NASA SL Flight Readiness Review

Transcription

1 NASA SL Flight Readiness Review U N I V E R S I T Y O F A L A B A M A I N H U N T S V I L L E C H A R G E R R O C K E T WORKS M A R C H 9,

2 Presentation Summary Project Overview Readiness and Design Summary Key Components Mission Performance Full-Scale Flight Analysis Payload Safety & Procedures Educational Engagement Project Management Questions UNIVERSITY OF ALABAMA IN HUNTSVILLE 2

3 Technology Readiness Level Actual system flight proven through successful mission operations Actual system completed and flight qualified through test and demonstration (ground or flight) Prototype demonstration in a flight environment Payload ground test to verify functionality. Sub-scale model or prototype demonstration in relevant environment (ground or flight) Component validation through analysis and experiments as outlined in the component description sheets. Design concept and/or application formulated Basic design principals observed and reported UNIVERSITY OF ALABAMA IN HUNTSVILLE 3

4 Concept of Operations Drogue Apogee Drogue Primary Fire (18.0 seconds) Main Main Parachute Primary Fire (600 feet) Coast & Roll Phase Drogue Secondary Fire (19.0 seconds) 600 ft. (73 seconds) Main Parachute Secondary Fire (550 feet) Launch (0 2.4 seconds) Landing (114 seconds) UNIVERSITY OF ALABAMA IN HUNTSVILLE 4

5 Vehicle Overview Vehicle Dimensions: Diameter: 6 inches Length: 119 inches Mass: lbs Center of Pressure (CP): inches Center of Gravity (CG): 76.5 inches No major dimensional changes since CDR Payload Briefing: Roll induction and counter roll Proportional Interval Derivative (PID) updates fin angle to actively control external fins CG CP UNIVERSITY OF ALABAMA IN HUNTSVILLE 5

6 Changes since CDR Recovery CDR Main Parachute: SkyAngle CERT-3 XL which yielded a landing kinetic energy of 110 ft-lbf. FRR Main Parachute: Fruity Chute 144 Iris Ultra Compact with predicted landing kinetic energy of 64 ft-lbf. Upper Airframe Removable rivets changed to screws with nut plates for threaded backing Aluminum all thread changed to steel all thread Solid Aluminum bracket changed to fiberglass with aluminum brackets at each end Lower Airframe Drogue bulkhead thickness changed from 0.25 to 0.5 UNIVERSITY OF ALABAMA IN HUNTSVILLE 6

7 Upper Airframe Key Components Tracker Assembly Located in the nose cone Tracker unit communicates with ground station via laptop to trace vehicle Avionics Bay Houses recovery avionics Two independent Stratologger altimeters Switches Switch mounts 9V batteries 3D printed sled UNIVERSITY OF ALABAMA IN HUNTSVILLE 7

8 Lower Airframe Key Components Fin Assembly Fins were created from fiberglass sheets Fin brackets were machined from stock 2024 aluminum Tail Cone Tail cone printed from ABS plastic Compression proof tested to ~1000 lbf Motor Aerotech L2200 Max Thrust: 697 lbs Impulse: 5104 Ns Burn time: 2.3 s Total Weight: 4783 g Propellant Weight: 2518 g Motor Case: RMS-75/5120 UNIVERSITY OF ALABAMA IN HUNTSVILLE 8

9 Key Components Recovery System Drogue Parachute: Fruity Chute CFC- 18 Main Parachute: Fruity Chute 144 Iris Ultra Compact Recovery Harness: 1 Tubular Nylon (50 ft each) Quick Links: 3/8 Oval-Shaped Threaded Steel Drogue Nomex: 18 x 18 Cloth Sheet Main Nomex: 36 x 36 Cloth Sheet Drogue Parachute Main Parachute UNIVERSITY OF ALABAMA IN HUNTSVILLE 9

10 Interfaces with Ground Systems Tacker 2 XBee radios were configured and linked to the XCTU software via the use of a laptop. One Xbee radio remained connected to Ground Station while the other was located in the nose cone. Coordinates were recorded throughout flight and upon landing. Final coordinates were verified by the use of a web mapping service (Google Maps). Rail Button Placement Structural Ground System Interface Close to CG Close to aft fins UNIVERSITY OF ALABAMA IN HUNTSVILLE 10

