1 STUDENT LAUNCH INITIATIVE 2011 – 2012 OC Rocketeers PDR Presentation December 12, 2011 Student...

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STUDENT LAUNCH INITIATIVESTUDENT LAUNCH INITIATIVE2011 – 20122011 – 2012

OC RocketeersOC RocketeersPDR PresentationPDR Presentation

December 12, 2011December 12, 2011

Student Launch Initiative

AIAA OC Rocketeers

AgendaAgenda Introduction of team members (representing 4 high schools in Introduction of team members (representing 4 high schools in

Orange County California)Orange County California) Mission statementMission statement Partners in Industry and EducationPartners in Industry and Education VehicleVehicle

• DesignDesign• Dual Deployment Recovery SystemDual Deployment Recovery System• GPS TrackingGPS Tracking

Engineering payloadEngineering payload Risks and SafetyRisks and Safety Educational OutreachEducational Outreach Sustainability of rocketry projects in Orange County, CASustainability of rocketry projects in Orange County, CA Budget and TimelineBudget and Timeline Status and Next MilestonesStatus and Next Milestones

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AIAA OC Rocketeers

Mission StatementMission Statement

We, the OC Rocketeers, will construct We, the OC Rocketeers, will construct and launch a rocket that will reach a and launch a rocket that will reach a mile high while deploying an UAV. mile high while deploying an UAV. The rocket will include a dual deploy The rocket will include a dual deploy recovery and will remain reusable.recovery and will remain reusable.

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Partners in IndustryPartners in IndustryThis year’s project requires new and This year’s project requires new and

varied expertise. We have turned to varied expertise. We have turned to industry and education for guidance in industry and education for guidance in the following areas:the following areas:• Small RC Aircraft DesignSmall RC Aircraft Design• Bendable Wing TechnologyBendable Wing Technology• Autonomous flight electronicsAutonomous flight electronics• Composite materials constructionComposite materials construction• High power rocketry experienceHigh power rocketry experience

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Small RC Aircraft DesignSmall RC Aircraft DesignDr. Robert DaveyDr. Robert Davey

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• Retired aeronautical engineering professor from Cal Poly Pomona• Air ForcePilot T37s and T38s• Designed instruments for Viking Mars Landers and Pioneer Venus Probe• Designed instrumentation for meteorological research• Over 50 years of RC airplane experience• Past mayor of Duarte, CA

Bendable Wing TechnologyBendable Wing TechnologyDr. Peter IfjuDr. Peter Ifju

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• Professor at UF Gainesville• Author of several papers on the design and mechanics of Micro Air Vehicles• Developed bendable wing technology for small UAVs for military and DARPA• Co-holds patent on that technology• Gave team a wing and shared details of construction so we could make our own

Autonomous Flight ElectronicsAutonomous Flight ElectronicsDoug WiebelDoug Wiebel

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• PhD Student and research associate at University of Colorado• Full scale pilot as well as avid RC Flyer• Lead for the open source software development team for the ArduPilot Mega autopilot at DIY Drones that we are using• Considered that team’s fixed wing expert

Composite Materials ConstructionComposite Materials ConstructionMike KramerMike Kramer

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• Director of Research and Development for Ducommun Aero Structures• Over 23 yrs experience in composite structure, design and development• Holds degree in Engineering Mechanics – Polymers and composites• Awarded patent for manufacturing multi-walled composite structures• Avid rocketeer, Rocketry Organization of California (ROC) member, youth mentor, NAR Level 3

High Power Rocketry ExperienceHigh Power Rocketry ExperienceMike StoopMike Stoop

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• Owner of Mad Cow Rocketry• NAR Level 3 and California Pyro 3• Has built, designed, and flown hundreds of rockets• Has flown well over 15 dual deploy on “K” and above (many on “M” or above)

Vehicle – Full SizedVehicle – Full Sized(scale model will be 4” diameter fiberglass)(scale model will be 4” diameter fiberglass)

