METEOR Stage Separation System Project Plan

1. Concept Level Project PlanP09102 – METEOR Stage Separation System JJ Guerrette (ME)

2. Concept Level Project Plan • Project Name • Stage Separation System (SSS) • Project Number • P09102 • Project Family • METEOR family of projects • Track • Aerospace Systems Technology • Start Term • 2008-TBD • End Term • 2008-TBD • Faculty Guide • Dr. Jeffrey Kozak (ME) • Faculty Consultant • Dr. Dorin Patru (EE) • Faculty Consultant • Dr. Vincent Amuso (EE) • Primary Customer • Project METEOR

3. Phase 0: PlanningMission Statement Product Description This project will provide Project METEOR with an SSS. METEOR is a pico-satellite launch system that will use a weather balloon to take a launch vehicle to ~90,000ft. The vehicle will then disconnect and propel the satellite payload to Low Earth Orbit (LEO). A multi-stage design will be used for its (propellant mass) : (total mass) ratio advantages. After a portion of the fuel is burned the rocket can discard the dead weight of the rocket body, fuel tanks, plumbing, and larger combustion chambers. The project scope includes a mechanical device as well as an electrical control system to precisely time the separation. If time allows, the project will also provide a system to deploy the satellite for final separation from the launch vehicle. Key Business Goals METEOR is the first university-based project in the world whose ultimate goal is to launch and place small payloads on near-Earth asteroids and lunar surfaces! This project will provide the students and faculty at RIT, and the scientific community at large, the opportunity to obtain small payload volumes for conducting micro-systems and other scientific experiments in outer space. METEOR will accommodate and promote these multi-disciplinary collaborations. The final product holds the potential to attract universities aimed at space-based research and satellite sciences. Primary Market The RIT scientific community and Project METEOR Secondary Market Universities looking to launch satellites weighing less than 1kg into space for a low cost Stakeholders METEOR Faculty Guides as customers Harris Corporation as a financier RIT Students and Faculty as customers NASA as a possible financier Universities with Space Research Programs as customers Aerospace Companies as possible financiers or competitors

4. Phase 0: PlanningStaffing Requirements Mechanical Engineers 3-4 The mechanical engineers will be tasked with parts fabrication, material acquisition, and the design of the mechanical portion of the SSS. They will also need to consider the explosive/mechanical/pressurized gas or other system that will trigger the separation. The ME’s will also have to create a dynamic model of the entire stage separation control system to ensure it fits the customer needs. The ME’s will also need to consider the integration of inter-stage mechanical and electrical systems across the stage boundaries. Electrical Engineers 2-3 The electrical engineers will design, purchase, and integrate the digital signal processors, microcontrollers and/or programmable logic controllers used in the SSS electrical system. The electrical system must activate the SSS and initialize the various separation events at the proper times. The timing will be dependent on the dynamic model developed by the ME’s. The EE’s must design an electrical circuit that will easily integrate with the main electrical system onboard the launch vehicle (yet to be developed). The EE’s will also need to consider the integration of inter-stage mechanical and electrical systems across the stage boundaries. Industrial and Systems Engineers 0-1 Currently there are no plans for mass production nor are there any ergonomics concerns. It might be helpful to have a systems engineer to assist with integration into the final rocket, although currently I have this task assigned to the other team members. Computer Engineers 0 At this time, there do not appear to be any CE applications, although this staffing plan is only preliminary. If the need arises, it will be reflected in the next step of the project. Business Majors 0 At this time the METEOR business plan has only been developed to have RIT as a customer. This project will not deal with extending the scope of the business plan.

5. Phase 0: PlanningResource Requirements People Dr. Kozak and Dr. Patru for guidance and METEOR project information Current METEOR SD teams who’s designs will ultimately affect the SSS Dave Hathaway Vendors – unknown at this time Environment METEOR design laboratory Simulation of conditions in LEO Safety issues with an explosive separation system Equipment • METEOR Lab contains 4 computers, storage space, and work space. Will need to do a complete sweep to see what else is available – Contact Faculty guides for access • METEOR’s concrete bunker may serve as an explosive test site. • Machine Shop and CNC Equipment– Team will need to contact Dave Hathaway to get swipe card access. Need to find out details about using CNC machines. • Environmental Chamber? • Computer Labs At this time, no commitments have been made other than for METEOR’s facilities. Materials Materials include stock metals, plastics, and electrical components that should be available with short lead times. Since this project won’t start until at least 2008-1, there should be enough time to order long lead time items should they arise during the planning phase.

