Minster Jr/Sr High School NASA Student Launch Initiative FRR

Transcription

1 Minster Jr/Sr High School NASA Student Launch Initiative FRR

2 I) Summary of FRR Report Team Summary: Minster Rocket Club Minster Jr/Sr High School 100 E. 7 th St. Minster, Ohio Mentor: Ted Oldiges NAR #89693 / Level 2 Launch Vehicle Summary: Size: 120 inches in length x 4 inches in diameter. Mass: (with motor) 21pounds Motor Choice: Cesaroni K635 High Power Rocket Motor Recovery System: Dual-deployment recovery comprised of a 15 Drogue and SkyAngle Cert3-Large main parachute, two altimeters, a barometric-based ADEPT 22 altimeter and barometric-based StratoLogger SL100 altimeter. The drogue will bring the rocket down at approximately 85 ft/s, from apogee, followed by the main deployment at 600 feet. The descent rate under the main will be 16 ft/s. Rail Size: Width 1 inch, Length 8 feet Milestone Review Sheet: Attached Payload Summary: Title: The effects of high velocity on the growth of yeast cells. Summary: The experiment is designed to study how individual yeast cells respond to stress under high velocity. Our experiment will use brewer's yeast and a cell growth chamber to measure the growth of cells under different velocities. The goal is to understand differences in the growth of yeast cells in normal and high velocity conditions. 2

3 II) Changes Made Since CDR Changes Made To Vehicle Criteria: Changed the secondary altimeter from the Missile Works PET2+ to the StratoLogger SL100. The Missile Works PET2+ was too difficult to calculate the Main deployment based on time. Chose the StrotoLogger SL 100 because it is different than our primary altimeter, the Adept 22, and allows for the downloading of flight information. Changed the deployment altitude of Main parachute for both altimeters. Previously the Adept 22 was set to fire its Main deployment at 800 feet. This has been changed to 600 feet to lessen the distance the rocket will drift. The secondary StratoLogger altimeter will fire its Main deployment at 500 feet. Firing the altimeters at the lower altitude will lessen the distance the rocket will drift from the launch stand. Changed the length of the rocket to 120 inches. This change came from our first fullscale test flight when the Main parachute did not deploy, even though both pyrotechnic charges fired. Before the flight occurred the team had a difficult time packing the main parachute into the body tube, the tube was just too short. It was determined after the flight that the Main chute was packed too tightly. Team extended the body tube holding the Main chute from 24 inches to inches. The additional 8.25 inches allows for ample space to properly pack the Main chute into the rocket with minimal space to spare. Changed the amount of black powder charge used to separate the body tube carrying the Main parachute. Upon extending this section 8.25 inches the calculations had to be run again to determine the correct amount of black power to use to separate this section. Upon ideal gas law calculations it was determined to increase the amount of black power from the previous 1 gram of FFFF to 2.25 grams FFFF. The mass of the rocket has been re-measured using a scale if full-up flight readiness and determined to be a final mass of ounces, up for the previous RockSim calculated mass of 260 ounces. This discrepancy is related to the fact that we did not put all the components into the RockSim simulation. 3

4 III) Vehicle Criteria Design and Construction of Vehicle: Structural Elements: Fiberglass tubing and fiberglass nose cone ensure a sturdy and light design. The fiberglass tubing used in the body tubes, inner tubes, and couplers will ensure extreme strength and durability that can withstand the pressures of the motor during launch. Fiberglass is used throughout the entire design of the rocket, from the body tubes to the bulkheads and everything in-between. The use of fiberglass was chosen for its strength and durability. The rocket will be comprised of three fins of ¼ inch Fiberglass. The fins will have a trapezoidal shape to increase surface area and still be aerodynamic. The rocket utilizes on-center attachment points with solid forged eye-bolts to keep alignment through the rocket down the middle. Each eye-bolt is rated for 900lbs of force for a solid connection point that the shock cord can attach. On the ends of the shock cord attachments are made with ¼ quick links rated at 600 pounds. Three centering ring hold the motor tube into the booster section throughout flight. The motor will be retained if the force of the motor is less than the threshold breaking force of the epoxy and the centering rings holding it into the booster section. The motor will be retained using an Aeropack RA54P retaining system 4

5 Electrical Elements: The avionics board is made from 3/16 fiberglass and is glued onto 1/4 brass tubes that slide over the 1/4 all-thread making a solid unit. The rocket electronics bay uses 24 awg solid-core wires for all electrical connections. There is a 2-pole rotary switch used to turn on each altimeter. There is a 9 volt battery holder that retains the battery onto the avionics bay sled. There is a washer taped to the end of each battery to minimize the play of the battery within the battery holder. Each battery is held onto the battery holder using zip-ties that pass through the fiberglass sled. All components within the avionics bay are glued and bolted down to the sled. 5

