Uah 2018 PDR Presentation

NASA SL
Preliminary
Design Review
University of
Alabama in
Huntsville
University of Alabama in Huntsville
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USLI PDR
Mission Summary
• Design, fabricate, test and fly a rocket and
payload to 1 mile in altitude
• Deploy a rover upon landing to autonomously
travel and unfold solar panels
• Conduct STEM outreach with students
*Throughout the presentation, all dimensions are in inches

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VEHICLE DESIGN

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Vehicle Summary
• Launch Vehicle Dimensions
– Fairing Diameter: 6 in.
– Body Tube Diameter: 4 in.
– Mass at lift off: 39.7 lbm.
– Length: 96 in.
• Concept
– L-Class Solid Commercial Motor
– Rover Delivery
– Electronic Dual Deployment
– Fiberglass Airframe

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Vehicle System Locations
Tracking/Rover
Deployment
Avionics Recovery
Rover Piston Avionics Fins (x4)
Main Drogue
Parachute Parachute
CG CP
51 in. 63 in.
Payload
Fairing Forward Aft
36 in. Airframe Airframe
Coupler
24 in. 12 in. 41 in.
University of Alabama in Huntsville 5

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Vehicle CONOPS
Deploy Drogue:
19 seconds
5,282 ft.
Powered Ascent:
0 – 3.2 seconds
0 – 1,050 ft.
Deploy Main:
50 seconds
600 ft.
Landing:
100 seconds
0 ft. Deploy Rover:
Team Command

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Flight Simulation
Attribute Value
• OpenRocket Sim: Apogee (ft.) 5282
– A 1-D in house Length (in.) 96
Monte Carlo
Max. Mach Number 0.56
simulation will be
used to verify results Rail Exit Velocity (ft./s) 55.7
– Results will also be Static Stability (cal.) 2.0
compared to flight
Motor Designation AT L1520T - P
tests for verification
Thrust-to-Weight Ratio 8.7
CG 51 in.
CP 63 in.
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Simulation Results
• Apogee of approximately 5282 ft. at 19 sec.
• Motor burnout at approximately 1050 ft. at 3.2 sec.
Burnout at 3.2 sec.
Apogee of 5282 ft. (19 sec.)
50 sec. Main deploy (600 ft.)

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Stability Analysis
• Stability of 2.06 cal. at rail exit
– Calculated with no wind conditions
• Stability of 2.74 cal. at motor burnout
Maximum Stability: 2.74
Takeoff Stability: 2.06

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UPPER AIRFRAME
Forward Body Tube

Nose Cone Payload Fairing Transition

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Forward System
Overview
Objectives
• Protect and deploy the payload
• House assembly for tracking vehicle location
• Transition upper airframe to payload fairing
Payload Piston Avionics Bay

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Nose Cone and Fairing
6.0 in. 2.0 in.
6.0 in.
24.0 in.
• 3D printed High Strength ABS
• Ejected with rover deployment • Responsible for housing the rover and rover
• Room to store ballast for stability deployment system
• No electronics housed inside • Filament wound fiberglass
• Shear pin interface
• Bulkhead at base
• 6 in. ellipsoid shape
• 2 in. shoulder

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Piston Overview
• Used to deploy rover from fairing
• Spring driven spike punctures cartridge
• Spring released by hotwire upon
command; redundant arming
Plunger
Ø 6.0 in.
•Machined from aluminum

•Powered by 8 or 12 gram CO2 cartridge
Cylinder •Plunger tethered to base
Ø 6.0 in. •Standard Operating Procedure in development

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Fairing Transition
• Aerodynamic transition between upper airframe and fairing,
load path supplemented with aluminum insert
• 3-D printed with ABS plastic, single piece design
• Threaded rod in tension connecting to aft bulkhead to built in
forward coupler

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Fairing Transition
• Problems with ABS single piece design
– Mass: 4.7 lbm
– Complicated FEA
– Structurally weak without aluminum insert
– Aluminum insert could pose manufacturing difficulties
• Other options considered:
– Aluminum brace with direct bulkhead connection, purely aerodynamic
cover