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Parameter Details

Length/Diameter 119 inches / 5 inches

Material Carbon Fiber

Shock Cord 1” Tubular Nylon

Center of Pressure/Center of Gravity 86.93”/71.45”behind nose tip

Stability Margin 3.1

Launch System / Exit Velocity 1” 6ft Rail/ 70.8 ft/s

Vehicle – Full Sized cont’dVehicle – Full Sized cont’d

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Parameter Details

Liftoff Weight 20.8 lbs

Descent Weight 17.8 lbs

Preferred Motor Aerotech K1050

Thrust to weight ratio 11.35 (1050 Newtons average thrust = 236 lbs / 20.8 lb vehicle)

Maximum ascent velocity 766.84 ft/s

Maximum acceleration 458.3 ft/s/s

Peak Altitude 5178 ft

Drogue – Descent rate 77.75 ft/s

Lower section under Main – Descent rate (Kinetic energy at ground level)

17.4 ft/s (48 ftlb-force)

Upper section under its own chute – descent rate (Kinetic energy at ground level)

17.2 ft/s (24.4 ftlb-force)

Vehicle – Forward SectionVehicle – Forward Section

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Parameter Details

Nose Cone Carbon Fiber 14” long

Body Tube Carbon fiber 5” diameter x 51.5” long

Bulkhead 3 ply x 3/32” = 9/32” fiberglass with “U” bolt for shock cord attachment


Sabot Carbon Fiber coupler, split lengthwise, hinged

Forward Cavity 8.5” x 5” diameter for ejection charge, shock cord, GPS, and forward section parachute (51.5” – 6” for avionics bay – 6” for nose cone – 31” for sabot)

Ejection Charge 1.5 grams

Vehicle – Avionics BayVehicle – Avionics Bay

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Parameter Details

Bay Material Carbon Fiber tubing 12” long – coupler for 5” body tube

Body Tube Carbon fiber 5” diameter x 1” long

Bulkhead 3 ply x 3/32” = 9/32” fiberglass with “U” bolt for shock cord attachment

Sled 1/8” plywood with ¼” threaded rods the entire length

Electronics HCX and Raven flight computers, Batteries

Terminal Blocks (for ejection chg)

Aft: Drogue primary and backup, Main primary and backupForward: UAV deploy primary and backup

Vehicle – Rear SectionVehicle – Rear Section

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Parameter Details

Body Tube Carbon fiber 5” diameter x 38.75” long

Centering Rings 2ply x 3/32” = 3/16” fiberglass with “U” bolt for shock cord


Rear Cavity 12.75” x 5” diameter for ejection charge, shock cord, GPS, and forward section parachute (38.75 + 3” for tailcone + 4” inside avionics bay – 6” for avionics bay overlap - 27” for motor)

Ejection Charge 2.0 grams (250lbs – 13psi)

Tender Descender

.33 grams (per the data sheet)

Aerotech K1050 Aerotech K1050

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Designation K-1050W-SU Total Weight 2128 grams

Manufacturer Aerotech Propellant Weight

1362 grams

Motor Type Single Use Average Thrust 1050.0 N

Diameter 54.0 mm Maximum Thrust 2164.0 N

Length 67.6 cm Total Impulse 2530.0 Ns

Propellant White Lightning

Burn Time 2.3 s

Cert Organization

TRA Isp 189 s

GPS TRACKINGGPS TRACKING

Beeline receives GPS positionBeeline receives GPS position• Encodes as AX.25 packet dataEncodes as AX.25 packet data• Sends as 1200 baud audio – 1 at each end of 70 cm ham bandSends as 1200 baud audio – 1 at each end of 70 cm ham band

VX-6R switched between two frequencies and extracts audioVX-6R switched between two frequencies and extracts audio TinyTrack 4 converts audio to digital NMEA location dataTinyTrack 4 converts audio to digital NMEA location data Garmin displays the digital location data on human screenGarmin displays the digital location data on human screen

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Transmitters in Vehicle

• Big Red Bee Beeline GPS• RF: 17mW on 70cm ham band• Battery and life: 750mAh 10 Hrs• Size: 1.25” x 3” 2 ounces

Ground Station

• Receiver: Yaesu VX-6R• TNC: Byonics Tiny Track 4• GPS: Garmin eTrex Legend

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Drift During RecoveryDrift During Recovery• Lower Sustainer Section

• I - Drops from 5,280 ft to 1,000 ft at 78 ft/s on 24” drogue• II - Drops from 1,000 ft to 850 ft at 61 ft/s on 24” drogue without the top section weight• III - Drops from 850 ft to 0 ft at 17.5 ft/s on 84” main