11 Mission Performance UNIVERSITY OF ALABAMA IN HUNTSVILLE

12 Trajectory Curves Flight Predictions Maximum Velocity ft/s Maximum Mach 0.57 Max Acceleration ft/s2 Target Apogee 5287 ft T/W 9.38 Rail Exit Velocity ft/s Stability Margin 2.18 calibers UNIVERSITY OF ALABAMA IN HUNTSVILLE 12

13 Altitude Predictions Coefficient of Drag Analysis: Predicted Cd measured from Full-Scale results input to RockSim (0.485) Open Rocket internally derives the Cd without manual input Wind (mph) Apogee (ft) UNIVERSITY OF ALABAMA IN HUNTSVILLE 13

14 Descent Calculations Drogue Parachute: Fruity Chute CFC-18 Parachute Diameter: 18 in Terminal Velocity: 87.1 ft/s Section Nose Cone/Upper Lower Airframe Mass (lb) Velocity (ft/s) KE (ft-lbf) Main Parachute: Fruity Chute 144 Iris Ultra Compact Parachute Diameter: 144 in Terminal Velocity: 12.8 ft/s Section Nose Cone Upper Airframe Lower Airframe Mass (lb) Velocity (ft/s) KE (ft-lbf) UNIVERSITY OF ALABAMA IN HUNTSVILLE 14

15 Drift Results and Predictions Worst Case Drift (20 mph) = 2,581 ± 153 ft Max wind speed to meet drift requirement: 18 mph Wind Speed Drift Distance (ft) 0 mph 0 5 mph 648 ± mph 1289 ± mph 1950 ± mph 2581 ± 153 UNIVERSITY OF ALABAMA IN HUNTSVILLE 15

16 Recovery System Tests Test Number Rocket / Section Volume (gram) Results 1 First launch/upper 4 Separation but main parachute did not eject from rocket 2 First launch/upper 5 Separation and main parachute ejected 3 First launch/upper 5 Separation and main parachute ejected 4 First launch/lower 3 Separation and drogue parachute ejected 5 First launch/lower 3 Separation and drogue parachute ejected Primary Charge Secondary Charge Main 5g at 600ft 5.5g at 550ft Drogue 3g at apogee 3.5g one second after apogee 1 Second launch/lower 3 Separation and drogue parachute ejected 2 Second launch/upper 5 Separation and main parachute ejected 3 Second launch/upper 5 Separation and main parachute ejected UNIVERSITY OF ALABAMA IN HUNTSVILLE 16

17 Monte Carlo Analysis Distribution of projected altitudes Normalized by random variable distributions Done to obtain more realistic range of altitude values Standard deviation of 117 feet 2σ of 234 feet UNIVERSITY OF ALABAMA IN HUNTSVILLE 17

18 Flight 1 Overview Launch Conditions Date February 4 th 2017 Location Wind Childersburg, AL 5 mph Temperature 56 F Motor Parachute Launch Rod Angle 4 Aerotech L2200 SkyAngle XL Objectives: Ensure structural reliability of vehicle components for launch, flight and recovery. Payload RIC not powered neutral position. Verify prediction methods. Test dual deploy recovery system. Match stability margin of final vehicle. Not fully ballasted. UNIVERSITY OF ALABAMA IN HUNTSVILLE 18

19 Flight 1 Analysis Key Flight Components Wet Mass (pounds) Stability Margin (caliber) Thrust to Weight 9.80 Cd (coast phase) 0.45 Apogee (ft) Apogee % Error Prediction Simulation % Flight Data Post-Flight Simulation % UNIVERSITY OF ALABAMA IN HUNTSVILLE 19

20 Flight 1 Recovery Drogue Parachute : Fruity Chute CFC-18 Terminal Velocity: 80.7 ft/s Main Parachute: SkyAngle CERT-3 XL Terminal Velocity: 17.2 ft/s Drift Landing Distance Wind Speed Drift Distance (ft) 5 mph 2079 Landing Kinetic Energies Section Nose Cone Upper Airframe Lower Airframe Mass (lb) Velocity (ft/s) KE (ft-lbf) SkyAngle CERT-3 XL UNIVERSITY OF ALABAMA IN HUNTSVILLE 20