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CENTRAL
SUBSYSTEM

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Central Subsystem
Overview
• Central Subsystem responsibilities:
– Primary coupler between airframes
– Flight Avionics
– Ejection System
– Tracking and Ground Station
– Recovery System

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Coupler
Aluminum Bulkheads
Stratologger CF
U Bolt Altimeter (2 Places)
(2 Places)
All-Thread (2
Places)
9V Battery (2 Places) 9 in.
12.5 in.
3D Printed
Avionics Sled
1 in.
1 in.
Switchband
Switch/Pressure
Equalization holes
(2 Places)
Black
Powder
Housing
(4 Places)
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Avionics
Recovery Avionics Subsystem
• 2 PerfectFlite StratoLoggerCF altimeters; each
with a 9V battery and SPDT momentary
activation switch
• 4 Safe Touch terminals, E-matches, and black
powder charges
• Full redundancy in avionics and ignition

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Recovery Deployment
Avionics
• Normally Closed SPDT Pull Pin • Primary Main fired at 600 ft.
Microswitch – Secondary fired at 550 ft.
– Prevents detonation during • Primary charges are roughly 4 g of
assembly black powder
– Helps preserve battery life • Secondary charges are 2 g larger
• Primary Drogue charge fired at apogee than primary
– Secondary fired one second after

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GPS Tracking Subsystem
System
• CRW will reuse a previously designed PCB that contains an Xbee Pro-
PRO 900HP RF module, and an Antenova GPS Chip
– PCB will includes traces for all relevant connections including
battery sources.
• Xbee transmits GPS coordinates to a receiver connected to the
ground station laptop.
• Tests will be performed prior to the full scale launch to verify
operation success
Structure Integration
• 3D printed mount to secure tracker and its essentials within the
transition section of the rocket.
• Three axis security and battery retention to ensure components are
kept in tact

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Recovery System
• Drogue Parachute Deployment: • Main Parachute Deployment:
– Deployment at apogee – Deployment at 700 ft. above ground
– Fruity Chute CFC-18 (CD = 1.5) level
– Shock Cords: 1 inch Nylon (50 ft.) – Fruity Chute 60 in. Iris Ultra (CD = 2.2)
– Connected between forward motor – Shock Cords: 1 inch Nylon (50 ft.)
retention bulkhead in lower airframe – Connected between fairing bulkhead
and avionics bay housing. and avionics bay housing.
– Descent speed under drogue: 62.2 ft/s – Descent speed under main: 15.23 ft/s
• Open Rocket Simulation between 0 and 20 mph winds showed a

maximum drift at 15 mph of about 1,700 ft.
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Recovery System
Calculations
• Required that each individual • The largest independent section
section will have a maximum is 15 lbm, so the safe descent
kinetic energy of 75 ft-lbf speed was determined to be
• For initial calculations, a 17.9 ft/s
conservative estimate of 75 ft- 8𝑚𝑔
lbf was used for the heaviest • 𝐷=
𝜋𝜌𝐶𝐷 𝑣 2
section – D = diameter of parachute, ft.
1 –
• 𝐾𝐸 = 𝑚𝑣 2 m = mass of vehicle, lbm
2 – g = force of gravity, ft/s2
– m = mass of the section, lbm – 𝝆 = density of the air, lbm/ft3
– v = velocity, ft/s – CD = Coefficient of Drag
– v = previously calculated velocity, ft/s
• Minimum Diameter must be
93.3 inches

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Load Path (Drogue and
Main)
• The load in 1, 2, and 3 are
causing tension under
Drogue and Main.
Shock cord applies load to
eyebolt in the coupler
bulkhead.
• The load in 4 is transferred
3 through the all thread and
down to the motor casing
2 then back up the tube.
1 represents force due to drag

4
represents the force due to

mass
University of Alabama in Huntsville 24

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AFT SUBSYSTEM

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Aft System
Objectives
• Objectives/Responsibilities
– Fin Design
▪ Optimize dimensions and materials for
flight stability
– Centering Ring/Thrust Plate
▪ Carry load path from the vehicle
▪ Centering and fin integration ability
– Forward/Recovery Retention
▪ Provide method for recovery attachment
▪ Carry thrust through the vehicle via
forward retention