6 Drawings and Schematics To Describe the Assembly of the Vehicle: nose cone a. payload b. upper body c. d. lower body Nose cone is attached to payload section at (a.) using four (4) large plastic rivets evenly spaced around vehicle. Payload section is attached to upper body tube at (b.) using two (2) 4-40 shear pins evenly spaced around vehicle. Inside the upper body tube is a 20 foot shock cord and Nomex sleeve, attached to forged eyebolts in the payload and avionics bay sections using 1/4 inch quick links. Attached to the shock cord using a large swivel is the Main parachute, a SkyAngle Cert3-L; while all being protected by a Nomex blanket. Upper body tube is attached to the avionics bay at (c.) using four (4) large plastic rivets evenly spaced around vehicle. Avionics bay is attached to lower body tube at (d.) using two (2) 4-40 shear pins evenly spaced around vehicle. Inside the lower body tube is a 20 foot shock cord attached to forged eyebolts in the avionics bay and upper centering ring sections using 1/4 inch quick links. Flight Reliability: The rocket has been launched twice, once on March 14 th and again on March 29 th. On the March 14 th launch the main parachute failed to deploy. A conclusion was made that the parachute was packed too tight and more airframe space was needed. Although the main parachute did not deploy the overall flight was perfect. The vehicle launched very stable and straight. On the March 29 th launch the rocket flew successfully with main chute deployment fulfilling the requirement of a recoverable and reusable rocket. All flights have been stable and straight, leaving the team confident in their design and confident that the rocket will perform reliably. Under the launch conditions at the time, the team was able to come close to achieving the 5280 ft. goal. Flight one achieved an altitude of 4981 feet, while flight two achieved an altitude of 4772 feet. The rocket is over the projected mass by five pounds because of unaccounted mass items in RockSim. Test Data and Analysis: 6

7 LAUNCH #1 - March 14, 2013 LAUNCH #2 - March 29,

8 The flight data above represents the altitude vs. time graphs of both launches. Graph one shows that the slope of the graph does not change after the main chute deployment. This illustrates the non-deployment of the Main parachute. Graph two illustrates how the graph changes after Main ejection of parachute, therefore the slope of the altitude vs. time graph flattened out. Many components of the rocket were tested in the March 14 th full-scale test flight when the main parachute did not deploy and the rocket came crashing to the ground at 72 ft/sec. All system remained 100% intact after a complete analysis of the rocket. The only failure was the nose cone, a crack was discovered and the nosecone was replaced. The integrity of the airframe, fins, and motor retention subsystem seems to be structurally sound even after the rocket crashed into the ground. Workmanship: Quality of workmanship was demonstrated after the March 14 th full-scale failure and the only failure was the nose cone itself. The team is able to work efficiently and quickly to construct pieces of the rocket. The team also demonstrates ingenuity in its ability to fix any problems that have arisen such as the major problem of integrating the parachute into the rocket. The team is dedicated to their work on the rocket and meeting their goal of a safe and perfect flight. They repeat procedures that lead to good results, and all take part in preparing the rocket for flight. All of these qualities of the team are what make them so successful in their goal of achieving mission success. Safety and Failure Analysis: The rocket is safe, stable, and should perform as expected. For example, the stability margin is 8.13 ( over-stable ). We are utilizing commercially made motors and many other commercial components for the recovery system. This will drastically decrease the margin of error for the vehicle. Both full-scale launches were successful and indicated no major design flaws or errors. Failure Modes Causes Effects Mitigations The main parachute fails to deploy -The parachute is not packaged in the most efficient method possible and gets stuck in the rocket The rocket hits the ground with only the drogue chute to slow it down. The rocket is either damaged with minor fractures, or is damaged beyond repair. Research methods for folding the main parachute. Practice folding several different ways to see which one works the best. 8

9 The rocket zippers The main chute deploys before it is supposed to. -Both altimeters deployed their ejection charges at around the same time. -The shock cord isn t long enough and isn t absorbing enough shock. -The structural integrity of the body tube is too weak. -The shear pins were not strong enough. -Not enough shear pins were used. -The ejection charge for the drogue chute was too strong The rocket part damaged by the shock cord must either be trashed and rebuilt, or fixed in a way that it doesn t not leave the rocket in a state of major structural vulnerability. The rocket drifts out of the 2500 ft radius of the launch pad. The rocket causes damage to property outside of the launch radius. Try using a longer shock cord if you can, or spread out the delay on the one altimeter from the other, so that they do not interfere with each other. Make sure that the amount of black powder being used in the ejection charges is what was tested for that many shear pins. The rocket assumes an unpredictable, unsafe flight path The payload gets lodged in the rocket and doesn t come all the way out the tube to collect data. -The rocket is unstable -Launch Lugs are not aligned properly -The payload fits too tightly within the rocket body tube -The shock cord gets wedged between the payload and the inside wall of the rocket The rocket damages property, hurts someone, or becomes damaged itself. No data is collected on the payload. Use a launch rail to align the launch lugs onto the rocket. Check them when their finished to make sure they re still straight. Drill holes below the payload in the rocket to relieve pressure. The drogue parachute is burnt by the ejection charges -The wadding wasn t properly covering the parachute -The altimeters fire with too short of an interval of each other, causing too much heat. The drogue chute either provides little support on the way down, or needs replaced soon after its recovery. Set the delay between the two altimeters to a larger interval, or find a way to keep the ejection charges from burning the chute with the wadding. 9

