THE STRATOS II+

GROUND CONTROL SYSTEM

Using the CompactRIO and LabVIEW to reach 21.5 km

H I NG

BE Y

ON

C
EA

Authors:
Radu Florea
Version:
V1.0
Sunday 30th October, 2016

DA

RE

.TUDELFT.

NL

Contents
1 Description

2 Products used

3 The Challenge

4 The Solution
4.1 Test Campaign . . . . . . . . . . . . . . . . .
4.1.1 Sensor and Actuator Subsystems . . .
4.1.2 Monitoring and Control Software . . .
4.1.3 Preparation for the Test Campaign . .
4.1.4 Outcome of Test Campaign . . . . . .
4.2 Launch Campaign . . . . . . . . . . . . . . .
4.2.1 Preparation for the Launch Campaign
4.2.2 Rain, Sun, and Fire . . . . . . . . . .
4.3 The Benefits of CompactRIO and LabVIEW
4.4 Conclusion . . . . . . . . . . . . . . . . . . .

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Description

Project Stratos represents the forefront of technology developed by Delft Aerospace Rocket
Engineering (DARE), a student society of TU Delft, having the ultimate goal of reaching space
with a rocket designed, built and launched entirely by students. As an intermediate step to
achieving this goal, the Stratos II+ rocket has been developed, and launched to a record breaking
altitude of 21.5 km, setting a new European altitude record for amateur rocketry. A picture of
the Stratos II+ rocket in the launch tower is presented in Figure 1.

Figure 1: The Stratos II+ rocket in the launch tower

In order to ensure the successful launch and flight of the Stratos II+ rocket, a multitude of
subsystems, have been developed, tested and integrated. These subsystems range from video
telemetry transmitters, separation mechanisms to propulsion systems and more. A critical subsystem, both during the propulsion system test campaign, as well as throughout the Stratos II+
launch campaign, is the CompactRIO-based ground control system (GCS). The GCS handles
all engine-related operations, such as filling, monitoring, ignition etc.

Products used

In order to develop a robust, modular, and easily maintainable GCS, the National Instruments
(NI) RIO architecture has been chosen as the basis for the new system. To this end, a number
of NI products have been used, all of them listed in Table 1.

Table 1: CompactRIO-based GCS overview

Module

Type

Purpose and Usage

NI 9203

20 mA 8-Ch AI Module

NI 9237

4-Ch Bridge AI Module

NI
NI
NI
NI

4-Ch Voltage AI Module

16-Ch Thermocouple Module
8-Ch High-speed DO Module
Combo 16-Ch DI/16-Ch DO Module

Acquire data from industrial grade

pressure sensors
Data acquisition from strain gage sensors
Data acquisition from actuator lines
Thermal data acquisition
PWM control of servo motors
Used to acquire state (On/Off) information on system components and
control the actuators in response to
the data received from all the sensors
Mounting chassis for the cRIO modules; communication with modules
Used for real-time control of the system, data processing and logging
All of the GCS software is developed
with LabVIEW
Used to develop the real-time control
software, running on the cRIO controller
Used to develop the FPGA software,
interfacing the modules

9215
9213
9474
9375

NI cRIO-9114

8-Slot FPGA Chassis

NI cRIO-9025

Real-Time Controller

NI LabVIEW
2013
Real-time
module

Software Package

FPGA
module

Software Add-on Module

Software Add-on Module

The Challenge

The Stratos II+ rocket is highly complex. In order to ensure the safety and the success of the
mission, all subsystems that are developed must work as reliably as possible. There is little
room for error in rocket science.
In order to be able to perform all test and launch operations as safe as possible, a remote
system (i.e. a ground control system) is needed. This system must be able to easily communicate with the rocket, gather data (i.e. engine pressure information, rocket weight, error
messages etc.) about the status of the subsystems, relay this data back to the remote station,
all while performing time-critical tasks that are crucial to the success of the test/launch.
Developing a rocket is subject to many changes during design, and especially during testing, as
there will always be different types of problems that need to be solved in between tests, giving
little time for the development of a dedicated custom electronic subsystem. Furthermore, the
ground control system is intended to be used for both for the engine test campaign and for the
launch campaign, thus, it must be easily adaptable.
The GCS must be modular so that it can be easily adapted or extended in order to accommodate
for any new requirements that may arise. At the same time it must be a robust system, since
it will be exposed to the extreme environment that rocket launching and testing. Reliability of
the GCS is crucial in order to ensure a high degree of safety in all conducted operations.