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Aft System
Components
• Design Overview
– Through the wall design/slotted body tube
▪ Slots allow for fin mounting integration
– G10 Fiberglass fins attached with seven 4-40 bolts per fin
▪ Fins will be mounted to centering ring
– 3-D printed centering ring/fin mounting bracket
▪ Can be removed from body tube for repair/inspection
– Aluminum Forward/Recovery retention bulkhead
▪ Uses U bolt for recovery system
Trapezoidal Fin(s) (4)
▪ Motor case tapped to allow for forward retention
Forward/Recovery
Retention Bulkhead
Motor/Motor Casing
Thrust Ring
Secondary Centering Ring
Fin Can/Centering Ring
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Motor Selection
• Other motors considered: Aerotech L1520R-P Specifications
– L1150 Motor Designation L1520T-P
▪ Too little total impulse
– L850 Apogee 5,282 ft.
▪ Too slow off the rail Stability 2.0 cal.
– L1390
▪ Too much total impulse Ballast 51 in.
Diameter 75 mm. (3 in.)
Length 25.7 in.
Propellant Mass 8.0 lbm
Total Impulse 835 lbf.-s
Max Acceleration 289 ft./s2
Velocity off the Rail 55.7 ft./s
Burn Time 2.5 sec
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Motor Retention
• Forward Retention
Bulkhead
– Screwed onto top of
motor
– Recovery retention is
fixed on U-bolt
– 3.9 in. diameter
– 0.5 in. thick Aluminum
– Fixed to body tube with
four ¼-20 screws

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Fin Can
• Requirements fulfilled by part: motor centering, fin
mounting, thrust takeout from motor
• Material: 3D printed high strength ABS plastic
• Location: inserted in the bottom of the aft body
tube
Fin Can

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Fin Can Dimensions

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Secondary Centering
Ring
• Purpose: align motor as it is inserted into the rocket
• Bolted to the aft body tube using 4-40 bolts
• Material: Polycarbonate

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Fin Design
• Trapezoidal Fin Design
– Allows more freedom in fin design
– Adjust fin shape to shift CP
• Fin Dimensions
– 8 in base
– 3.5 in height with extended base for body tube insertion
– Seven holes allow integrated mounting to centering ring located
inside body tube
– Rounded leading edge
• Fin Material
– G10 Fiberglass
– Will be fabricated/designed in house
• Fin Mounting
– Fins mounted through the body tube to centering ring
– Replaceable upon breakage/damage
• Flutter speed
– Calculated to be 1444.76 mph (Mach 1.88)

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Fin Material
• Fins made out of G-10 • Flexural Modulus:
fiberglass – Crosswise: 2400 ksi
• This material was – Lengthwise: 2700 ksi
chosen for its high • Compressive Strength: 65 ksi
strength to weight • Its density is 0.065 lbm/in^3.
ratio
• Tensile Strength:
– Crosswise: 38 ksi
– Lengthwise: 45 ksi
• Flexural Strength:
– Crosswise: 65 ksi
– Lengthwise: 75 ksi

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Fin Retention
• Each fin mounted with
seven 4-40 bolts;
normal to fin face
• Four sets of ten 4-40
bolts normal to body
tube surface used to
maintain body tube
shape under motor
thrust

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Subscale Rocket
3.0 in Subscale Rocket
6.0 in Full-Scale Rocket
• Approximately half-scale
– 4 in. body → 2.125 in. body – 3 in. motor → 1.5 in. motor
– 6 in. fairing → 3 in. fairing – 96 in. length→ 49 in. length
– Mach 0.56 → 0.49 – 9.0 G → 15.2 G

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PAYLOAD DESIGN

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Payload Summary
• Objective: Design an autonomous rover that will deploy from
the interior of the rocket, move a minimum of 5 ft. away from
the rocket, and deploy solar panels
• The rover’s design consists of a rectangular chassis, two

expandable wheels, and a stabilizing arm
• The rover measures temperature, pressure, location, and

transmits this data with images to a ground station

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Rover Assembly
• The tail will be wrapped around the chassis while inside the fairing.
• Rover will be kept collapsed passively by the fairing.
• The collapsed diameter is 5.7 in with 0.15 in of clearance.

