TERMINATOR 5 BILL RILEY TRIPOLI LEVEL 3 CERTIFICATION PROJECT. Bill Riley Tripoli #12294
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1 TERMINATOR 5 BILL RILEY TRIPOLI LEVEL 3 CERTIFICATION PROJECT Bill Riley Tripoli #12294 RocketRiley@ip-mail.net
2 Bill Riley Terminator 5 Tripoli Level 3 Certification Project Table of Contents Rocketry Warehouse Terminator Project Description and Objectives... 3 Dual Deployment Configuration... 3 Scale Drawing... 5 RockSim Renderings... 8 RasAero II... 8 High level list of materials... 9 Avionics Altimeter Configurations Construction Details Nose Cone & Auxiliary Payload Bay Forward Body Main Avionics Bay Main and Aux AV Bay Soak Testing Remote test run simulation and fire MrfPyros Aft Body & Tailcone Recovery System Ground Test Applicable CTI motors Pro M1540-P Motor Data Preliminary Flight Profile w/cti M RasAero II Analysis Selected Motor & Flight Simulation Analysis of RasAero flight simulation data Draft Pre-Flight Checklist Flight Recap May 21, Bench Testing Findings Page 1 of 41
3 Flight Postmortem October 15, 2017 L3 Attempt Flight data recap Raven 3 Flight Data Version History Reference Materials Page 2 of 41
4 Rocketry Warehouse Terminator 5 Project Description and Objectives My reason for pursuing Tripoli level 3 certification includes a desire to build and safely fly larger and heavier airframes that span the L and M range of motors. For the purpose of attaining Level 3 certification, I selected the Terminator 5 fiberglass airframe from Rocketry Warehouse. The stock kit is 5 inches in diameter with a 75mm motor mount, stands 100 tall, and weighs 19 lbs prior to construction. With the primary objective of a safe flight and recovery, and a target altitude of roughly 10-12k feet, I intend to use a CTI M1540 Imax motor. Configured for flight, it s estimated to weigh 35 lbs, resulting in an average thrust to weight ratio of 9.8:1. The rocket will be configured to allow either 1010 or 1515 rail buttons, allowing it to also be flown from the high power pads on L motors. Dual Deployment Configuration In order to preserve space in the aft airframe for longer motors, the drogue and main parachute will be deployed from the forward body tube and nose cone respectively. Deployment events will be controlled by fully redundant Marsa54L altimeters w/mrfbridge boards. Nose cone main chute deployment events will be initiated by paired Marsa MrfPyro boards mounted in an auxiliary AV Bay attached at the nose cone. (Refer to scale drawing, avionics schematics and layout.) Even though the booster section is not intended to separate from the main AV Bay, an appropriately sized recovery harness and drogue will be included as a safety measure. Page 3 of 41
5 Note: Because the Marsa gadgets are relatively new and some failure modes may not yet be known, a Raven 3 will be implemented as a tertiary altimeter, mounted in the nose cone auxiliary altimeter bay. In the event that neither apogee event successfully separates the drogue payload bay, which would result in a high velocity return, the Raven 3 will discharge the main parachute as a failsafe. Even though this increases the risk of shredded recovery gear it reduces the risk of an uncontrolled, high velocity return. The Raven 3 will be configured to initiate a main ejection charge at 500 AGL, well after the primary and secondary main parachute charges should have already fired by the Marsa54L s. (The Raven 3 will be used as tertiary for the main only, not the drogue.) Page 4 of 41
6 Scale Drawing Page 5 of 41
7 Main Chute 28" Aux Avionics Bay (3) #4 Nylon Shear pins Drogue Chute Main Avionics Bay 22" (8) 8-32 stainless screws w/ PEM nuts 100" cg 66.5" 5" 38" cp 80.1" 12" 3.75 Page 6 of 41
8 Nose Cone and Aux AV Bay Detail 10" Charge holders 28" 32" Main Parachute (3) #4 shear pins for Main chute (2) Marsa MrfPyro Boards in upper AV Bay (3) Schurter Switches for Marsa MrfPyros and Raven 3 (3) #4 shear pins for Drogue chute 2" 5" 10" Page 7 of 41
9 RockSim Renderings RasAero II Page 8 of 41