The Solution

Having a set of highly demanding requirements, with a limited time-frame, the choice to have
the CompactRIO as the core for the new Stratos II+ ground control system is evident.

Stratos II+ is powered by the DHX-200 Aurora rocket engine, a hybrid propulsion system
making use of liquid nitrous oxide as oxidizer, in order to burn the solid grain fuel (a mixture
of sorbitol, paraffin, and aluminium powder). The system makes use of the self-pressurizing
properties of nitrous oxide for oxidizer feeding.
The Aurora has a peak thrust of 12 kN (enough to lift a car), and specific impulse Isp = 205s,
making it one of, if not the biggest hybrid engine ever built by students. It is designed to run
for 25 s, with an average thrust of 8 kN , delivering a total impulse of 180 kN s.

4.1

Test Campaign

The Stratos propulsion team has undergone a total of 14 engine tests with the DHX-200 Aurora,
over a span of 2 years, performing numerous design changes and improvements throughout the
tests. The propulsion system test stand, at the TNO, Rijswijk facilities, is presented in Figure
2.

Figure 2: DHX-200 Aurora ready to be fired at TNO, Rijswijk

The feed system for the test campaign is presented in Figure 3. The feed system components
that are controlled through the GCS, together with their abbreviations, are presented below:
FV-1 Fill Valve 1 is the main actuator for filling the run-tanks. It is a combination
of a pneumatically actuated 1/2 valve and a small electrically actuated solenoid valve.
Actuation gas is nitrogen at a maximum of 8 bar originating from a separate N2 gas
cylinder cylinder with gas regulator. It is a normally closed (NC) valve.
DV Dump Valve is similar to FV-1. It is used to dump the nitrous oxide from the run
tanks in case of unforeseen issues or a power failure. It is a normally open (NO) valve.
BV Bleed Valve is a normally open (NO) solenoid valve used to vent gaseous nitrous
oxide from the top of both interconnected run-tanks during the filling procedure. Inside
the tanks it is connected to riser tubes that effectively limit the fill level of liquid N2 O in

both tanks to 85%. It also is a safety measure that automatically vents the run-tanks in
case of a power failure. It has a 1 mm orifice.
MV-1 Main Valve 1 is a 1/2 ball valve that is actuated by a servo.
MV-2 Main Valve 2 is a 1/2 ball valve that is actuated by a pneumatic actuator
operating from the same low-pressure nitrogen line as FV-1. It adds redundancy to the
main oxidizer line in case of an emergency engine shut down. It is a normally closed (NC)
valve.
IV 1/2 Ignition Valve are two normally closed (NC) solenoid valves connected in series
for redundancy and actuated at the same time used for priming the combustion chamber
with nitrous oxide prior to ignition.
XV Extinguisher Valve is a normally closed (NC) solenoid identical to IV 1/2 that
dumps nitrogen into the chamber after motor cut-off to properly extinguish any remaining
combustion.
XCV Extinguisher Check Valve is a one-way/check valve that separates the nitrous
oxide filled injector bypass line from the high pressure nitrogen architecture. It allows
nitrogen to be dumped into the chamber at any point in time.
PS-1 - PS-4 Pressure Sensor is used four times: One sensor measures the pressure
in the run-tanks (PS-1), another sensor measures combustion pressure just behind the
injector (PS-2), a third sensor measures the inlet pressure just before the injector plate
(PS-3) and a last sensor measures the feed system pressure right before the main valve
assembly (PS-4).