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Rover Assembly
• Rover wheels will expand to
14.24 in. diameter when
deployed
• Wheels rotate
independently. Allows for
steering via differential
• Lid will slide open via linear
gear driven by a DC motor
• Solar panel will increase its
effective area from 0 to
100%
• Solar panel will charge
battery for distance
extension

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Rover Chassis Trade
Study
3D Printed ABS Aluminum Base/3D
Aluminum Unibody
Unibody Printed ABS Walls
Ease of Manufacturing 2 5 4
Strength to Weight 5 2 3
Environmental
5 2 1
Protection
Total Score 12 9 8
• Aluminum Unibody selected

– Highest strength to weight design
– Resistant to drastic changes in temperature
– Least deflection under load protects motors and electronics
• 3D Printed ABS Unibody is secondary selection
– Will be used if aluminum unibody is too difficult to manufacture

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Rover Chassis Design
• The chassis will be milled out of a single block of 6061-T6 aluminum

• The chassis will house all electronics
• The drive motors will be mounted directly to the sidewalls
• The tail will be mounted to the bottom of the chassis

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Rover Chassis Stress
Analysis
• The chassis can sustain a 30G (210 lbf) load to the sidewall, simulating a load from
the wheel during adverse deployment conditions (left)
• The chassis can sustain a 30G (210 lbf) load to the base, simulating loading from
inside the rocket upon landing (right)

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Rover Tail Trade Study
Wheel
18 inch 11 inch
Rotation
Measuring Sideways
Tape (Wrapped Hinged
around) Aluminum Tail
Ease of
5 2
Manufacturing
Strength 3 5
Tail Length 5 3
Total Score 13 10
Counter moment
from tail
• Measuring Tape selected

– Ease of manufacturing
– Results in a longer tail and moment arm
• Sideways Hinged Aluminum is secondary selection
– Will be used if measuring tape fails integration and deployment
tests

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Trade Study: Wheel
Design
• Main Goals for design: Expanding wheels
– 6 in. diameter constraint while inside rocket
– > 6 in. diameter desired for handing terrain
• Chosen Design: Umbrella wheel
– Desired for handling terrain
– All designs similarly decent in other categories
Telescoping
Foam Umbrella wheel
Wheels
Cost 3 4 3
Design Complexity 2 4 3
Low Risk of Damage 4 5 4
Terrain Effectiveness 4 1 5
Total 13 14 15

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Trade Study: Wheel
Material
• Main Considerations:
– Pushing wheels out of rocket without taking damage
– Ease of manufacturing wheel shapes
• Chosen Material: Aluminum
– Highest strength while maintaining low weight
– Easiest to manufacture wheels
Aluminum ABS Polycarbonate
Cost 4 3 3
Design Complexity 5 4 4
Weight 3 5 4
Strength of Material 5 3 4
Total 17 15 15

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Wheel Design
• Current Chosen Design: Umbrella
Wheel – 0.703 lbm
– 5.7 in. diameter wheel expands to 14 in.
diameter wheel
– Linear extension spring for compression
and expansion
– Keeps compressed while in rocket,
expands naturally once out
– Spring located on the exterior, pulls in to
bring spoke vertical
– Rod used for assembly of main wheel to
spokes

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Wheel Design
Main Wheel
• Made of Aluminum 6061 – T6
• Eight notches for eight spokes, holes for attaching spokes with rod

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Wheel Design
Spoke
• 6061 – T6 Aluminum
• 0.75 in. extrusion for grip with expanded wheel
• Circular piece for attaching to wheel base

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Wheel Design
Motor Mount
• 6061 – T6 Aluminum
• Attaches to wheel base