• Top Section (with UAV)• I –Drops from 5,280 ft to 1,000 ft at 78 ft/s on 24” drogue• II – Drops from 1,000 ft to 0 ft at 17 ft/s on 60” parachute

• UAV (if not separated from parachute)• I – Drops from 5,280 ft to 1,000 ft at 78ft/s on 24” drogue• II – Drops from 1,000 ft to 0 ft at 18.5 ft/s on 24” parachute

Lower Sustainer Section

Wind (MPH)

Wind (ft/s)

I - Drogue Range (feet)

II - Drogue Range (feet)

III - Main Range (feet)

Total Range (feet)

0 0.00 0 0 0 05 7.33 404 18 358 780

10 14.67 807 36 715 155815 22.00 1211 54 1073 233820 29.20 1614 72 1431 3117

Top Section

Wind (MPH)

Wind (ft/s)


II - Top Parachute

Range (feet)

Total Range (feet)

0 0.00 0 0 05 7.33 404 425 829

10 14.67 807 850 165715 22.00 1211 1275 248620 29.20 1614 1700 3314

Drogue if parachute does not separate

Wind (MPH)

Wind (ft/s)


II – UAV Parachute

Range (feet)

Total Range (feet)

0 0.00 0 0 05 7.33 404 398 802

10 14.67 807 796 160315 22.00 1211 1194 240520 29.20 1614 1593 3207

RecoveryRecovery

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• Recovery System consists of:• G-Wiz Partners HCX Flight Computer (4 pyro events)• 1.10” x 5.50” 45 grams • Accelerometer based altitude

• Raven Flight Computer (4 pyro events)•1.80" x 0.8" x 0.55." 27 grams • accelerometer based altitude

• Deployment bag with 84” Main Parachute• Two Tender Descenders in series (primary and backup)

Other Parachutes:• 24” Drogue• 60” Parachute for top body section• 24” Parachute on UAV

• Avionics Bay is coated with MG Chemicals SuperShield Conductive Coating 841 to minimize RF Interference

Recovery InterconnectRecovery Interconnect

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• Flight computers are powered from Duracell 9VDC batteries• Design includes 4 safety switches

• Raven Flight Computer Power (normally open)• HCX Flight Computer CPU Power (normally open)• HCX Pyro Power (normally open)• HCX Pyro Shunt (normally closed – last to be switched)

Recovery EventsRecovery Events

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• Redundant Dual Deployment from two different flight computers• Deployment consists of three separate events

• Event #1: Near apogee a black powder charge deploys the drogue parachute

• Rocket is in two sections tethered together

• Lower body tube with motor and fins• Nose cone, upper body tube with UAV, avionics bay

• Exposed and on the 1” Nylon shock cord:

• Drogue fully deployed• Main held in bag by Tender Descenders• One of two GPS (to clear carbon fiber body tube)


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AIAA OC Rocketeers

• Event #2: At 1000 ft (backup at 900 ft) a second ejection charge separates the rocket further

• Lower body tube with motor and fins still on drogue tethered to the avionics bay only• Upper body tube tethered to the nose cone and the opened sabot is all under another deployed parachute• Second GPS is now exposed on the 1” nylon shock cord• UAV has deployed from the sabot and is under its own parachute


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AIAA OC Rocketeers

• Event #3: At 850 ft (backup at 750 feet) a third black powder charge in the Tender Descenders deploys the main. There are now three pieces descending

• Lower body tube with motor and fins still on the main parachute tethered to the avionics bay• Upper body tube tethered to the nose cone and opened sabot under its own parachute• UAV has deployed from the sabot and is under its own parachute waiting for safe release

Launch SimulationsLaunch Simulations

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• Simulations were run using Rocksim• Over 100 simulations were run to fine tune vehicle• Dimensions, weights, and launch conditions were varied• Once vehicle was designed varied engines to attain 1 mile altitude• Verified top speed was still subsonic• Verified range with varied winds

UAV Payload SystemUAV Payload System

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The UAV System consists of• 2.4 GHz RC Control via Spektrum DX-7• 900 MHz telemetry link using X-Bee for

• Altitude via barometric pressure• Speed via pitot tube and pressure sensor• Artificial horizon via 3 axis magnetometer