4.1.1

Sensor and Actuator Subsystems

An inventory of the test sensor subsystem is presented in Table 2. The location of some sensors
on the test set-up is illustrated in Figure 4 (PS-4 has been left out, since the actuators and feed
system are not drawn in the figure).
Table 2: Sensor overview. PS = Pressure Sensor, LC = Load cell, TC = Thermocouple, RC =
Relay Contact Sensor
ID

Description

Range

LC-1
LC-2
PS-1
PS-2
PS-3
PS-4
TC-1 - TC-8
RC-1 - RC-9

LC measuring run tank weight

LC measuring thrust
PS measuring run-tank pressure
PS measuring combustion chamber pressure
PS measuring inlet pressure
PS measuring feed system pressure
TC measuring casing temp. at different locations
RC monitoring relay switching

0 - 2 kN
0 - 50 kN
0 - 100 bar
0 - 100 bar
0 - 100 bar
0 - 100 bar
-50 - 800 C
0V/24V (On/Off)

The use of load cells, pressure sensors, and thermocouples is self-explanatory. The relay contact
sensors are used to monitor the switching of the relays used in actuator control. This is done
to detect any failure that might occur within the actuation subsystem.
A total of nine different actuators are used to control the propulsion system. An inventory of
the actuator subsystem is presented in Table 3.

BV
PRV-2

PRV-1

Nitrous
Oxide
Cylinder
1

Nitrous
Oxide
Cylinder
2

Nitrous
Oxide
Cylinder
3

PS-1

PG

DV

FV-1

CV-1 - CV-3
CGR-1

CGRV-1

N2O
N2

Run tanks

IV-1

PS-4

SV-1

MV-2

IV-2

CV-5
CGR-2 CGRV-2

SV-2

PS-3

MV-1
XCV

PS-2
CV-6
Large
Nitrogen
Cylinder

Small
Nitrogen
Cylinder

Motor

XV

BV:
Bleed Valve
CV:
Check Valve
CGR: Compressed Gas
Regulator
CGRV: Compressed Gas
Regulator Valve
DV:
Dump Valve
FV:
Fill Valve
IV:
Ignition Valve
MV:
Main Valve
PG:
Pressure Gauge
PRV: Pressure Relief
Valve
PS:
Pressure Sensor
SV:
Service Valve
XV:
Extinguisher Valve
XCV: Extinguisher Check
Valve

Figure 3: Feed system layout for the test campaign

Figure 4: Isometric view of the test setup with indicated location of sensors (hoses and actuators
are not shown).

Table 3: Actuator overview. BV = Bleed Valve, DV = Dump Valve, FV = Fill Valve, HC =

Heater Cables, IV = Ignition Valve, MV = Main Valve, XV = Extinguisher Valve
ID

Control method

Description

BV
DV

Solenoid (On/Off)
Solenoid (On/Off)

FV
IV 1/2

Solenoid (On/Off)
Solenoid (On/Off)

MV-1
MV-2

Servo - 50Hz PWM

signal
Solenoid (On/Off)

XV

Solenoid (On/Off)

HC

Contactor (On/Off)

Squib

Relay (On/Off)

Bleed valve used for venting run tanks

Dump valve used for dumping the oxidizer from the
run tanks
Fill valve used to fill run tanks with oxidizer
Ignition valves used for priming the combustion
chamber with oxidizer before ignition
Main valve used for opening the main oxidizer feed
line of the engine
Second main valve used for redundancy and quick
cut-off in case of emergency
Extinguisher valve used to dump nitrogen in the
combustion chamber to properly extinguish any remaining combustion
Heater cables used to heat up the run tanks in order
to pressurize the oxidizer
Squib used to ignite the pyrotechnic charge, igniting
the motor