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Main Wheel
• Can withstand 120 lbf before yielding
• Load: Pushed out by piston, no more than few pounds
• Will likely be more distributed to entire wheel base

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Spoke
• Can withstand 35 lbf before yielding to 40 ksi
• Max Stress – 15 ksi
– Full weight of rover and motor torque

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Motor Mount
• Can withstand 900 lbf before yielding
• Load: Pushed out by piston, absorbed by other parts
• Max load by piston no more than a few pounds

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Solar Deployment
Gear System Hinge
• Sliding solar panel lid utilizing
remote servo gear Simplicity 3 4
• Solar panels will remain static Functionality 5 3
• Solar panels recharge battery Weight 2 2
Cost 1 1
Total Score 11 10
• Two different designs considered for solar

panel deployment mechanism
̶ Gear system lid
̶ Hinged lid
• Lid with gear system was selected
– Hinge mechanism would be harder to
close once opened
– Gear system would be easier to bring the
cover back over the solar panels
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Rover Mass Budget
Component Mass (lbm)
Chassis 2.5
Wheel Assembly 1.4
Lid/Solar Deployment 1.0
Tail 0.1
Electronics 1.4
10% Margin 0.6
Total 7.0
• The mass of all components totaled 6.4 lbm.

• A 10% Margin was added to the total weight to
account for fasteners, adhesives, and design changes
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Battery Trade Study
• Three different batteries considered
– 3x Li-Ion 18650 in series
– 4x CR123a Surefire in series
– 8x Energizer Recharge Power in series
• Trade studies conducted by rating each battery’s benefits on a scale of 1 – 5
• Li-Ion 18650 was selected based on criteria
Energizer Recharge Power

Li-Ion 18650 CR123A Surefire
Plus
Power 4 3 4
Capacity 5 4 4
Weight 4 3 2
Safety 3 5 5
Reusability 5 5 5
Power Density 5 3 2
Total 26 23 22

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MCU Trade Study
Arduino Mega Arduino Uno PCB with Beaglebone Raspberry Pi 3
ATMega 2560
Clock Speed 3 3 3 5 5
I/O Pins 5 3 5 3 4
Operating 4 3 4 2 4
Voltage
Power Draw 4 4 4 3 1
Complexity 4 4 2 5 2
Volume 3 4 3 4 3
Mass 4 5 4 4 3
Cost 4 4 2 2 4
Total 31 30 28 28 28
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Component Selection
Component Selection Features
• (7 – 12) Vin
MCU Arduino Mega • I2C, SPI, UART, GPIO
• 16 MHz
• Accelerometer
• Gyroscope
Adafruit LSM9DS0
IMU • Magnetometer
• 3 Axis
• I2C, SPI
• Press range: (300 – 1100) hPa
Temperature and Adafruit BMP280 • Temp range: (-40 – 85) °C
Pressure Sensor • SPI, I2C
• 0.8" x 0.7" x 0.1"
• 12 V
• At load 410 mA
Cytron DC Geared Motor
Motor • Stall torque 1.18 Nm
SPG30-300K
• Mass: 160 g
• Brushed

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Selection cont.
Component Selection Features
• 100mA
Solar Cell OSEPP Monocrystalline Solar Cell • 5V
• 4” x 3” x 0.2”
• 5V
• 20 mA
GPS Adafruit MTK3339
• 10 Hz updates
• -165 dBm sensitivity
• 28 mile range (with high gain antenna)
• 900 MHz
Radio X-Bee PRO
• Data rate 200 kbps
• UART, SPI
• 5V DC
Lid Motor NMB Technologies PPN7PA12C1 • Brushed
• 0.022 lbm
• 3.3 V output
DC/DC converter LM3671 Buck Converter • 600mA draw
• 0.6" x 0.4" x 0.1"
• 640×480 VGA
Camera ArduCam CMOS OV7670
• 3.3V supply needed
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Power Budget
𝐼 𝑚𝐴 ∗𝑉 𝑉 ∗𝐷𝐶 ∗𝑇𝑖𝑚𝑒 ℎ𝑟
Required battery capacity = 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 ∗11.1 𝑉
Current Voltage Duty Efficiency Necessary Capacity