• 1.2 GHz Video downlink• Video data converted to USB for interface similar to web cam

Note: Rocket also uses two separate GPS transmitters for tracking

UAV DesignUAV Design

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• Fuselage length: 30 inches• Wingspan: 30 inches• Weight: 1 lb• Material

• Wing: Carbon Fiber Composite• Fuselage: Carbon Fiber Composite

• Electronics• Selectable RC control or Autonomous• Real Time video• Telemetry

• GPS Position• 3 axis accelerometer• Airspeed

• Microswitch and solid state relays turn electronics ON when UAV deploys

Note: Photo from similar UAV at University of Florida Gainesville UAV lab

UAV Electronics SystemUAV Electronics System

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Main UAV ElectronicsMain UAV Electronics

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Ardupilot Mega Autopilot GPS MediaTek MT3329 Axis Magnetometer - Arduino CPU board - Position for autopilot - Telemetry for gnd stn - IMU “Shield/Oil Pan” - Position for ground stn

X-Bee 900 MHz tx Sony Video Camera Lawmate Video Tx - Relays telemetry data - provides real time video - Relays video real time - Position information

UAV – Bendable WingUAV – Bendable Wing

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• Developed by Peter Ifju and others at the University of Florida in Gainesville• Uses molded carbon fiber cloth• Functional airfoil is also like a tape measure – it can be bent but straightens back out

• Dr Ifju shared the design and fabrication techniques with us• He gave us one wing• We had that wing digitized through a 3d laser imaging firm (resulting in an .igs file)

• A mentor helped us create a digital file for use with a CNC machine• We are looking for some inexpensive time on a CNC machine so we can create a mold to make our own wings

UAV – Bendable WingUAV – Bendable Wing

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UAV – Bendable Wing FabricationUAV – Bendable Wing Fabrication

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All photos taken at the composites lab at University of Florida Gainesville

Foam Mold Release Film + Carbon Fiber Release Film

Vacuum Bag Place into oven Vacuum and bake

UAV – Ground StationUAV – Ground Station

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UAV Ground Station• Allows RC control of UAV• Allows switching between RC control and autonomous flight• Displays real time telemetry data• Displays real time video from the UAV

Payload/Vehicle IntegrationPayload/Vehicle Integration

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Photos from “Development of a Composite Bendable-Wing Micro AirVehicle” by Dr. Peter Ifju et al URL: http://baronjohnson.net/Publications/ASM2007.pdf

• UAV is encased in a sabot• Protects the UAV from ejection charge• Provides a clean method for deploying the vehicle from the body tube

• Deployment and flight plan• Ejection before main at 900 ft• UAV will descend under parachute until verified flight-worthy• Parachute will be released• UAV will fly under RC control• If save, UAV will fly pattern under autonomous control• Return to RC control for landing

RisksRisks

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5 Risk: The rocket weather cocks

10 Risk: The Rocket lands in mud

15 Risk: A parachute misfires

20 Risk: The tracking device isn’t accurate

25 Risk: The UAV hits an object

30 Risk: The battery(s) of our electronics bay fall out

4 Risk: The engine “chuffs”

9 Risk: The rocket lands in a dangerous area

14 Risk: The batteries die during launch

19 Risk: A servo cable on the UAV catches

24 Risk: A part or battery disconnects

29 Risk: No recovery system

3 Risk: the rocket struggles off the launch pad

8 Risk: Interference of the lawmate video transmitter and xbee telemetry

13 Risk: a parachute fires at the wrong alititude

18 Risk: The electronics in the UAV over heat

23 Risk: Sheer pins aren’t put in place

28 Risk: Loss in signal via controller

2 Risk: The rocket folds upon itself

7 Risk: The parachute tangles around the UAV

12 Risk: The engine explodes

17 Risk: The UAV Motor propeller breaks during sabot release

22 Risk: Tracking device is damaged in launch

27 Risk: The black powder is not the correct amount

1 Risk: rocket misfires Mitigation: check continuity

6 Risk: The Parachute doesn’t detach from the UAV

11 Risk: The Rocket’s fins break

16 Risk: The altimeters aren’t set to fire the parachutes

21 Risk: Tracking device doesn’t transmit radio waves

26 Risk: The electric match doesn’t ignite the black powder

Risks MitigationRisks Mitigation

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5 Mitigation: the design is not over stable

