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STUDENT LAUNCH INITIATIVE 2011 – 2012 AIAA OC Rocketeers CDR Presentation February 6, 2011

Student Launch Initiative AIAA OC Rocketeers. STUDENT LAUNCH INITIATIVE 2011 – 2012 AIAA OC Rocketeers CDR Presentation February 6, 2011. Student Launch Initiative AIAA OC Rocketeers. Agenda. Introduction of team members (representing 4 high schools in Orange County California)

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STUDENT LAUNCH INITIATIVE 2011 – 2012 AIAA OC Rocketeers CDR Presentation February 6, 2011

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  1. Student Launch Initiative AIAA OC Rocketeers STUDENT LAUNCH INITIATIVE2011 – 2012AIAA OC RocketeersCDR PresentationFebruary 6, 2011

  2. Student Launch Initiative AIAA OC Rocketeers Agenda • Introduction of team members (representing 4 high schools in Orange County California) • Scale model testing and results • Full Scale Design • Vehicle • UAV Payload – Description, Safety, and Testing • Recovery System and Events • GPS • Integration • Feedback form checklist • Risks and Safety • Educational Outreach • Budget and Timeline • Corrected 3 slides, added scale launches 2&3 & RC plane testing

  3. Student Launch Initiative AIAA OC Rocketeers Scale Model TestingHow it affected the final design

  4. Student Launch Initiative AIAA OC Rocketeers Black Powder Calculations Scale rocket is 3” diameter (surface area on a bulkhead is π r2 or 7.07 in2).. We need at least 100 lbs of force + another 105lbs for the three #2 Nylon screws. The amount of black powder then is C D2 L where C is psi * .0004. D is the diameter in inches (3), and L is the length in inches (12).

  5. Student Launch Initiative AIAA OC Rocketeers Testing – Black PowderPhenolic Sabot

  6. Student Launch Initiative AIAA OC Rocketeers Testing – Black PowderPhenolic Sabot • Learned from testing leading to a design change • Forces on the sabot are substantial • Increasing the black powder charge with a lot of leakage will result in damage before total deployment is reached • Ejecting the sabot towards the avionics bay can contribute to damage through collision • We need to change the design to allow for piston deployment to minimize gas leakage through the sabot

  7. Student Launch Initiative AIAA OC Rocketeers Testing – Black PowderPiston pushing Phenolic Sabot

  8. Student Launch Initiative AIAA OC Rocketeers Testing – Black PowderPhenolic Sabot • Learned from testing leading to a design change • Piston needs to be made very strong to avoid damage • We will use Blue Tube filled with foam with double thickness bulkheads for further scale model testing • Sabot needs to be made very strong to avoid damage • We will use Blue Tube with double thickness bulkheads for further scale model testing • Don’t increase Black Powder when using a piston • Keep pressure distributed evenly on contacting parts – an eyebolt pushing on a bulkhead can be catastrophic

  9. Student Launch Initiative AIAA OC Rocketeers Testing – Black PowderPiston pushing Bluetube Sabot

  10. Student Launch Initiative AIAA OC Rocketeers Testing – Black PowderRear Section Drogue and Main

  11. Student Launch Initiative AIAA OC Rocketeers Conclusion – Black Powder Testing

  12. Student Launch Initiative AIAA OC Rocketeers Scale Test Flight Lucerne Dry Lake 1/14/2012 Scale model was flown at Lucerne Dry Lake in the Mojave Desert on January 14,2012 Flight used engine ejection for a single main parachute Vehicle was stable with an extremely straight flight Parachute deployed and vehicle returned with no damage

  13. Student Launch Initiative AIAA OC Rocketeers Scale Test Flights Lucerne Dry Lake 1/28/2012 • Scale model was flown again twice on January 28, 2012 with full electronic deployment and a weighted Barbie payload in lieu of the UAV • Flight #1 – Cesaroni I236 Blue Streak • Motor was smaller than first flight due to availability – low altitude and everything deployed nearly at once • Flight #2 – Cesaroni I236 Blue Streak • Adjusted flight computers and we had our three separate events as planned Launch Nose Cone & Sabot Drogue + Main Barbie Payload Drogue

  14. Student Launch Initiative AIAA OC Rocketeers Scale Test Flights Lucerne Dry Lake 1/28/2012 • Flight #1 – Cesaroni I236 Blue Streak • Graph from Raven (very late deployment) • Details from HCX: • Maximum Altitude: 1398 ft • Max Speed: 260 ft/s • Max Acceleration: 166 ft/s/s • Flight #2 – Cesaroni I236 Blue Streak • Graph from Raven (proper, but a little late, deployment) • Details from HCX: • Maximum Altitude: 1140 ft • Max Speed 246 ft/s • Max Acceleration: 181 ft/s/s Scale Launch #2 Scale Launch #3