10 High level list of materials Construction Materials: Rocketry Warehouse Terminator 5 kit West Systems Epoxy 105/205 West Systems 404 High Density Filler Proline 4100 Epoxy (External Fillets) JB Weld high temp epoxy (for components affixed to motor mount tube) Aeropack RA75P Retainer 1515 Rail buttons (1/4-20 PEM nuts;.328 dia. 21/64 drill bit) 8-32 PEM nuts also installed to allow 1010 rail buttons on future L flights. #4 Nylon screws (shear pins) Avionics: Fully redundant Marsa54L altimeters, with MrfBridges and MrfPyros for wireless remote deployment of main recovery gear from the nose cone. Featherweight magnetic switches to control power to Marsa54Ls. Shurter rotary switches for MrfPyros and Raven 3 in auxiliary nose cone AV bay. Shurter rotary switch for RealFlight Systems GPS-1 in main AV bay. Real Flight Systems GPS-1 Telemetry Tracking Module Batteries: o Marsa54L: 7.4v 500 mah LiPo o Marsa MrfPyro: Integrated batteries o Raven 3: 3.7v 300 mah LiPo o RFS GPS-1: 7.4v 2200 mah Lipo ¼ inch Grade 8 all-thread rod (tensile strength 155k psi; compared to stainless at 75k psi) Recovery: Drogue: 36 TAC-1 drogue (Giant Leap) (88 fps) Main: 84 Fruity Chute Compact Iris (16 fps; max deployment velocity 120 fps.) Kevlar harnesses o Drogue: 25 x 7/16 Kevlar, (rated 5,300) lbs; 6 to nosecone o Main: 25 x 7/16 between aux AV bay and Main (rated 5,300) lbs; 6 to nosecone Page 9 of 41
11 Avionics Altimeter Schematic Tertiary Main Ignitor ` ` Optional Featherweight Raven 2 (Tertiary Altimeter) Schurter Rotary Switch MrfPyro MrfPyro Schurter Rotary switch Primary Remote (w/integrated battery) Seconodary Remote (w/integrated battery) Schurter Rotary switch Aux AV Bay Components Redundant Primary Main Ignitor Redundant Secondary Main Ignitor Main AV Bay Components MrfBridge MrfBridge Primary Secondary Primary Drogue Ignitor Secondary Drogue Ignitor Marsa54L w/ MrfBridge Primary Altimeter Marsa54L w/ MrfBridge Secondary Altimeter Featherweight Mag Switch Featherweight Mag Switch Page 10 of 41
12 Altimeter Configurations Primary Secondary Tertiary Marsa54L Marsa54L Featherweight Raven 3 Configuration Accel OR Baro; Accel OR Baro; Channel 1 Channel 2 No Kalman Drogue: Apogee (Apo 1) No Kalman Drogue: Apogee +1.5 sec (Apo 2) not used Main: 500 ft Channel 3 Channel 4 Channel 5 Channel 6 (pyro) Main: 1,000 ft Main: 800 ft (M3) Channel 7 (pyro) (M1) (M2) Page 11 of 41
13 Construction Details NOTE: Only the Main channel is used. Nose Cone & Auxiliary Payload Bay The nose cone coupler/ auxiliary AV Bay, containing the main chute, is retained in the nose cone and forward airframe by means of three (3) #4 nylon shear pins each. (Refer to shear pin table). i This allows for two separation events; one for the drogue, initiated from the main AV Bay, and the other for the main chute, initiated by the MrfPyros mounted in the nose cone auxiliary AV bay. Page 12 of 41
14 Construction Photos Figure 1 Preparing the Aux AV Bay switch band, test fit the switches. Figure 2 Aux AV Bay w/ 2 sided sled. Figure 3 Bench testing pyros and Raven 3. Page 13 of 41
15 Figure 4 2 Sided Aux AV Bay, w/ 2 Marsa MrfPyros and a Featherweight Raven 3 Figure 5 Assembled Aux AV Bay Forward Body The forward body, containing the drogue chute simply has holes near the forward end for #4 nylon shear pins, and near the aft end for attaching the AV Bay coupler as described below. Page 14 of 41
16 Figure 6 Forward Body with Main AV Bay mounted. Main Avionics Bay The AV bay is affixed to both the forward and aft bodies by means of four (4) 8-32 stainless machine screws each, using PEM nuts embedded within the AV Bay. The AV Bay will remain attached to both the forward and aft body tube (booster) during drogue deployment. According to the following specs, four (4) stainless 8-32 screws should be sufficient to withstand recovery forces. ii Screw Size Min Dia Area Shear /lbs sq ft , Page 15 of 41
17 Figure 7 Main AV bay with dual Marsa54L altimeters, using Featherweight magnetic switches. Figure 8 Real Flight Systems GPS-1 tracking module, with batteries for all systems. Figure 9 Close-up of GPS-1 and antennas. Page 16 of 41
18 Figure 10 GPS-1 modem antenna attachment. Figure 11 Stainless safety wire retainer Page 17 of 41