10 The shock cord breaks when the section containing it splits. -The shock cord Parts of the rocket was weakened from fall without a all of its previous tests parachute in the rocket -The Quicklink on the end of it was not closed, and it came off in flight. Full-Scale Flight Data: Using the full-scale motor Cesaroni K635, the rocket traveled to a peak altitude of 4981 feet. Using RockSim the calculated altitude should have been 5315 feet in a 10 mph wind. The final mass of the rocket was well above the anticipated mass and explains the motors inability to achieve said 5315 feet. More care needs to be taken into consideration when entering all masses in RockSim. Mass Statement: The final estimated mass of the vehicle and subsystem components is 337 ounces. Component Nose Cone Section Payload Section Booster Section Main section Motor Mass 26 oz 52 oz 112 oz 85 oz 62 oz The total mass was measured by weighting each section in its ready full-up flight condition. 10

11 Recovery Subsystem: The vehicle bulkheads at the payload section and centering ring attachment are made out of 3/32 fiberglass. These bulkheads are then epoxied to the inside of the body tube with added filets. On the avionics bay these bulkheads are double up to create a cap that fits on top of the avionics bay. Attached to the bulkhead is a forged eye-bolt for attachment to the quick links on the shock cord. Around the nuts and holes epoxy was applied to prevent the nuts from loosening. To attach the shock cord to the eye-bolts the use of 1/4 quick links was used. These quick links are rated for 900 pounds of force. With the eye-bolt and quick link combination our recovery attachment system will be robust enough to withstand all the stress it will undergo in the ejection process. The Adept22 and PerfectFlite StratoLogger altimeters are very well constructed altimeters are considered and industry standard. We have used both altimeters before and have had no problems. The 2-pole rotary switches are attached to the avionics bay 1 band and are accessible from outside of the avionics bay. This system keeps the switches in place during flight and does not allow for inadvertent shut-off. The switch leads are attached to the wires with solder and shrink tubing where needed as to prevent any shorting of wires. The same is done to the battery holders. These 9- volt holders are epoxied to the bottom fiberglass sled and bolted so that they will not move. All wires are zip-tied in place to prevent any movement during flight. The avionics bay in this rocket was designed for redundancy. There is an Adept22 and PerfectFlite StratoLogger altimeter. Both altimeters are attached to a terminal strip where e-matches can be installed for the four ejection charges. There are four ejection charge wells on the electronics bay. There are two on the top, for the main parachute ejection and two on the bottom for drogue parachute ejection. Each altimeter will be wired to one charge for each side of the electronics bay. With this setup two ejection charges will be ignited for each parachute ensuring complete separation of the separate pieces of the rocket. The altimeters are programmed so that the charges are lit at different heights to avoid over pressurization of the rocket. 11

12 We are using a 15 parachute manufactured by TopFlight that will be deployed at apogee and will slow the rocket down to a suitable speed for the main parachute to deploy at 600 feet. The main parachute is a SkyAngle CERT3-Large parachute that will slow the rocket down to 16 ft/s before landing. This is a safe speed to avoid damage to the rocket upon impact with the ground. The drogue parachute is attached to the shock cord with a quick link and that shock cord is attached to the electronics bay. The two grams of black powder is sufficient to separate the rocket and deploy the drogue parachute. The drogue parachute provides enough drag to pull out the remainder of the shock cord. Then at 600 feet the other set of ejection charges are fired and the main parachute is deployed. During our test launches the recovery system worked exactly as planned. The ejection charges were powerful enough to separate the rocket. The main parachute was also large enough to slow the rocket so the rocket withstood no damage and all pieces are fully reusable. We are using no transmitting devices. The only other electronics onboard is an Astro GPS system. The recovery system is not very sensitive to transmitting devices that would create an electromagnetic field. The only electronics in the electronics bay are the two altimeters. They are not sensitive to the field for they use a pressure difference when detecting things such as apogee and height for drogue shoot deployment. Safety/Failure Risk Cause Effect Risk Mitigation Parachute does not deploy Ejection charge not fired, parachute not properly packed Rocket will come down too fast, mild to serious damage to rocket Follow proper folding and packing techniques and ensure altimeters work properly Rocket not fully separated Ejection charges not lit, not powerful enough Rocket will come down too fast, mild to serious damage to rocket Test black power charges before launches, test for continuity in altimeters to ensure charges will be set off 12

13 Ejections charges do not fire Current not sent through ematches Parachutes do not deploy, rocket does not separate, minor to serve damage to rocket Test for continuity in the altimeters before filling charges, test the altimeters with the packaged computer program Wires in electronics bay break Too much use, bending wire in unnatural directions Wires must be replaced and time is lost Use stranded wire, keep wires tidy Rocket over pressurized by the ejection charges Both ejection charges set off at the same time, too much black powder Serious airframe damage, damage to electronics bay and recovery aspects Stagger the fire height of the redundant charges, test black powder charges before hand Mission Performance Predictions: Mission Performance Criteria: Our goal is to build and test a rocket that will achieve an altitude of one mile, eject a scientific payload, and return safely to the ground. In order to do this, we must first create a stable and reasonable rocket design on a simulation program such as RockSim. Our scientific payload will be equipped with a cell growth chamber that will be activated upon lift-off. At 600 feet, the main parachute will be ejected from the rocket, allowing it to land safely and nearby. This will be accomplished by using computer software to program an altimeter to eject the section containing the drogue parachute at apogee and the main parachute at 600 feet. To ensure safety and to maintain a reliable ejection system, there will be a second altimeter programmed to eject at the same flight events, except with a slight delay. Current motor selection is Cesaroni K635RL. Simulated Center of Pressure (CP): 89 in from nose. Simulated Center of Gravity (CG): 57 in from nose. 13