21 Flight 2 Overview Launch Conditions Date February 18 th 2017 Location Wind Murfreesboro, TN 4 mph Temperature 54 F Motor Parachute Launch Rod Angle 7 Aerotech L1420 SkyAngle XL Objectives: Payload RIC powered Demonstrate ability to control roll Verify launch detect system Verify altitude, kinetic energy & drift prediction methods Test dual deploy recovery system UNIVERSITY OF ALABAMA IN HUNTSVILLE 21

22 Flight 2 Analysis Key Flight Components Wet Mass (pounds) Stability Margin (caliber) Thrust to Weight 6.02 Cd (coast phase) Apogee (ft) Apogee % Error Prediction Simulation % Flight Data Post-Flight Simulation % UNIVERSITY OF ALABAMA IN HUNTSVILLE 22

23 Flight 2 Recovery Drogue Parachute : Fruity Chute CFC-18 Terminal Velocity: 86.2 ft/s Main Parachute: SkyAngle CERT-3 XXL Terminal Velocity: 18.9 ft/s Drift Landing Distance Wind Speed Drift Distance (ft) 4 mph 2177 Landing Kinetic Energies Section Nose Cone Upper Airframe Lower Airframe Mass (lb) Velocity (ft/s) KE (ft-lbf) SkyAngle CERT-3 XXL UNIVERSITY OF ALABAMA IN HUNTSVILLE 23

24 Payload Final Design

25 Changes Made Since CDR Housing modified to include holes and stand-offs for components that ease the assembly process. Went from one voltage regulator for three servos to one regulator for each servo, total of three. Final Dimensions Length: 9.05 Diameter: 5.82 Weight: 4.7 lbs UNIVERSITY OF ALABAMA IN HUNTSVILLE 25

26 Payload Vehicle Integration Forward of motor case and aft of drogue recovery system. Attaches to body tube via two aluminum bulkheads. All thread holds bulkheads and payload as one piece. Installation Payload and bulkhead assembly is inserted into lower body tube. Bulkheads anchored to body tube with fasteners. Control rods attached to servos with fasteners. Fins attached to control rods with fasteners. UNIVERSITY OF ALABAMA IN HUNTSVILLE 26

27 Control Algorithm The coding logic is broken into six states and ground tested extensively. The is flow can be summarized as follows: State 0 Sitting on the launch pad, awaits launch detect State 1 Launch detect flag triggered, awaits motor burnout State 2 Determine roll direction and rotate control fins eight degrees so as to oppose initial rolling direction and hold for three seconds State 3 Return fins to a zero degree rotation (neutral) for one second State 4 Rotate control fins the opposite way of State 2 s direction and hold for three seconds State 5 Return fins to a zero degree rotation (neutral) and hold for remainder of flight UNIVERSITY OF ALABAMA IN HUNTSVILLE 27

28 Flight Test The control algorithm was tested and verified in a full scale flight UNIVERSITY OF ALABAMA IN HUNTSVILLE 28

29 Flight Comparison Validation that changing the fin angle of attack effects the roll rate UNIVERSITY OF ALABAMA IN HUNTSVILLE 29

30 Uncertainty & Calibration The roll rate is proportional to the oncoming air velocity squared. Measurements for velocity accumulate error quickly due to integration Alignment & Calibration of the IMU and servos has been difficult but is improving with each flight UNIVERSITY OF ALABAMA IN HUNTSVILLE 30

31 Verification and Testing UNIVERSITY OF ALABAMA IN HUNTSVILLE

32 Requirements Verification for Launch Vehicle Key items were included in the vehicle verification plan with traceability through the test plan Legend: V = Vehicle, P = Payload, R = Recovery, S = System, H = Hazard, T = Test Example: For a full list of Requirements & Verifications, see FRR Document, Appendix H: Vehicle Verification Requirements UNIVERSITY OF ALABAMA IN HUNTSVILLE 32

33 Tests Conducted **In addition to full scale and sub scale test flights UNIVERSITY OF ALABAMA IN HUNTSVILLE 33

34 Launch Day Procedures UNIVERSITY OF ALABAMA IN HUNTSVILLE

35 Launch and Assembly Procedures Standardization Allows for seamless modular changes to well developed documents Development Optimized operating procedures through test flights Review and Hazard Assessment Significant changes to existing procedures, particularly safety-critical items, have been subjected to peer review and hazard assessment Simulation and Training A red team runs approved procedures in a controlled environment to verify accuracy Implementation Finalized procedures are carried out under the supervision of the safety monitor and team mentor UNIVERSITY OF ALABAMA IN HUNTSVILLE 35

