Figure 1-1. Model Designed on SolidWork s Scale Model 3D Printed Test Rea dine ss Setup Test Perform Functional Test Take Pictures of Flow Operations Obtain Results Mission Readines s Review Figure 1-1. Additive Printing Integration 126

153 Test Flow Injector System Functional Test 2.1 Objectives The objective of this experiment is to analyze the aerodynamic stability of the rocket used for the USLI competition. 2.2 Criteria for Success The rocket shows static and dynamic stability at all Reynolds numbers tested at. Forces and moments will be taken into account when analyzing stability. The rocket will have a static stability margin of 2.0 at the time of rail exit in accordance with the requirements in the USLI handbook. 2.3 Facilities The sub-scale model testing will be performed using the Open Circuit Wind Tunnel in Rickover hall at USNA. A. 72 in scale model rocket B. 6 sections surgical tubing - 3 ft 1 cm diameter C. 6 autonomous pressure gages 2.4 Materials 2.5 Test Overview The test will involve turning the wind tunnel on while all pressure ports are connected. TEST DATE: TEST PERSON: 127

154 Step Description 0 Attach pressure tube to each port through the inside of the rocket. 1 Attach scale model aft section to the sting balance. 2 Run surgical tube through the bottom of the wind tunnel out to the pressure gages. 3 Ensure sting balance is properly attached through the bottom of the test section 4 Run flow through test section to ensure all pressure ports and force measuring devices are securely fitted. 5 Run program at initial test speed. 6 When flow steadies tabulate data for given speed. 7 Perform steps 5-6 as needed for each successive test speed 8 Once all data is taken, run again at initial test speed Initial Injector Assembly Test Comment Done? (Y/N) Date Initial 9 Perform free-stream velocity sweep from initial to final test speeds, simultaneously tabulating data. 10 When finished tabulating velocity sweep, move wind tunnel test speed down to 0% 11 Shut down wind tunnel and wind tunnel software 12 Detach the assembly in reverse order of attachment. 128

155 APPENDIX J: FULL SCALE SOLIDWORKS BLUEPRINTS 129