14 Simulated Flight Profile: Motor Thrust Curve: Validity of Analysis: Our scale rocket is 1/2 the size of the actual rocket. The stability margin was about 3.5. This means that the subscale was stable enough to be launched safely. The launch later on supported this because we noticed that the rocket flew up straight and steady. The motor used for the subscale was an Aerotech F40-4 motor. The predicted altitude of the subscale rocket was 1400 ft, three hundred feet diffence from the actual 1100 ft. measured by onboard altimeter. A final conclusion of the difference and actual altitude 14

15 was based on the fact in that weather and atmospheric variables were to blame. The half-scale launch validated our construction process and design elements in regards to the full-scale vehicle. The only implication this launch raises is the accuracy of the simulations on the full-sized vehicle in its ability to reach the desired altitude of 5280 ft. Kinetic Energy: A dual deployment recovery system will be used, consisting of a 15 inch drogue parachute in the lower body and a SkyAngle CERT3-Large main parachute in the middle body tube. Both the drogue parachute and main parachute will be attached by quick links to provide a secure connection to the rocket, yet also be able to be disconnected by hand when needed. The drogue will be deployed at apogee by the Adept 22 altimeter. The StratoLogger SL100 altimeter will be programmed to provide secondary deployment one second after apogee to ensure recovery deployment. The main parachute will be deployed at 600 feet AGL by the Adept 22 altimeter. The StratoLogger SL100 will provide back-up ejection at 500 feet AGL. The rocket is expected to descend at 85 ft/s on the drogue parachute and 16 ft/s on the main parachute. The team will also use a Garmin Astro GPS system to assist in locating the rocket after landing. Critical Points in Flight Velocity Mass KE Main Deployment 85ft/s; 25.91m/s 336 oz.; 9.55kg Landing 16ft/s; 4.87m/s 336oz.; 9.55kg Predicted Altitude & Drift Compared to Wind Speed: Wind Speed Altitude Wind Speed Drift

16 Vehicle Verification: Requirement Status Altitude Completed - Test flight & Rocksim KE Completed - Calculations Launch Readiness Completed - Tested for 2 hours 8 ft Launch Rail Completed - Verified length of rail Total Impulse <2560 n-s Completed - Visual inspection of motor 10% Ballast Completed - No ballast on board 1/2 Scale Test Flight Completed - Launched Drift Rate Completed - RockSim & full-scale test flight GPS Completed - Visual finding rocket Full-Scale Test Flight Completed - Launched Payload Integration: The Payload Coordinator has given the predicted dimensions of the experiment package area to Design Lead who will determine the final specific layout of the payload within the rocket. The stated length of the rocket section can be changed slightly if necessary to accommodate a longer or shorter package. However the use of 4-inch airframe allows ample room for the equipment package. The payload area has been designed as an isolated section of the rocket, and is independent of other systems bays. Therefore it does not need to interface with other avionics, greatly simplifying the integration requirements. The cell growth chamber is self-contained and self-sustaining. The growth chamber will be secured within the airframe using packing material. The cell growth chamber is a sturdy container that houses five sealed test tubes. In each test tube is water and yeast that mixes upon acceleration of vehicle. The cell growth chamber is sealed and not opened until back home where analysis under a microscope can be made on the growth structure of the cells. 16

17 IV Payload Criteria: Experimental Concept: Our payload has a completely original design. We built our cell growth chamber from scratch, to ensure that our data is precise enough to measure the difference in the amount of cell growth at different velocities. The significance of our payload is to experimentally determine the relationship between cell growth and velocity. With this relationship we will be able to conclude if it possible for living organisms to produce normal functioning cells at high velocities. Science Value: Creativity and Originality: As a society we are fascinated in being able to travel outside our Earth system. To go beyond this system and do so in a relatively short amount of time we will need to travel at higher velocities. The question we ask is this, is it possible to travel at high velocities and allow a living organism to produce normal functioning cells. Uniqueness and Significance: The main goal of our payload is to find a relationship between the current cellular production of a normal cell and one that forms at high velocities. The goal of the cell growth chamber is to determine if a high velocity will affect the cellular growth of a living organism. Science Payload Objective: We will have one growth chamber at ground level that forms cells under no velocity, and another chamber that forms cells under high velocity as the rocket ascends into space. We will take both samples back to Wright State University and have them compared at the cellular level in the development of the two samples. We will compare a normal sample to one under duress from high velocity and determine if it will form into a normal cell. Mission Success Criteria: To have a successful payload, we must also have a successful launch first. If the rocket does not perform at its best, than neither can the payload. If the rocket s recovery system does not deploy correctly, then damage could not only be done to the rocket, but also the payload. 17