  15. Student Launch Initiative AIAA OC Rocketeers UAV Testing • UAV Testing began with the Payload team learning to fly under the direction of one experienced team member • First flights at ROCtober in Lucerne showed the foam model to be underpowered • The plane was reworked with a more powerful brushless motor and the final RC electronics and flown again testing the release mechanism as well • Next Steps • Add autopilot to foam model • Build the final RC plane as is and fly • Add autopilot to the RC plane • Finally, integrate the bendable wing Release mechanism Test

  16. Student Launch Initiative AIAA OC Rocketeers How the testing affected the full scale vehicle design

  17. Student Launch Initiative AIAA OC Rocketeers FullScaleDesign

  18. Student Launch Initiative AIAA OC Rocketeers Vehicle – Full Scale

  19. Student Launch Initiative AIAA OC Rocketeers Vehicle – Full Scale cont’d

  20. Student Launch Initiative AIAA OC Rocketeers Vehicle – Forward Section

  21. Student Launch Initiative AIAA OC Rocketeers Vehicle – Avionics Bay

  22. Student Launch Initiative AIAA OC Rocketeers Vehicle – Rear Section

  23. Student Launch Initiative AIAA OC Rocketeers Aerotech K1050(Alternate: Cesaroni K600)

  24. Student Launch Initiative AIAA OC Rocketeers Launch Simulations • 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

  25. Student Launch Initiative AIAA OC Rocketeers UAV Payload System • The UAV System consists of • 2.4 GHz RC Control via Spektrum DX-8 • 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

  26. Student Launch Initiative AIAA OC Rocketeers UAV Mechanical Components • Mechanically, the UAV is composed of two main parts • Bendable wing developed at University of Florida • Fuselage, vertical and horizontal stabilizer (modified to fit) from the Electrifly RC Airplane • Wing • Wingspan 30 inches • Weight 12 grams • Material Carbon Fiber • Fuselage • Length 30 inches • Weight 140g • Material fiberglass • Parachute release mechanism is electrically controlled servo activated by one channel of the AR-8000 RC receiver • Vehicle with electronics is 1 lb (estimated) • Note: UAV Photos from similar UAV at University of Florida Gainesville UAV lab and Electrifly Web Site

  27. Student Launch Initiative AIAA OC Rocketeers UAV Bendable Wing • Wing design was developed at University of Florida (UF) for use in UAVs deployed from a tube • Wing is fabricated using Carbon Fiber in a vacuum forming heat process • Carbon fiber cloth is 6 oz 3K Plain Weave pre-preg • Cloth is laid at 45 degree angle to direction of motion of the wing through the air • 30 inch wing uses 3 layers of carbon fiber • Cloth is laid over the mold and placed in a vacuum bag (mold and vacuum bag are protected with release film • The pressure is then lowered as close to 30” of mecury as possible • The vacuum bag and contents are baked at 260 – 350 degrees for about 6 hours • The wing is then removed and trimmed to size • Status: We have one wing given to us from UF and Northrop Grumman is making our mold and loaning us time and supervision on their non-flight autoclave

  28. Student Launch Initiative AIAA OC Rocketeers UAV Control Electronics and Operation • Main UAV control is via Radio Control (Spektrum DX-8 transmitter and AR-8000 receiver) on 2.4GHz – This is the default operation • Ardupilot Mega (APM) is switchable autopilot to provide autonomous control with Open Source software and support at DIYDrones • APM accepts data for flight and telemetry from on-board • Inertial Measurement Unit (IMU) • GPS Receiver • 3 Axis magnetometer • Airspeed sensor Spektrum DX-8 and Receiver APM and IMU GPS 3 Axis Magnetometer Airspeed Sensor

  29. Student Launch Initiative AIAA OC Rocketeers The ArduPilot Mega (APM) • The ArduPilot Mega is: • An Inertial Measurement Unit based autopilot • Consists of • Arduino based CPU board • IMU Shield • GPS and Sensors as separate boards • Runs Open Source software (Lead programmer Doug Wiebel is one of our mentors) • Includes firmware for the autopilot • Ground support station software for a PC • Is supported by a community at DIY Drones • Can be commanded to take over control from RC and act as an autopilot • Can be programmed for autonomous flight by a simple mission scripting language • Fly to a GPS waypoint • Loiter at a waypoing • Climb or descend • Change speed • Land • Uses Xbee to transmit telemetry to ground station