Component Time (hr)
(mA) (V) Cycle (%) (%) (mAhr)
Arduino Mega 50.0 5.00 1.00 100 100 22.5
Pressure/
1.12 5.00 0.25 100 100 0.13
Temp
IMU 6.10 5.00 1.00 100 100 2.75
Wheel Motors 820 11.1 0.17 100 100 136
Lid Motors 96.0 5.00 0.01 100 100 0.43
Radio 210 3.30 1.00 100 80.0 78.0
Camera 20.0 3.30 0.25 100 80.0 1.86
GPS 20.0 5.00 0.25 100 100 2.25
Voltage
600 5.00 1.00 100 100 270
Regulator
Required Capacity Available Capacity

Safety Factor
(mAhr) (mAhr)
514 2600 5.06
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Component
Block Diagram

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Payload Software Flow
Diagram
Once acceleration is
Remove RBF; Takes acceleration Rover transmits
zero for several
Payload detects data throughout acknowledgement,
iterations, waits for
launch via flight, calculates waits for confirmation
deployment signal
acceleration changes signal
from ground station
Supplies power to Get position data via

Transmit data back
Receives motor, begins taking GPS and
to ground station,
confirmation signal; temperature, accelerometer;
save on board to
Delays 30 seconds pressure, and IMU Sample 2 times per
eeprom
data second
If position change by Once distance Transmit data back

a certain margin, traveled, deploy Measure battery to ground station,
back up, turn motor, solar panels, end voltage save on board to
begin moving again data collection eeprom

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REQUIREMENTS COMPLIANCE

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Requirements
Compliance Plan
• All requirements, both USLI and derived, will be complied
with, and verified using the following methods
• The requirements may be found in the PDR Document
• Inspection • Demonstration
– Nondestructive/passive examination of – System verification through repeatable
the system exhibition of the design feature
– No numerical data collected – Pre-determined pass/fail criteria
– Design components present, use of – Parachute deployment, repeat flight
checklists, follow safety guidelines tests, capability to launch within an hour
• Analysis • Testing
– Calculation of performance prior to any – Demonstration of system with known
physical testing input and output values
– Completely theoretical based on – Numerical data feedback as well as
expected performance demonstrative verification
– Simulation software, FEA, hand – Static motor fire, flight test with
calculations, CAD altimeters, recovery location tracking

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NAR and FAA Compliance
• Test launches will only occur at

NAR or TRA sponsored launch
events.
• Only the mentor is allowed to
handle rocket motors
• The rocket will use an L motors
and will not exceed the impulse
limit set by NASA

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Launch Vehicle
Verification
Recovery Coupler Motor Thrust/ Load Simulation/ Overall System
Ejection Strength Path Aerodynamics Performance
Does the
Will the Will the
Is the load path rocket reach
parachutes rocket
sufficiently Is the simulation the expected
eject properly buckle at
strong/how does accurate/is the altitude/does
with the the coupler
the motor behave rocket stable? every
planned under max.
when fired? component
explosives? thrust?
work properly?
Multiple Static fire of the
Apply Launch a Launch the
ground motor, measuring
calculated subscale version full-scale (final)
ejections of thrust through the
moment to of the rocket rocket multiple
each high-risk loadpath
coupler multiple times times
component components

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General Requirements
Compliance
• Most of the General Requirements are fulfilled through
inspection of the schedule and design documents
• The TRA Mentor’s (Jason Winningham) credentials have
been confirmed
• Outreach will be demonstrated through the Outreach
Reports
• The team will demonstrate the ability to teleconference
during the review
• Rocket rail launch capability, reusability, and readiness will
be demonstrated at the test flight

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SAFETY

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CRW Safety Commitment
• Training and Communications are key
– Weekly Safety Briefings on relevant current activities
– Create Hazard analysis and Standard operating procedures
• Team work and proper supervision are how risks and hazards
can be minimized
– No team member shall work alone when manufacturing and testing the
rocket and its components.
– CRW members double and triple check each other’s work to ensure
that all steps of manuals and standard procedures are followed
– Supervision from experienced mentors and staff ensures all procedures
are done correctly.