18 Experimental Logic, Scientific Approach, and Method of Investigation: To prove our hypothesis that the higher the velocity the more stress that will be placed onto cell growth, we will first need to examine the cell growth from the no velocity chamber to determine a normal growth pattern. After the control has been determined we can measure any variance in the high velocity chamber. Tests and Measurements: Our cell growth chamber is a self-contained system of five sealed test tubes that allow the water and yeast mixture to occur upon liftoff. This set-up allows for a long wait time on the launch pad. After the rocket has landed the mixture will have to be taken to Wright State University where Dr. Chuck Chimpaglio will assist us in the measurement of the two cell chambers. Expected Data and Accuracy: We expect our cells in the high velocity chamber will differ enough in their features that we will be able to determine if the cell is a viable candidate for normal growth. The only downfall to this experiment is waiting to get back home to measure the difference in samples. Containers will only be opened in a lab environment to eliminate contamination of the samples. If the rocket crashes we could lose all our data from a breach in the cell growth chamber. Experiment Process Procedures: Once the cell growth chambers are set-up there is nothing more to do but wait for gravity to take over on lift-off. This is where the water and yeast will mix on their own. This set-up makes for a long pad life because there is no outside help required. Payload Design: Design and Construction: There is one main part to the payload, the cell growth chamber. Within the cell growth chamber are five sealed test tubes that contain water and yeast. The chamber must set in a vertical position not to be tipped past 45 degrees causing the water and yeast to unintentionally mix. Other than the five test tubes there is some packing material to help keep the tubes from rattling around. Repeatability of Measurement: The purpose of using five test tubes is to make sure we get a good sample of data. If we were only using one test tube something may go wrong and we would have no data. Using five test tubes allows for one or two bad samples and still achieves good data. 18

19 This experiment allows for constant repeatability of measurement. We can measure the difference in the control and independent variable as many times as we can launch the rocket. Flight Performance Predictions: We have flown our payload safely already. However, we have not yet taken the high velocity chambers to the university to be observed. We are only allowed a certain amount of help with this and do not want to over-step our welcome. The cell growth chamber proved itself on both launches with a 100% mixture of all test tubes. We have a high confidence that our experiment will work but are unsure of the actual results. Workmanship to Achieve Mission Success: The payload has continuously been worked on during the construction phase, to make sure it is working the best it possibly can. On the first launch, the rocket came down without the main parachute and the payload survived without any breach of materials. We plan on continuing to make the payload better, by strengthening seals and reviewing test procedures. This should further prevent any mishaps from happening again, and will ensure that we get successful test data. Test and Verification Program With each flight we analyze each part of the payload to ensure that no part of the payload has been breached. We continue to do tests on the payload, to make sure all seals are tight and that no contamination occurs. Verification Payload Requirement: The engineering or science payload may be of the team s discretion, but shall be approved by NASA. NASA reserves the authority to require a team to modify or change a payload, as deemed necessary by the Review Panel, even after a proposal has been awarded. 3.2 Data from the science or engineering payload shall be collected, analyzed, and reported by the team following the scientific method. 3.3 Unmanned aerial vehicle (UAV) payloads of any type shall be tethered to the vehicle with a remotely controlled release mechanism until the RSO has given the authority to release the UAV. Verification: Complete payload analysis Payload Test, Analyze data in University Lab N/A 19

20 3.4 Any payload element which is jettisoned during the recovery phase, or after the launch vehicle lands, shall receive real-time RSO permission prior to initiation the jettison event. 3.5 The science or engineering payload shall be designed to be recoverable and reusable. Reusable is defined as being able to be launched again on the same day without repairs or modifications. N/A Payload inspection Safety and Environment for Payload: There are a limited amount of environmental concerns with the launching of this rocket. Since there are a lot of controlled variables in this experiment, the probability of these problems are very slim. One environmental concern would be a small effect on the ecosystem. This could include an unexpected motor ejection, a rocket s recovery system unpredictably faults, or the rocket coincidently getting stuck in a tree. The smoke that comes from the motor may be potentially harmful to the environment and the organisms within it, including humans. If the rocket disappears into a wooded area, it may endanger an animal s life if it gets hit, or if it tries to digest a part or parts of the rocket. With the specified launch site, these problems should not arise, and have a very small chance of happening. The cell growth chamber offers little to no environmental impact because of the un- invasive nature of the living organism. 20

21 V) Launch Operations Procedures Checklist: Pre- Check: Inspect exterior of rocket for damage or cracks Inspect Aeropack motor retention Inspect rail buttons Inspect payload bulkplate Inspect rivet and shear pin holes Inspect shock cords for fraying or heat damage Inspect shock cord attachment points Inspect drogue and main parachute Inspect heat shields for heat damage Test E-match continuity Test igniter continuity Prepare Avionics Bay: Set external switches to off position Install washers on bottom of 9V batteries Install batteries into battery holder Secure batteries with zip-ties Verify Primary - Adept22 programming Verify Primary - Adept22 battery continuity Set primary altimeter switch to off position. Verify secondary - StratoLogger battery continuity Verify secondary - StratoLogger programming Set secondary altimeter switch to off position. Close avionics assembly make sure nuts are tight Verify all altimeter switches are off Add E-matches to ejection wells and wire to terminal blocks. Clear area and warn for possible e-match firing. Power up Primary - Adept22 and arm ejection verify E-Match continuity Set primary altimeter switch to off position Power up secondary - StratoLogger and arm ejection verify E-Match continuity Set secondary altimeter switch to off position Fill drogue ejection wells with 2g of FFFF Black Powder Stuff ejections wells with wadding to fill Tape ejection wells shut Fill main ejection wells with 2.25g of FFFF Black Powder Stuff ejections wells with wadding to fill Tape ejection wells shut Verify switches still safe 21