  30. Student Launch Initiative AIAA OC Rocketeers UAV Support Electronics • Data gathered by the UAV is used by the APM autopilot for flight as well as transmitted real time to a ground station • Radio telemetry downlink uses X-Bee transmitter in the UAV and an X-Bee receiver at the ground station on 900 MHz • Sensors gather and relay information regarding • Airspeed • Attitude (for artificial horizon) • Altitude • Exact location • In addition, the UAV carries a video camera • Video is transmitted to the ground station via a 1.2 GHz transmitter in the UAV and a matching receiver on the ground • Video is fed to the ground station via a video to USB converter – making it appear as a web cam input

  31. Student Launch Initiative AIAA OC Rocketeers UAV Electronics System

  32. Student Launch Initiative AIAA OC Rocketeers UAV – Ground Station • 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

  33. Student Launch Initiative AIAA OC Rocketeers UAV Safety • The UAV will descend on parachute until it can be verified it is flightworthy and not fouled on shock cords or shroud lines • The UAV detachment from the parachute is manual allowing a human to make the final decision • The UAV can be manually switched back to RC control at any time during the flight • If RC communications is lost the AR-8000 receiver sends a signal to the APM autopilot to switch to RC control and the AR-8000 sets servos and throttles to a preset (low throttle and circle) – needs testing • Alternatively, the APM autopilot can be programmed to return to home (needs testing) • If power is lost to the APM autopilot it automatically returns to RC control • If power is restored to the APM autopilot in flight, it will reload a backup program and restart where it left off

  34. Student Launch Initiative AIAA OC Rocketeers UAV Test Plan Note:UAV will be built from a commercial “Rifle” almost ready to fly RC plane from Electrifly with the University of Florida bendable wing. We are also using a foam Wild Hawk as a rugged trainer. Integration is at the guidance of Dr. Robert Davey, an aeronautical engineer and retired professor from Cal Poly Pomona • Install only RC control with batteries, servos, and power components into the foam Wild Hawk and verify the plane is flightworthy and can be controlled • Install the APM autopilot into the foam Wild Hawk and integrate with the ground station and X-Planes for a full “Hardware-in-the-loop” PC simulation on the ground • Validate the scripting performs as it is intended • Validate the scripting can be changed in the air • Validate that control can be switched between RC and APM autopilot • Validate the UAV reaction to loss of RC signal • Validate the APM autopilot reaction to loss of power and return of power • Go to Lucerne Dry Lake and repeat the testing in step 1 (RC only control) and 2 (APM autopilot control with the plane actually in the air • Build the Rifle kit as-is with no modifications (i.e. use the wing that came with the Rifle) • Repeat steps 1 through 3 with the Rifle • Replace the Rifle wing with the bendable carbon fiber wing • Go to Lucerne Dry Lake and repeat steps 2 and 3 flying on RC and autopilot • Include the vehicle and validate in test flight of full scale vehicle launch

  35. Student Launch Initiative AIAA OC Rocketeers Recovery • 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 • Avionics Bay is coated with MG Chemicals SuperShield Conductive Coating 841 to minimize RF Interference • 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

  36. Student Launch Initiative AIAA OC Rocketeers Recovery Interconnect • Flight computers are powered from Duracell 9VDC batteries • Raven CPU and Pyro are on separate batteries • HCX CPU and Pyro are on separate batteries • Design includes 4 safety switches (CPU power on before pyro) • Raven Flight Computer CPU Power • HCX Flight Computer CPU Power • Raven Flight Compuer Pyro Power • HCX Pyro Power

  37. Student Launch Initiative AIAA OC Rocketeers Black Powder Charges • A total of six separate black powder charges are used • The Drogue uses one black powder charge from the HCX pyro 2 as primary and one from the Raven pyro 1 as the backup to deploy at apogee • The Sabot uses one black powder charge from the HCX pyro 3 as primary and one from the Raven pyro 2 as the backup to deploy at an altitude of 1,000 ft • The Main uses one black powder charge from the HCX pyro 4 as primary and one from the Raven pyro 3 as the backup to deploy at an altitude of 800 ft

  38. Student Launch Initiative AIAA OC Rocketeers Recovery Events • 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)