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ATF, DOT, and NPFA
Compliance
• Rocket motors, e-match, igniters are purchased
by the mentor or appropriate PRC staff with
the proper license to ensure legality and
compliance.
• Motors will be stored in Type 2 Magazine and
transported in Type 3 magazines.

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Safety Plan
• Hold weekly Safety Briefings with the entire CRW team
• Each sub-team will designate a Safety Representative to work with the
• Safety Officer
– Aid in Hazard and failure mode analysis for their respective sub-section of the
rocket
• A Component Description Sheet will be created for each component used in the
rocket
– Analyze failure modes
– Track evolution of the component to aid in verification process
• CRW has identified the required success criteria and a method of verification for
each (as outlined in the PDR report)
• A Test Plan has been created based on the verification of all identified success
criteria (as outlined in the PDR report)

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Safety Representatives
Bao H.
Safety Officer
Davis H. Andrew W.
Launch
Vehicle Lead Payload Lead
• The Safety Officer will be responsible for the overall safety outlined by the
SLI Handbook
• The Launch Vehicle lead and the Payload lead will be responsible for the
reliability and risk assessment of their systems.

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Safety Briefings and
Trainings
Training Activity Date
Red Cross First Aid CPR/AED/FA 10/13/2017
Basic Emergency Procedures 10/17/2017
Process Hazard Analysis 10/18/2017
Safe Testing Procedures 10/24/2017
Root-Cause Analysis 10/24/2017
Outreach Safety Procedures 11/7/2017
Sub-scale Launch Safety
11/14/2017
Procedures
Hazardous Material
11/21/2017
Handling/Disposal
Fire Extinguisher training 11/21/2017
TBD TBD
• The Red Team have completed training for First Aid

and CPR/AED
• Additional training content will be added based on
relevance to the stages in the development cycle.

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Launch and Assembly
Procedures
• The Test Plan and Verification Processes will be used
to optimize the final design, assembly, and launch
procedures
• Final rocket assembly procedures have been
developed to fit the design concept
• Any changes to the design that require updating the
assembly or launch procedures will be coordinated
through the team safety officer
• Simulated runs of all procedures will take place at
least one week prior to any launch

11/3/2017 74
USLI PDR
Published Information
• 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
11/3/2017 75
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PROGRAM MANAGEMENT

11/3/2017 76
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Work Breakdown
Structure
Payload Launch Vehicle
• Mechanical Structure • Aft
• Wheel Design • Motor Selection
• Chassis Design • Fins
• Vehicle fabrication • Lower Body Tube
• Electrical Design • Simulation
• Component Selection • Central
• Schematic Development • Avionics
• Software • Recovery
• Rover software • Forward
• Ground Station
CRW • Upper Body Tube
• Nosecone
• Payload Fairing
Management Safety
• Website Updates • Risk Identification and Analysis
• Outreach Coordination • Mitigation Strategy Development
• Schedule and budget tracking • Safety Briefing
• Requirements Verification • Manufacturing and Testing supervision
• Interface management

11/3/2017 77
USLI PDR
Schedule
• Schedule Philosophy
– Work around finals and Winter Break
– Internal deadlines 2 weeks ahead of NASA deadline
for all documents
– Identify backup dates for critical test launches
• Upcoming Events
– Launch Opportunities: Nov 18, Dec 16, Jan 20, Feb
17
– CDR Internal due date: Dec 22

11/3/2017 78
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Budget/Funding
Summary
• Launch vehicle- two Rover Frame
4% Rover
subscales (6 flights) and two Recovery
22%
Electronics
11%
full scales (6 flights) - $5,760

• Payload- two fully operation
rovers -$1,010 Airframe
13%
• $750 margin for

shipping/unexpected
expenses
• Proposed to ASGC and UAH
Propulsion Research Center Motors
for funding and 50%
Rover Frame Rover Electronics Airframe Motors Recovery
11/3/2017 University of Alabama in Huntsville 79