22 Prepare Recovery: Install heat shield onto lower body tube harness Fold drogue parachute and harness Slide protected parachute and harness into lower body tube Attach lower body tube harness to lower avionics bay Verify closed anchor to lower avionics bay Slide lower avionics bay into lower body tube Install two (2) 4-40 nylon shear pins Attach booster harness to upper avionics bay Verify closed anchor to upper avionics bay Pass booster harness though lower booster body tube Slide lower booster section into upper avionics bay Install four (4) large rivets onto booster section Install heat shield onto booster harness Fold main parachute and harness Attach main parachute to booster harness Verify closed anchor for main parachute Roll chute and harness into the heat shield protector Slide protected parachute and harness into the upper booster body tube Attach booster harness to lower payload bulkplate Verify closed anchor for booster harness Slide payload section into upper booster section Install two (2) 4-40 nylon shear pins Install experiment into payload section Activate GPS transmitter Install GPS transmitter into nose cone with four (4) screws Slide nose cone into upper payload section Install four (4) large rivets onto payload section Verify avionics bay vent holes are open and unobstructed Verify all switches still in off position Prepare Motor: Inspect & clean motor case as needed Assemble Cesaroni motor following manufacturer s instructions Slide motor into rocket Verify Aeropack motor retainer is secure Complete flight card Take igniter, masking tape, and small flat screwdriver for arming 22

23 Pre-Flight Checklist: Verify all switches still in off position Verify CG / CP relationship RSO approval LCO approval Photographers and recovery crew ready Radio check for LCO, Recovery Igniter in hand Pad Checklist: Verify all switches still in off position Install rocket on rail Position rocket tilt direction if needed Pause for photos by rocket Arm Adept22 altimeter Turn on Adept22 and verify continuity and self diagnosis Previous apogee (x2) Repeating three (3) continuity beeps Arm StratoLogger altimeter Turn on StratoLogger and verify continuity and self diagnosis Preset number Main deploy altitude Previous apogee Battery voltage Repeating three (3) continuity beeps Install motor igniter Verify no ignition current by shorting launch clip lead Attach launch leads to motor igniter Launch Checklist: Retreat to safe distance GPS / Radio Check Photography Check Recovery Check LCO Check Proceed with launch under LCO s direction. Countdown: LAUNCH! 23

24 Post-Flight Checklist: Successful Launch: Verify that vehicle is not hazardous to retrieve Verify that all FFFF Black Powder is expelled from ejection wells Listen to altitude beeps Walk rocket back to base Inspect for damage Download altimeter data to PC Store cell growth chamber in sealed container Contingency - Abort Launch: Unload motor and igniter, store until ready to use Unload payload and FFFF Black Powder from ejection wells Contingency - Crash Landing: Verify that vehicle is not hazardous to retrieve Verify that all FFFF Black Powder is expelled from ejection wells IF NOT: Unload payload and FFFF Black Powder from ejection wells Take photos of landing Dig out of the ground and locate all the components Analyze the rocket for damage, and reusability Take notes on what went wrong 24

25 Safety and Environment (Vehicle & Payload): Safety Plan: Carlin Elder will have the role of Student Safety Officer and will oversee that all team participants comply with all team shop safety rules and the NAR High Power Safety Code requirements at all times. Ted Oldiges, Advisor and team mentor, will act as the Adult Safety Officer; he will ensure compliance with the safety requirements and will be the person ultimately responsible for supervising all construction and launch procedures. All team members have been briefed on NAR High Power Safety Code Requirements, hazard recognition, accident avoidance and facility safety procedures. Several copies of the Requirements will be posted on the walls around the workspace in order to ensure that team members are constantly reminded of Safety procedures. Halfway through the project, there will be another safety meeting, where the NAR High Power Safety Code requirements will be read again, and the team will be re-briefed on hazard recognition and accident avoidance. All team members will be briefed on safe ways of using potentially hazardous materials, but only NAR Level 2 certified members, or members under the direct supervision of Level 2 certified members, will be handling these materials (with the exception of high power motors which will only be handled by levelappropriate personnel). To ensure safety procedures, a safety "exam" has been administered before the beginning of the construction phase. No team member is allowed to participate in construction in any way unless they have passed this safety exam. A safety checklist will be written for pre-launch briefings and before any launch the team will ensure that all items of the checklist will have been verified to be safe: No launch shall be allowed to proceed unless safety requirements have been met. As materials are acquired for construction, the safety plan will continue to be updated for usage of the materials and submit caution statements in plans, procedures, and other working documents. In order to be aware of all potential errors and safety problems, failure modes of the proposed design of the rocket, payload integration, and launch operations have been assessed. Some failure modes of the proposed design of the rocket are potential error in the dual deployment system. A failure in the primary or back up altimeters will cause a failure of the dual deployment recovery system. A failure of the altimeter batteries to provide the required voltage for system usage will cause error in recovery. Error to obtain accelerometer data will cause failure of the drogue to deploy at apogee and main to deploy at 600ft. Error in barometric reading will cause failure of the backup altimeter to deploy the drogue 1.00 seconds after sensing apogee and to deploy a backup main charge at 500ft. Flight computers from different manufacturers will be used as a protection against electronic recovery failure. The dual deployment system has a chance of premature triggering of 25