19 Main and Aux AV Bay Soak Testing First Test: All avionics were powered up in sequence and allowed to run as if on the pad for two hours. Aux AV Bay and Main AV Bay about 24 inches from each other. GPS-1 powered down at 1:42. No adverse issues. Distance Test: After charging all batteries, all avionics powered on in sequence. Attempted with a distance of 25 yards between Aux and Main bays. Inconsistent results in detecting MrfPyros. Reduced to 20 yards with no issues. Remote test run simulation and fire MrfPyros At a distance of 20 yards, powered up all devices in sequence, then ran Marsa flight simulation to test reliability of communication to MrfPyros. Apogee e-matches and Main e-matches successfully fired as expected on both AV Bays. Aft Body & Tailcone Construction will be typical through-the-wall attachment of fins to the motor mount, using reinforcing fillets on the root edges, inside the outer airframe wall, and exterior to the airframe. Page 18 of 41
20 Figure 12 Split fins installed ensuring they are properly aligned and perpendicular with airframe. Figure 13 Showing lower pair of PEM nuts installed, allowing for small or large rail buttons to be installed. Page 19 of 41
21 Figure 14 Note: Aeropack retainer is recessed in tail cone, thereby allowing retainer cap to also act as a thrust ring, transferring motor thrust to outer airframe. Figure 15 After injecting internal fillets, mask and pull external fillets using Proline black epoxy. Page 20 of 41
22 Figure 16 First look at the assembled airframe. Preliminary weight w/o motor, 23.5 lbs Page 21 of 41
23 Recovery System Ground Test Deployment charges for both drogue and main were calculated to require between 1 ½ and 2 grams of BP. Successful test using 2 grams as shown below. (Video of test may also be viewed at ) Page 22 of 41
24 Page 23 of 41
25 Page 24 of 41
26 Applicable CTI motors The goal is to identify a CTI M-class motor that does not require grain bonding, an altitude between 10k and 12k feet, and that will not linger in the transonic range ( fps). [From Thrustcurve.org iii ] Motor M1101 M2250 M1230 M1830 M1770 M1160 M2075 M1670 M1810 M3100 M1401 M1675 M1400 M2080 M1300 M3700 M1540 M2045 M2150 M1590 M840 M1545 M2020 Bond? iv Guide Burnout Burnout Max Max Apogee Max Velocity (m/s) Time (s) Altitude Acceleration Velocity (f/s) Time (s) Altitude (m) (G) (ft) ,996 Bond , , , , , , , ,456 Bond , ,635 Bond , ,755 Bond ,981 Bond ,981 Bond , , , , , ,751 Bond ,151 Bond ,443 Page 25 of 41
27 M2245 Bond ,184 Pro M1540-P Motor Data Motor Data Brandname Pro M1540-P Manufacturer Technology Man. Designation 6819M1540-P CAR Designation 6819-M1540-P Test Date 5/4/2009 Single- Use/Reload/Hybrid Reloadable Motor Dimensions mm x mm (2.95 x in) Loaded Weight g ( oz) Total Impulse Ns ( lb-s) Propellant Weight g ( oz) Maximum Thrust N ( lb) Burnout Weight g (74.48 oz) Avg Thrust N ( lb) Delays Tested plugged ISP s Samples per second 1000 Burntime 4.44 s Notes 33% M Page 26 of 41
28 Preliminary Flight Profile w/cti M1540 Page 27 of 41
29 RasAero II Analysis Selected Motor & Flight Simulation Preliminary Simulation results M1540-IM-None Launch conditions Altitude: Ft. Relative humidity: % Temperature: Deg. F Pressure: In. Launch guide data: Launch guide length: In. Velocity at launch guide departure: ft/s The launch guide was cleared at : Seconds User specified minimum velocity for stable flight: ft/s Minimum velocity for stable flight reached at: In. Page 28 of 41
30 Max data values: Maximum acceleration:vertical (y): Ft./s/sHorizontal (x): Ft./s/sMagnitude: Ft./s/s Maximum velocity:vertical (y): ft/s, Horizontal (x): ft/s, Magnitude: ft/s Maximum range from launch site: Ft. Maximum altitude: Ft. Recovery system data P: 36" TAC-1 Drogue Deployed at : Seconds Velocity at deployment: ft/s Altitude at deployment: Ft. Range at deployment: Ft. P: 84" Fruity Chute Iris Ultra Compact Deployed at : Seconds Velocity at deployment: ft/s Altitude at deployment: Ft. Range at deployment: Ft. Time data Time to burnout: Sec. Time to apogee: Sec. Optimal ejection delay: Sec. Landing data Time to landing: Sec. Range at landing: Velocity at landing: Vertical: ft/s, Horizontal: ft/s, Magnitude: ft/s Analysis of RasAero flight simulation data According to RasAero, the flight will be in the transonic region at 2.1 seconds for 1.6 seconds (885 to 1,941 ), with MaxQ reached at 3.7 seconds at an altitude of 2,543 ft, resulting in lbs of drag. The flight will reach apogee of 12,695 ft. at 26 seconds flight time. Page 29 of 41