USLI PDR
Outreach
• Girls Science and Engineering Day
– Before project started, but good
practice
– 80 middle school girls participated
• FIRST Robotics
• Boy Scout STEM Winter Camp
– Invited to teach space, robotics,
and maker culture
• Science Olympiad at UAH, February
2018

11/3/2017 80
USLI PDR
Web Presence
• Website updated and
reformatted to highlight
current content while
preserving 2017 team
documents
• Facebook and Instagram kept
current
• Press release posted
• www.chargerrocketworks.com

11/3/2017 81
USLI PDR
Questions

11/3/2017 82
USLI PDR
Picture Credits
• NASA USLI
• https://www.nasa.gov/audience/forstudents/studentlaunch/handbook/index.html
• Wikipedia
• https://upload.wikimedia.org/wikipedia/commons/d/dc/PIA16239_High-Resolution_Self-
Portrait_by_Curiosity_Rover_Arm_Camera.jpg
• NASA
• https://www.nasa.gov/sites/default/files/images/640942main_orion_chute_full.jpg
• Thrustcurve.org
• http://www.thrustcurve.org/simfilesearch.jsp?id=1898
• Wonderfulengineering.com
• http://cdn.wonderfulengineering.com/wp-content/uploads/2015/03/NASA-Tests-Mars-Rocket-Booster-6.jpg
• Professionalgrantwriter.org
• https://www.professionalgrantwriter.org/wp-content/uploads/2016/03/shutterstock_127266677.jpg
• National Association of Rocketry
• http://www.nar.org/wp-content/uploads/2014/05/Logo.gif
• Youtube
• https://i.ytimg.com/vi/i3T9Hps3iqs/maxresdefault.jpg
• Emotionalhealth.net
• http://emotionalhealth.net.au/wp-content/uploads/2013/05/question-marks.jpg

11/3/2017 83
USLI PDR
Appendix A:
Electronics Mass Budget
Component Mass (g) Number per rover Total Mass (g) Total Mass (lbm)
Arduino Mega 37.0 1 37.0 0.08
BMP280 1.30 1 1.30 0.00
SPG30 geared
160 2 320 0.71
motor
Motor Shield 30.0 1 30.0 0.07
LSM9DS0 2.30 1 2.30 0.01
Solar cell 8.50 3 25.5 0.06
Camera 10.0 1 22.5 0.05
900 MHz Xbee 8.50 1 6.50 0.01
Brushed DC motor 9.98 2 20.0 0.04
Battery 150 1 150 0.33
GPS 8.50 1 8.50 0.02
Voltage regulator 0.90 1 0.90 0.00
Total mass - - 625 1.38

11/3/2017 84
USLI PDR

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NASA SL

*Throughout the presentation, all dimensions are in inches

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville 5

University of Alabama in Huntsville

Apogee of 5282 ft. (19 sec.)

50 sec. Main deploy (600 ft.)

University of Alabama in Huntsville

Maximum Stability: 2.74

Takeoff Stability: 2.06

University of Alabama in Huntsville

Forward Body Tube

University of Alabama in Huntsville

Payload Piston Avionics Bay

University of Alabama in Huntsville

University of Alabama in Huntsville

•Machined from aluminum​

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

• Open Rocket Simulation between 0 and 20 mph winds showed a

University of Alabama in Huntsville

1 represents force due to drag

represents the force due to

University of Alabama in Huntsville 24

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

6.0 in Full-Scale Rocket

University of Alabama in Huntsville

University of Alabama in Huntsville

• The rover’s design consists of a rectangular chassis, two

• The rover measures temperature, pressure, location, and

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

• Aluminum Unibody selected

University of Alabama in Huntsville

• The chassis will be milled out of a single block of 6061-T6 aluminum

University of Alabama in Huntsville

University of Alabama in Huntsville

• Measuring Tape selected

University of Alabama in Huntsville

Low Risk of Damage 4 5 4

University of Alabama in Huntsville

Aluminum ABS Polycarbonate

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

University of Alabama in Huntsville

•Machined from aluminum