10 Mitigation: Make sure launch site is dry

15 Mitigation: double check programming on the altimeter is correct

20 Mitigation: Make sure tracking device works

25 Mitigation: UAV can be switched from autopilot to manual mode Each member in the payload subsection will know how to fly the UAV

30 Mitigation: zip tie batteries and double check connection

4 Mitigation: make sure igniter is all the way in the engine

9 mitigation: Launch site is clear of all hazardous materials

14 Mitigation: use fresh batteries

19 Mitigation: test the cables before flight and have a large enough opening

24 Mitigation: use strong connectors and zip ties to secure wires

29 Mitigation: Double-check our rocket is set up correctly

3 Mitigation: use the correct size launch rod

8 Mitigation: Make sure that the frequencies do not interfere with one another


18 Mitigation: Air vents will be placed for the entering and exiting of air – this will provide enough ventilation

23 Mitigation: double check the rocket before placing on the launch pad

28 Mitigation: using a 2.4GHZ radio for long range and less interferences

2 Mitigation: body tube and nose cone are fiberglass

7 Mitigation: Make sure the parachute is correctly folded

12 Mitigation: make sure there is no defects in engine

17 Mitigation: A folding propeller will be used – this opens up when the motor powers on.

22 Mitigation: Make sure Tracking device is secure and is fully encased in the Styrofoam

27 Mitigation: have a backup charge to either “blow it out or blow it up”

1 Mitigation: check continuity

6 Mitigation: Check harnesses and linkages

11 Mitigation: Use in wall fins


21 Mitigation: double check tracking device is on

26 Mitigation: make sure there electric match is touching the black powder

SafetySafety

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• Follow NAR and TRA safety rules for launch• Safe material usage restrictions• Safe distance from launch pad• Safe recovery area• Inspection by range safety officer before flight

• Follow our check list when preparing for launch• Have fire extinguisher and first aid kit on site• Follow our own (AIAA OC Section Rocketry) safety rules for shop• MSDS referred to as needed (can be found on our web site)• Manuals are posted on the web site since they contain set-up information for recovery electronics• Presentation given to all team members with their signature that they attended and understand

Educational OutreachEducational Outreach

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• Space 2011 Education Alley (Sept – too early for credit) • Girl scout workshop and launch outing in October/November 2011• Giving presentation to AIAA professional society council meeting with all AIAA members in Orange County invited in 2012• Newspaper articles

• Article in Sunny Hills High School (Fullerton, CA) school paper• Try for article in the Orange County Register• Try for article in local paper in Orange, CA – The Foothills Sentry

• Presentations at Orange County 4H clubs• Contact Discovery Science Center for youth booth• Youth Expo at the Orange County Fair Grounds

Sustainability of youth rocketrySustainability of youth rocketryOrange County, CAOrange County, CA

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• Monthly build sessions as NAR Section #718• Monthly launches with local clubs (Rocketry Organization of California - ROC, Diego Area Rocket Team –DART, and Tripoli San Diego • Annual booth at the Education Alley portion of Space (2012 and beyond)• Annual booth at Youth Expo at the Orange County Fairgrounds• Maintain web site at http://aiaaocrocketry.org promoting rocketry and providing information at all levels

Budget - ExpendituresBudget - Expenditures

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Budget – IncomeBudget – Income

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• NASA Grant for SLI teams• Fundraising letters

• Boeing• Raytheon• Northrop Grumman• Lockheed Martin

• Sees candy sales

TimelineTimeline

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Status and Next MilestonesStatus and Next Milestones

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Milestone Status

Full Size Rocket Design Complete

Scale Model Rocket Design Complete

Scale Model Rocket Build Scheduled Start 12/17 (break)

Scale Model Rocket Launch Early January 2012

UAV conceptual design Complete

UAV Hardware identified Complete

UAV Bendable Wing Looking for CNC machine time

UAV Materials (except mold) Complete

UAV Final Design January 2012

UAV Build and Test January – February 2012

Thank you for letting us Thank you for letting us be part of SLI againbe part of SLI again

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1 STUDENT LAUNCH INITIATIVE 2011 – 2012 OC Rocketeers PDR Presentation December 12, 2011 Student...

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