31 Draft Pre-Flight Checklist Before launch day Charge LiPo batteries, including spares. Charge on-board MrfPyro batteries. Charge RFS BaseStation 2. Check voltage of all batteries and label. Verify all altimeter settings. Verify GPS-1 settings & reception. Attach flash battery and save almanac (14 days). Measure ejection e-match resistance. Pre-measure ejection charges (2 gram vials) and assemble charge holders; DO NOT attach ematches to terminal blocks. o 2 grams primary apogee; 2.5 grams backup apogee. Ensure sufficient #4 nylon shear pins Remember to take motor ignitor and tube. Prep Auxiliary AV Bay Verify MrfPyro rotary switches are OFF. Assemble Aux AV Bay. Secure charges in nose cone holders. o 2 grams primary and backup; 2.5 grams tertiary. Attach nose recovery harness, load main parachute. Attach harness to fwd side of Aux AV Bay. Insert Aux AV Bay into nose cone, and insert shear pins. Launch Day Verify altimeters and assemble main AV Bay Ensure all switches OFF Attach altimeter batteries only Attach e-matches to MrfPyros Attach e-matches to Marsa54Ls Power ON MrfPyros Power ON both altimeters, verify MrfBridges and MrfPyros are properly detected via on-board LCD. Verify beep codes. (2 rising=pyro not found; 3 rising = pyro found.) Verify e-match continuity as expected. (the purpose is testing the electronics) Marsa 1 beep=bad; 2 beeps=good Power OFF and remove e-matches. DOUBLE CHECK ALL SWITCHES OFF Page 30 of 41
32 Verify GPS and assemble main AV bay IMPORTANT: Attach GPS-1 RF antenna before connecting battery & powering up. Verify GPS rotary switch is off (left position). Connect GPS battery; verify flash battery still attached. Power GPS-1 and verify reception. Power off via GPS-1 Shurter rotary switch. Assemble AV Bay. Secure safety wires on eye nuts. Attach deploy charges connections. Prep forward body tube and drogue chute Attach harness to aft side of Aux AV Bay bulkhead (now on nose cone). Attach forward body tube to nose cone AV Bay coupler with shear pins Pack drogue and insert into forward tube, followed by remaining harness. Attach harness to forward AV Bay eye nut. Insert main AV Bay into forward bay, and attach with four (4) 8-32 stainless machine screws. Assemble motor per instructions Verify torque of forward and aft closures. Complete assembly Load assembled motor into airframe. Check fit of Aeropack retainer. Attach harness to motor eye bolt and body harness. Attach harness to aft AV bay eye nut. Attach aft AV Bay to aft body and affix with four (4) 8-32 stainless machine screws. Power up GPS-1 via screw switch and verify reception, then power off. Take to pad: Motor ignitor, ignitor tube, tape, magnet, small slotted screwdriver, wire cutters, RFS GPS Basestation. Pre-flight check Complete L3 form, TAP Pre-flight data form, Flight card TAP review RSO review Page 31 of 41
33 At Pad Load on pad Enable nose cone MrfPyros and Raven 3 via rotary switches Warning: Nose Cone Charges are now HOT Power up GPS-1 and verify reception Enable Marsa54L #1 o Verify beep codes (5, 5, 3 long, [cont. test], 3 rising=pyros found; 2 beeps = pass) Enable Marsa54L #2 o Verify beep codes Insert motor ignitor, attach leads, continuity check Flight Events: Time (Seconds) Event 3.7 sec Max Q 4.4 sec Burn-out 25 sec Apogee event 161 sec Main event sec Backup Main sec Tertiary backup sec Landing Page 32 of 41