6. Phase 1: Concept DevelopmentIdentify Customer Needs - Interviews Primary Customer(s) Dr. Kozak (already interviewed) -Aerodynamics are not a concern, because of the thin atmosephere at 90,000 ft and above -Current design plan is for 3 stages Dr. Patru (only preliminary interview complete) -Established some basic needs of a stage separation system. -Discussed commercial suppliers of separation devices -Plan to interview again on stage separation needs after performing background research Other Stakeholder(s) I would like to interview somebody who works for one of the space development companies mentioned on the following slide. I need more information on current SSS’s in order to do benchmarking. I have no concrete plan thus far. Another person to interview would be possible payload customers who want their experiments launched. If any are interested in upper atmospheric test conditions, then a mid-stage payload is a possibility. I will consult with faculty guides to discuss possible solutions. Past Senior Design Team(s) Past Projects: 04036, 05005, 06006, 06007, P07102, P07103, P07104, P07105, P07106, P07107, P07108, P07109, P07110 Current Projects: P08101, P08102, P08105, P08106 Future Projects: P09101, P09103 The bold project numbers have a physical integration relationship with P09102. Before the Stage Separation System can be designed, more concrete knowledge of the rocket body design will need to be established. This is planned for P08106. If the project needs access to compressed gas, there is an integration option with P08105, which includes NOX tank design. The timing of the separation system will also need to coordinate with the tajectory control system which is not yet fully developed, but has a start in P07106. The SSS electrical system may need to be controlled remotely from the Launch Platform or from the ground, in which case P07103 and P08101 (METEOR Instrumentation Platform) will be good resources

7. Current Work Complete Engine Testing Horizontal Test Stand Rocket Body Concept Instrumentation Platform

8. Source: http://www.neaelectronics.net Phase 1: Concept DevelopmentIdentify Customer Needs - Benchmarking Competitive or Cooperative Solutions NEA Electronics sells a few commercial stage separation systems that might be used for benchmarking. I have yet to find direct competitors seeking to launch pico-satellites (~1kg) into space. There are several private companies developing systems to launch micro-satellites (~100kg) or people into orbit. Some of them include SpaceX, XCOR Aerospace, Rocket Propulsion Engineering Corp., Rocketplane Kistler, Scaled Composites. Although none of these companies are current direct competitors, their public information is extensive. For instance, Rocketplane Kistler has a 42 page “Flight Experiments Design and Requirements Document” that gives a detailed description of the development process for their K-1 launch system. These companies will also serve as great models should RIT decide to turn METEOR into a business. As far as current benchmarking, team members should visit the sites below to get an idea of what METEOR is trying to accomplish. Internet Search METEOR General Info: http://meteor.rit.edu/RIT Project METEOR homepage http://www.personalspaceflight.info/ good source of information on space development companies http://www.spacex.com/ http://www.xcor.com/ http://www.rocketplaneglobal.com/ http://www.rocketplanekistler.com/ http://www.scaled.com/ Stage Separation Info: http://www.neaelectronics.com/ Technical Literature Search http://www.aiaa.org for Technical Paper Searches and relevant research http://www.knovel.com.ezproxy.rit.eduAccess through RIT library includes full PDF textbooks, such as Elements of Propulsion – Gas Turbines and Rockets, which has a method for calculating rocket stage parameters for certain propellant/weight combinations RIT Library for Ordering Technical Papers Need to expand more on the Technical Literature Search. Not much information on stage separation devices are available through internet searches alone.

9. Phase 1: Concept DevelopmentIdentify Customer Needs - Interpret Needs Statements: METEOR Launch Vehicle Needs: 1.1) Product needs to deliver payload into LEO (200-2000km altitude) 1.2) Needs to be controllable (human, other) 1.3) Needs to ensure safety to participants 1.4) Needs to be cost effective (cheaper than current options of $2,000-10,000 per lb of payload) 1.5) Spent stages need to be safe to the launch location community SSS Needs: 2.1) Needs to act as a stage separation and stage connection system 2.2) Needs to perform in altitudes from Sea Level to 1200mi: Gravitational acceleration: 9.81m/s^2 - 5.7m/s^2 Pressures: 1atm to vacuum Temperatures: -70°C to +85°C 2.3) Needs to be light. Total rocket mass of ~200kg with a (propellant) : (structure) ratio of 10:1 (stage separation is part of structure) 2.4) Needs to have minimal effect on rocket trajectory (need to quantify) 2.5) Plan needs to account for unknown budget (currently assuming smallest METEOR SD budget to date of $2000) 2.6) Needs to remain attached to lower stage in order to reduce mass on upper stages 2.7) Needs to offer means of recovery for spent stages 2.8) Needs to be testable on the ground and at altitude

10. Phase 1: Concept DevelopmentIdentify Customer Needs - Interpret Organize the Needs into a Hierarchy • Need to perform more interviews to gain a better understanding of the needs and to expand the list Establish the Relative Importance of the Needs • Need to consult with Faculty guides to determine relative importance of needs

11. Future PlanWhere do you go from here? At this point I need to continue searching for separation devices that can be used for benchmarking. Through my research thus far, I have realized that the integration of the SSS with the rest of the launch vehicle will be a major factor in its success. I need to interview Dr. Patru to get more information about onboard electrical systems, as well as the possibility of inter-stage systems integration. I also need to talk to Dr. Kozak in order to quantify the SSS need number 4: minimal effect on rocket trajectory.