26 the deployment charges, causing a loss of visibility of the rocket during its descent if it is blown too far away to be visible. GPS- based telemetry system placed inside the nosecone will mitigate possible failure. Possible failure modes of the rocket will continue to be looked at as the process continues. Possible failure modes of the payload integration are problems with deployment of the yeast culture at apogee. Possible failure modes of launch operations include misfires, and overall motor failure. In context of the payload, possible failure modes would cause a halt in the scientific experiment as well as a safety hazard. In order to ensure all safety concerns are addressed a listing of personal and material hazards have been listed below. NAR High Power Safety Regulations are posted in the work area. Each member will be tested and briefed on all potential failure modes listed in this document as well as others that we will continue to compile as the process continues. As for environmental concerns, correct disposal of rocket motor is the most pressing issue. Material Safety Data Sheets (MSDS) and User Guides for software and electronics will be uploaded to the website. Material Risk/Mitigation Strategy: Epoxy (Application & Sanding) 2-part Expanding Foam APCP Rocket Propellant Toxic Fumes, Skin Irritation, Eye Irritation Toxic Fumes, Skin Irritation, Eye Irritation Skin Irritation, Inadvertent Ignition, Burns to skin Team members will work in well ventilated areas and wear face masks at all times to prevent inhalation of toxic fumes. Gloves will be worn at all times to prevent skin irritation. Goggles will be worn at times to prevent eyes irritation. Team members will work in well ventilated areas and wear face masks at all times to prevent inhalation of toxic fumes. Gloves will be worn at all times to prevent skin irritation. Goggles will be worn at all times to prevent eye irritation Gloves will be worn at all times to prevent skin irritation. Propellant will be kept away from ignition sources, such as 26

27 matches, igniters, heat sources, and stored in proper Type 3 or Type 4 magazines to prevent inadvertent ignition. E-matches/Igniters Black Powder Paint Burns to skin, Inhalation of toxic fumes, Eye Irritation Explosive-may cause serious physical injury, death. Toxic fumes, skin irritation Eyes, throat, lungs, nose irritations, vapors contain toxic fumes, vapors may cause flash fire or explosion, may cause central nervous system disorder. Only team members eighteen or older will handle E matches/igniters. Team members will wear gloves at all times when dealing with E matches or igniters. They will only be dealing with igniters in a solid state and will be the NAR regulation distance away from the rocket when igniting so as to avoid any accidental injuries. Black Powder will be kept away from heat, sparks, and open flame. Impact, friction, and static electricity will be avoided. Team members will be briefed on fire prevention and emergency procedures which will include proper response to a spill or leak of black powder. Contaminated areas would need to be entirely water cleaned before cleaning. Will be stored in a cool, dry place at all times. Team members will wear face masks and protective gloves while handling paints at all times. All painting will be done outside or in an area with a prime ventilation system. 27

28 Fiberglass (Application and Sanding) Inhalation, skin and eye irritation Team members will wear protective mask and gloves at all times, they will not touch the fiberglass with their bare hands. All fiber glassing application will be done in a ventilated area such as a garage. Goggles will be worn at all times as well. Physical Risks: Risks Consequences Mitigation Laceration Saws, knives, Dremel tools, band saws All members will follow safety procedures and use protective devices to minimize risk Sandpaper, fiberglass Abrasion All members will follow safety procedures and use protective devices to minimize risk Drill press Puncture wound All members will follow safety procedures and use protective devices to minimize risk Soldering iron Burns All members will follow safety procedures to minimize risk Computer, printer Workshop risks Toxic Risks: Electric shock Personal injury, material damage All members will follow safety procedures to minimize risk All work in the workshop will be supervised by one or more adults. The working area will be well lit and strict discipline will be required Risks Consequences Mitigation Toxic fumes Epoxy, enamel paints, primer, superglue Superglue, epoxy, enamel paints, primer Toxic substance consumption Area will be well ventilated and there will be minimal use of possibly toxic-fume emitting substances All members will follow safety procedures to minimize risk. Emergency procedure will be followed in case of accidental digestion. 28

29 Scheduling and Facilities Risks: Risks Consequences Mitigation Unable to complete construction of rocket and/or payload homes if necessary. Workshop space unavailable Design facilities unavailable Team members unavailable Unable to complete project Unable to complete project We will insure the availability of our workshop space for the times that we need it. We will also work at team members We will insure the availability of our design facilities and work at team members homes if needed. We will plan meetings in advance and insure that enough team members will be present to allow sufficient progress. Rocket/Payload Risks Risks Consequences Mitigation Unstable rocket Errant flight Rocket stability will be verified by computer and scale model flight. Improper motor mounting Weak rocket structure Propellant malfunction Damage or destruction of rocket. Rocket structural failure Engine explosion Engine system will be integrated into the rocket under proper supervision and used in the accordance with the manufactures recommendations. Rocket will be constructed with durable products to minimize risk. All members will follow NAR Safety Code for High Powered Rocketry, especially the safe distance requirement. Attention of all launch participants will be required. Mentors will assemble the motors in accordance with manufacturer's instructions. Parachute Parachute failure Parachute Packaging will be double checked by team members. Deployment of parachutes will be verified during static testing. Payload Launch rail failure Separation failure Payload failure/malfunction Errant flight Parachutes fail to deploy Team members will double-check all possible failure points on payload. NAR Safety code will be observed to protect all member and spectators. Launch rail will be inspected prior each launch. Separation joints will be properly lubricated and inspected before launch. All other joints will be fastened securely. 29