34 Flight Recap May 21, 2016 During assembly of the rocket, all charges were connected using ematches that had been tested, and all electronics were powered on and tested as the rocket was being assembled at the launch site. After assembling the rocket, there was a lengthy wait for the away pad. When the pad was available, the rocket was loaded and prepped for flight. On the pad, the Featherweight Raven 3 (configured as a tertiary backup for the main) signaled the correct codes. However, both Marsa54L altimeters beep codes indicated failed continuity tests. At that point the launch was scrubbed. After returning home, I measured voltages on all batteries, but the batteries on both MrfPyros were discharged below an acceptable level. (Unsure, but I may have left switches on when troubleshooting at the launch site.) Bench Testing Working under the assumption that the MrfPyro batteries were inadvertently left on for an extended period prior to the flight, I tested the behavior of the MrfPyros over time, allowing the batteries to discharge. After recharging all batteries, both Marsa54L altimeters were tested as originally configured for flight. All ematches were manually verified using a multimeter prior to the test. The Marsa54L s indicated valid continuity. Using the onboard diagnostics, the impedance of the ematches was measured with each test. Findings Once the MrfPyro batteries discharged for a few hours they began to fail continuity tests. The onboard diagnostics showed unpredictable and erroneous ematch impedance as the onboard MrfPyro batteries discharged. The voltage was sufficient for the MrfPyros to communicate wirelessly with the Marsa54L receivers, but the continuity checks were unreliable. Detailed diagnostic data from all tests was forwarded to John at Marsa Systems for analysis. After analysis, John determined that a firmware change would enable the MrfPyros to more accurately and reliably measure the impedance of connected ematches, particularly at reduced voltages. After being updated, the Marsa s, MrfBridges, and MrfPyros were re-tested. After leaving the MrfPyros on for an extended time (replicating the scenario of an extended wait for pad availability), the configurations were testing using onboard simulation. All ematches fired as intended. Page 33 of 41
35 Flight Postmortem October 15, 2017 L3 Attempt After prepping the rocket per the checklist, the rocket was loaded on the launch pad and all electronics were enabled and passed power-up checks. The flight was very close to the simulations, as shown in the table below. Unfortunately, the apogee charges appeared to be insufficient to separate the airframe, and the drogue chute was not deployed. Real-time GPS tracking indicated the rocket was in a ballistic return when the main chute deployed at 100, at approximately 550 fps, shredding the main chute. Nonetheless, this slowed the descent sufficiently to save the onboard electronics, allowing all data to be downloaded for analysis. The only damage sustained to electronics was one broken LCD display, and a GPS receiver antenna. Flight data recap Peak Peak Alt Alt Peak Peak Descent Baro Accel Velocity Accel Velocity SIM Marsa avg fps Marsa Raven GPS avg fps Page 34 of 41
36 Google Earth View Page 35 of 41
37 Raven 3 Flight Data Figure 17 Zipper of fiberglass airframe Page 36 of 41
38 Figure 18 Airframe damage Figure 19 Airframe damage Page 37 of 41
39 Figure 20 Closeup of airframe damage Figure 21 Post-flight apogee charge holders; both fired. Page 38 of 41
40 Version History Version Date Details 1.0 1/15/2016 Initial version Need to add details for Raven3 configuration. 1/22/2016 Add construction photos of Aux AV Bay. Details for Raven 3 configuration /24/2016 Photos testing Aux AV Bay 1.2 2/14/2016 Photos of forward body, and completed main AV bay /6/2016 Photos of aft body and assembled airframe /13/2016 Update design for Real Flight Systems GPS-1 Update to 84 main chute (17 fps) 1.5 4/30/2016 Update drogue to 36 (88 fps); Ground test results; update misc. as-built info 1.6 5/1/2016 Changed Marsa54L settings; other minor corrections and edits 1.7 7/11/2016 Added diagnostic information for scrubbed flight /29/2016 Updated checklist in preparation for 10/15 flight. 1.9 Updated with L3 flight postmortem and photos. Page 39 of 41
41 Reference Materials i Pressure in unvented airframe: Pressure at sea level: 14.7 psi Pressure at 12,000 ft: 9.35 psi Differential: 5.35 psi Area 5" rocket sq in Pressure: psi 3 #4 Nylon shear pins: 114 psi (avg) Shear Pin Shear Strength #2 Nylon Screws #4 Nylon Screws # of Pins Peak Load (lbs) Peak Load (Each Pin) # of Pins Peak Load (lbs) Peak Load (Each Pin) Avgs Avgs Avgs Page 40 of 41
42 ii iii iv Page 41 of 41
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