  39. Student Launch Initiative AIAA OC Rocketeers Recovery Events • 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

  40. Student Launch Initiative AIAA OC Rocketeers Recovery Events • 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

  41. Student Launch Initiative AIAA OC Rocketeers UAV Events • Event #4 is technically not part of the recovery • system but is next in the sequence of events • Occurs after successful recovery event #2 at 1,000 ft • (altimeter controlled black powder ejection of the sabot • with full deployment of the UAV from that hinged-on-one-end sabot via spring pressure from the bendable wing) • Full UAV deployment is visually validated • Wings have fully unrolled • UAV is not tangled in shroud lines or shock cords • Appears to try to fly away from the parachute • Is safely away from spectators • UAV is at or below 400 ft as indicated on the ground station telemetry (per the FAA AC 91-57 “Do not fly model aircraft higher than 400 feet above the surface”) • Range Safety Officer has given the OK • The UAV is released by command from the ground via the 2.4GHz RC radio via a servo controlled latch

  42. Student Launch Initiative AIAA OC Rocketeers UAV Events • After the UAV is flying without the parachute • First the UAV is flown as an RC plane until it is validated that we have full control and the plane is functioning properly • The RC transmitter on the ground sends a signal to the UAV electronics to fly autonomously (via the APM autopilot) • The UAV will fly to pre-programmed waypoints (these waypoints can also be changed from the ground station) • After the autonomous flight, the RC transmitter will send a signal to the UAV electronics to fly under RC control again • The UAV will be landed under RC control

  43. Student Launch Initiative AIAA OC Rocketeers Drift 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

  44. Student Launch Initiative AIAA OC Rocketeers Configuration of the HCXFlight Computer • HCX Provides 4 Pyro Ports • Pyro 1 – Not Used • Pyro 2 – Drogue deployment via black powder charge at Apogee + 2.0 seconds for Mach Delay • Pyro 3 – UAV deployment via black powder charge at 1,000 feet • Pyro 4 – Main deployment via Tender Descender black powder charge at 800 feet

  45. Student Launch Initiative AIAA OC Rocketeers Testing of HCXFlight Computer • G-Wiz Partners Flightview Software allows configuration and testing • Power-ON: Sign-on beeps verified (2 low beeps for JP7 in followed by status of pyro connections: 1=connected 2=not connected) • Pyro Connection beeps: Check all open is 4 double beeps. Short one at a time to hear single beep. Final is 2-1-1-1 since pyro 1 is not used • Bench Test: Shows battery voltages, pyro connections (lights), and allows test firing of each pyro – expected light lit • Test Flight: Simulated flight validated all three pyros fired (lights lit) when expected

  46. Student Launch Initiative AIAA OC Rocketeers Configuration of the RavenFlight Computer • The Raven Provides 4 Pyro Ports • Pyro 1 – Drogue deployment via black powder charge at Apogee + 2.0 seconds for Mach Delay • Pyro 2 – UAV deployment via black powder charge at approximately 1,000 feet (992 feet) • Pyro 3 – Main deployment via Tender Descender black powder charge at 800 feet • Pyro 4 – Not Used

  47. Student Launch Initiative AIAA OC Rocketeers Testing of RavenFlight Computer • The “Featherweight Interface Program allows configuration and testing • Power-ON: If not vertical gives battery voltage as series of high beeps followed by low beeps every few seconds forever. If vertical gives status of pyro connections (high pitch = connected and low pitch = not connected) • Pyro Connection beeps: Check all open is 4 low beeps. Short one at a time to hear low pitch change to high pitch beep. Final is H-H-H-L since pyro 4 is not used • Test Flight Simulation: Simulated flight validated all three pyros fired (lights lit) when expected • After the flight is back on the ground, the Raven must be tilted to start the altitude beeps

  48. Student Launch Initiative AIAA OC Rocketeers GPS TRACKING • Ground Station • Receiver: Yaesu VX-6R • TNC: Byonics Tiny Track 4 • GPS: Garmin eTrex Legend • 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 • Beeline receives GPS position • Encodes as AX.25 packet data • Sends as 1200 baud audio – 1 at each end of 70 cm ham band • VX-6R switched between two frequencies and extracts audio • TinyTrack 4 converts audio to digital NMEA location data • Garmin displays the digital location data on human screen

  49. Student Launch Initiative AIAA OC Rocketeers Payload/Vehicle Integration • 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 safe, UAV will fly pattern under autonomous control • Return to RC control for landing Photos from “Development of a Composite Bendable-Wing Micro Air Vehicle” by Dr. Peter Ifju et al URL: http://baronjohnson.net/Publications/ASM2007.pdf

  50. Student Launch Initiative AIAA OC Rocketeers Feedback Form Checklist

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