30 Ejection falsely triggered Recovery failure Transportation damage V) Project Plan Unexpected or premature ignition/personal injury/property damage Rocket is lost Possible aberrations in launch, flight and recovery. Proper arming and disarming procedures will be followed. External switches will control all rocket electronics. The rocket will be equipped with radio and sonic tracking beacons. Rocket will be properly packaged for transportation and inspected carefully prior to launch Project Budget - $3, Vehicle Tubing $ Fin Material $ Missile Works PET2+ $ Adept 22 $ Parachutes, recovery gear* $ Garmin Astro GPS $ Miscellaneous supplies (tools, glues) $ Scale Model Tubing $ Fin Material $ Motors Scale Model Motors $ Preliminary Flight Motors $ Final Flight Motors $ Payload Environmental Chamber $ Travel Partial Travel Expenses $ Total $ 3, Travel Budget: Gas $75/Person * 10 People $

31 Rooms $120/Room * 5 Rooms * 5 Nights $ 3, Total $ 3, Cost per Team Member $ Funding Plan: Minster Rocket Club has sufficient money earning opportunities to cover for possible discrepancies between the estimated budget and actual project expenses. Additionally, it is our policy to provide necessary economic help to all SLI students who cannot afford the travel expenses associated with the program. Every year we award several full expense travel scholarships to TARC students. The monetary amounts and the names of recipients are not disclosed. Every year we raise funds by selling concessions at local county fairs. We find this is an excellent way to earn the support of the community and increase our visibility. Minster Rocket Club has received a significant amount of publicity as a result of our increasing finishes at the TARC contest. Many local newspapers and news channels carried the story. Educational Engagement: Education engagement is in the process of starting their outreach into the community and after-school programs. They are building foam rockets with elementary and middle school students. Education team has set-up an information booth at basketball games and is working to inform the public on rocketry. Worked with local Boy Scout troop on a build and fly session in rocketry. 31

32 Huntsville Launch-display planning and design Huntsville Launch-trip planning and trailer prep Huntsville Launch-display construction Huntville Launch-practice Launch-load trialer Huntville Launch-load trialer Huntville Launch-launch! Team safety briefings Team safety briefings Huntville Launchlaunch! Huntville Launch-load trialer Huntville Launchpractice Launch-load trialer Huntsville Launchdisplay construction Huntsville Launch-trip planning and trailer prep Huntsville Launchdisplay planning and design Series1 11/1/2012 4/17/2013 4/13/2013 4/6/2013 3/1/2013 2/28/2013 1/1/2013 Series Series1 Series2 LV-final plans complete construction LV-Avionics Bay ejection LV-Purchase of LV motors by tripoli Mentor LV-Test Luanch 1-no payload LV-Flight certification by Tripoil mentor LV-desing modifications-if necessary LV-test 2-if necessary LV-test 2-fight certifiion LV-puchase all materials and components LV-all materials and components LV-all materials and components in hand LV-all materials and components in hand LV-all materials and components LV-puchase all materials and components LV-test 2-fight certifiion LV-test 2-if necessary LV-desing modificationsif necessary LV-Flight certification by Tripoil mentor LV-Test Luanch 1-no payload LV-Purchase of LV motors by tripoli Mentor LV-Avionics Bay ejection LV-final plans complete construction Series1 1/28/2013 1/1/2013 4/6/2013 4/6/2013 3/15/2013 3/9/2013 3/9/2013 3/9/2013 2/6/2013 2/11/2013 1/18/2013 Series Series1 Series2 32

33 Sub-scale- finalize plan, consturction Sub-scale- Purchase of components Sub-scale-bulid Avionics Bay and Payload testing Sub-scale- test Recovery ejection charges-using Sub-scale-Launch date Sub-scale-Filght Certification from Sub-scale-Purchase of, Sub- scale motor Sub-scale- Purchase of, Sub- scale motor Sub-scale- Filght Certification from Sub-scale- Launch date Sub-scale- test Recovery ejection charges-using Sub-scalebulid Avionics Bay and Payload testing Sub-scale- Purchase of components Sub-scalefinalize plan, consturction Series1 1/5/2013 1/5/2013 1/5/ /22/ /1/ /24/ /24/2012 Series Series1 Series2 Avionics Bay = purchase all components Avionics Bay = construction Avionics Bay = low pressure ground testing Avionics Bay=design monification Avionics Bay= low preussure ground testing Avionics Bay= all components in hand Avionics Bay=Ready to fly Avionics Bay=Ready to fly Avionics Bay= all components in hand Avionics Bay= low preussure ground testing Avionics Bay=design monification Avionics Bay = Avionics Bay = low pressure construction ground testing Avionics Bay = purchase all components Series1 3/3/2013 1/15/2013 2/24/2013 2/19/2013 2/18/2013 1/24/2013 1/18/2013 Series Series1 Series2 33