4.1.2

Monitoring and Control Software

The monitoring and control software is the part of the GCS that brings everything together,
making sure that all conditions for a safe and successful test are met. It acquires data from
the modules, processes it, and performs real-time engine control actions based. The software
functions are presented below:
Automated pre-flight/pre-test systems check - this operation is performed in order to
verify the full functionality of the engine firing procedure, as well as to detect and localize
any actuator malfunctions such that the test/launch will be successful. This operation is
performed using the timer functions of the real-time controller, and by making use of the
information provided by the RC-1 to RC-9 relay switches.
Oxidizer tank filling and pressurization - these operations are initiated after all systems
have been set up, and the pad has been cleared of all personnel. First, the tank filling
(up to a weight of 80 kg) operation is performed. Based on data from the run tanks
pressure sensor, and the weight load cell, the bleed valve is opened, in order to vent the
tanks, whenever the mass differential over a time period of two minutes is less than a
predefined value (based on experience from tests). The pressurization operation follows,
during which the heater cables are turned on until a pressure of 60 bar is reached.
Time critical engine start-up sequence - in order to start up the engine, a time critical
sequence, initiated by the GCS operator, is conducted by the software. The sequence
involves squib activation, combustion chamber priming and main valve opening. If any
of these steps is not within the allowed time frame, it will result in an engine misfire.
Time critical runtime engine diagnosis - this operation is performed during engine runtime,
and it involves real-time monitoring of the pressure and temperature levels during the
propulsion systems operation. By processing this data in real-time, the software is able
to detect possible engine malfunctions and perform an immediate shut down.
Emergency shut down sequence - this sequence is performed in the case of an engine
malfunction during its operation. It involves closing the main feed line valve, and purging
the combustion chamber with nitrogen.

4.1.3

Preparation for the Test Campaign

Having set all the requirements for the new ground control system, work on the system started in
preparation for the final engine test campaign. An entire electrical system has been built around
the CompactRIO, focusing on general system robustness. Pictures of the GCS development,
assembly and testing are presented in Figure 5 and in Figure 6.

Figure 5: Ground control system close to being ready

4.1.4

Outcome of Test Campaign

Over the span of two years, and throughout 14 tests, the propulsion team has worked tirelessly
to improve the DHX-200 Aurora. Throughout the development of the engine, numerous failures
have been encountered and overcome. Failure modes such as grain cracking, chamber thermal
failure, combustion instabilities, and, even, nitrous oxide decomposition.
Overcoming all the hurdles in the development of the engine has been an immense challenge,
however, with the last test of the engine, all problems have been dealt with, and the Aurora
ran for 23 s after which the fuel ran out, resulting in the rupture of the chamber, due to its
walls being directly exposed to the hot flames. The video of the last test is shown below:
https://www.youtube.com/watch?v=S-hwm05Xo9o
Throughout the test campaign, the GCS proved that it is a highly robust and reliable system. This allowed the team to focus better on solving the failure modes of the engine, rather
than trying to fix faulty circuitry. Furthermore, it allowed us to quickly adapt the software to
new requirement. The LabVIEW user interface provided a good overview of the engines status
throughout the tests, it was clear, simple and easy to use by all the team members.

Figure 6: Testing all subsystems in preparation for the test campaign

Figure 7: The propulsion team ready for testing at TNO, Rijswijk

Figure 8: Propulsion team member monitoring the engine status during testing, using the
LabVIEW user interface

4.2

Launch Campaign

Having proven the flight readiness of the engine, the Stratos II+ team now focused on the launch
campaign, taking place in the south of Spain, throughout the month of October.
4.2.1

Preparation for the Launch Campaign

Having a variety of subsystems that need to be integrated, certain adaptations need to be made
to these systems for them to be able to function as a whole. The GCS, thus, needed to be
adapted, hardware and software wise, in order to be able to communicate with the rocket and
perform a different set of tasks than the ones performed during the test campaign. Furthermore,
the feed system (presented in Figure 9) layout has been altered for the flight version.
As it can be seen from the figure, the instrumentation on the engine has been reduced, and an
extra servo-actuated filling valve has been added (FV-2). Furthermore, a new voltage sensing
module (NI 9215) has been installed in the RIO chassis, in order to measure and diagnose actuator circuits. Once again, the modular architecture of the CompactRIO proves to be of great
benefit, allowing for the hardware changes to be conducted in a quick manner, and without any
complications.
The software running on the GCS has been extended with the DARE proprietary LaunchBox Protocol, and a register-like memory map, so that the system will be able to communicate
with all other subsystems and route information through to the control panel (CP). The protocol has been implemented over the serial RS-232 communication bus, using LabVIEW, which
allowed a quick and straight-forward implementation of the new software.