36 Launch and Assembly Procedures Step-by-step process starting with packing and prep that begins the day before launch Safety precautions and PPE requirements highlighted in RED Verification signatures required for each subteam s respective section Ejection charge and motor installation performed by team mentor Launch pad and rocket retrieval conducted by designated Red Team members Safety monitor delegates and oversees all launch and assembly procedures UNIVERSITY OF ALABAMA IN HUNTSVILLE 36

37 Launch and Assembly Procedures Pre-travel Preparation Pre-launch Assembly Motor Installation Final Checkout Prep Ejection Charges Upper Airframe Payload Verify Stability Margin Pack Supplies Drogue Verify Thrust to Weight Ejection Charges Flight Card Main Lower Airframe UNIVERSITY OF ALABAMA IN HUNTSVILLE 37

38 Program Management UNIVERSITY OF ALABAMA IN HUNTSVILLE

39 Program Schedule Spring 2017 UNIVERSITY OF ALABAMA IN HUNTSVILLE 39

40 Educational Engagement Event Date Type of Engagement Number of Individuals Impacted UAH Discovery Days 10/29/2016 Outreach: Direct Interaction 100 Girl's Science & Engineering Day 11/5/2016 Education: Direct Interaction 160 Girl Scouts STEM Fest 11/12/2016 Education: Direct Interaction 80 UAH Discovery Days 11/19/2016 Outreach: Direct Interaction 500 Society of Women Engineers: FIRST LEGO League Qualifier 1/14/2017 Education: Direct Interaction 400 UAH Engineering Organization Presentations 2/22/2017 Outreach: Indirect Interaction 300 Science Olympiad 3/4/2017 Education: Direct Interaction 50 FIRST LEGO League: Alabama Championship 3/4/2017 Outreach: Direct Interaction 100 8th Annual Gala for Sacred Hearts 3/4/2017 Outreach: Indirect Interaction 25 UAH Discovery Days Apr-17 Outreach: Direct Interaction 500 James Clemens High School Presentation Apr-17 Outreach: Direct Interaction 100 Total Impacted 2315 UNIVERSITY OF ALABAMA IN HUNTSVILLE 40

41 Program Total Budget Summary UNIVERSITY OF ALABAMA IN HUNTSVILLE 41

42 Program Budget Breakdown Full-Scale (One) Subscale (One) UNIVERSITY OF ALABAMA IN HUNTSVILLE 42

43 Program Budget Progression UNIVERSITY OF ALABAMA IN HUNTSVILLE 43

44 Questions? UNIVERSITY OF ALABAMA IN HUNTSVILLE 44

45 Appendix UNIVERSITY OF ALABAMA IN HUNTSVILLE 45

46 Drift Analysis Model Assumptions: Apogee occurs directly above launch rail. The parachute opens over a set time period. The drift distance stops when the first component lands. Horizontal acceleration is based on relative velocity Drogue drag neglected once main is fully deployed Validated against flight data from similar rocket UNIVERSITY OF ALABAMA IN HUNTSVILLE 46

47 Information on Website For the convenience of all team members, the following items will be located on the CRW team website: Material Safety Data Sheets Operators Manuals CRW Safety Regulations Safety Briefing slides Standard Operating Procedures The Safety Officer will work to keep this information relevant and up to date UNIVERSITY OF ALABAMA IN HUNTSVILLE 47

48 Thrust (lbf) Full-Scale Thrust Curves L1420 L Time (s) UNIVERSITY OF ALABAMA IN HUNTSVILLE 48

49 Flysheet UNIVERSITY OF ALABAMA IN HUNTSVILLE 49

50 Flysheet cont. UNIVERSITY OF ALABAMA IN HUNTSVILLE 50

51 Flysheet cont. UNIVERSITY OF ALABAMA IN HUNTSVILLE 51

52 Flysheet cont. UNIVERSITY OF ALABAMA IN HUNTSVILLE 52