PRV

Nitrous
Oxide
Cylinder
1

Nitrous
Oxide
Cylinder
2

Nitrous
Oxide
Cylinder
3

Nitrous
Oxide
Cylinder
4

BV

N2O
N2

Nitrous
Oxide
Cylinder
5

Run tank
PG

PS-1
FV-1

CV-1 - CV-5

IV-1

FV-2
MV-1
CGR-2 CGRV-2

DV

PS-2

BV:
Bleed Valve
CV:
Check Valve
CGR: Compressed Gas
Regulator
CGRV: Compressed Gas
Regulator Valve
DV:
Dump Valve
FV:
Fill Valve
IV:
Ignition Valve
MV:
Main Valve
PG:
Pressure Gauge
PRV: Pressure Relief
Valve
PS:
Pressure Sensor
SV:
Service Valve
XV:
Extinguisher Valve
XCV: Extinguisher Check
Valve

CV-7
Motor

Small
Nitrogen
Cylinder

Figure 9: Feed system layout for the launch campaign

4.2.2

Rain, Sun, and Fire

The Stratos II+ launch campaign spanned three weeks, in the month of October, at the INTA
(Instituto Nacional de Tecnica Aerospacial) base, in Mazagon, southern Spain. Throughout
these three weeks, all system and payload testing and integration has been performed. Figure
10 shows the ground control system being set up on the launch pad.
With all the subsystems ready, the rocket set up in the tower, the go-for-launch is given. The
procedures went smoothly, and the rocket launched to 21.5 km! A compilation video of all the
launch campaign footage is shown below:
https://www.youtube.com/watch?v=IcXskiv1iyg

4.3

The Benefits of CompactRIO and LabVIEW

The RIO architecture was of great benefit to the entire project, as it allowed for swift changes in
the ground control system, without having to resort to hacked solutions. It, thus, resulted in
an increased system reliability, and increased confidence of the team in the GCS. The straightforward connection of sensors and actuators to the system allowed more members to work with
the system, reducing issues resulting from faulty connections.
Developing the software in LabVIEW represents a great advantage, since the monitoring and
control software could be developed in a short amount of time, due to the intuitive graphical
programming style. The debugging features of LabVIEW were of great use especially when
implementing the Launch-Box Protocol, as it allowed for the evaluation of the message string
at every step of its encoding and decoding. Furthermore, the user interface could be adapted
at any time, giving it flexibility in terms of the information that was desired to be displayed.

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Figure 10: CompactRIO-based ground control system being set up on the launch pad

Figure 11: The Stratos II+ rocket lifting off the launch pad

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Basing the ground control system on the CompactRIO has greatly reduced the development
time that would have been needed if a custom solution for the GCS would have been chosen.
This has also allowed the team members to spend more time on analysing information, in order
to improve on the efficiency of the rockets subsystems, without having to be concerned with a
badly functioning GCS.

4.4

Conclusion

The launch of the Stratos II+ rocket represents a great achievement for the entire team. The
experience gained throughout the project is invaluable. We were able to develop highly sophisticated systems, conduct propulsion tests and launch operations in a professional manner,
leading to a better understanding of professional life after university.
Having the CompactRIO as the basis for the ground control system, greatly reduced the development time for the GCS. It allowed us to have a fully functional, robust, modular system
within four and a half months after the start of the development. Furthermore, the ease of
programming in LabVIEW reduced the development time even further. Developing a custom
solution for the GCS would have resulted in at least ten-eleven months of designing, building
and testing the custom equipment and software. Thus, through the use of National Instruments
products, the development time has been reduced by more than 50%.
Using the CompactRIO and LabVIEW reduced the implementation issues, thus, the team
was able to focus on improving the design of the rocket, the efficiency of the propulsion system
etc., effectively allowing us to become better engineers.
Project Stratos has been an incredible and unforgettable experience. The aftermovie of the
launch campaign is presented below:
https://www.youtube.com/watch?v=WWNzVV-Pr I

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Figure 12: The Stratos II+ team on the launch pad

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