Charger Rocket Works 2009-2010 University Student Launch Initiative Preliminary Design Review Presentation

1. University Student Launch InitiativePreliminary Design Review Submission: December 4, 2009 Presentation: December 10, 2009

2. Overview Preliminary Design Review (PDR) Objectives Mission Statements Project Overview Vehicle Criteria Structures Propulsion Payload & Recovery Criteria Verification and Testing Approach Safety Tools Risk Mitigation Questions/Discussion

3. PDR Objectives Introduce vehicle and payload design to USLI engineering review board Confirm vehicle and payload design meet USLI competition requirements Evaluate safety and mission assurance plans Demonstrate flight operations can be executed safely Detail cost and schedule for production, testing and operations Address risks and impacts to vehicle, cost, and schedule

4. Mission Statement USLI Mission Statement: The NASA University Student Launch Initiative is a competition that challenges university level students to design, build, and fly a reusable rocket with a scientific payload to one mile in altitude. The project engages students in scientific research and real-world engineering processes with NASA Engineers. (Cited from the NASA Education Website) Charger Rocket Works Mission Statement: Further our understanding of the science and engineering of high powered rocket thru developing and flight testing. Build a knowledge base with which to achieve even greater heights. Reach out to educate and inspire others to pursue a future in science, technology, engineering, and mathematics.

5. Project Overview Bellerophon & Pegasus Greek hero Bellerophon slew the Chimera on the back of the winged horse Pegasus. Pegasus : booster stage – homage to UAHuntsville’s mascot Bellerophon: payload - autonomous hybrid lander Bellerophon Pegasus

6. Project Overview Team Objectives Develop in-house airframe manufacturing capability* Develop a safe and reusable rocket with operations procedures** Reach closest to 1 mile in altitude*** Recover Bellerophon and Pegasus intact Successfully demonstrate a mechanical recovery release system Successfully demonstrate the Bellerophon hybrid lander Reach out to 500+ students in the local area

7. Project Overview Mission Description Bellerophon & Pegasus launch preparation and walk-out Avionics and payload power up (1.5 hr max pad-stay) Launch, powered flight, & coast Bellerophon & Pegasus separate at apogee and descend on drogue Bellerophon parasail deploys at 700 feet altitude and begins flight maneuvers Pegasus main parachute deploys at 500 feet altitude Bellerophon & Pegasus touch down and are recovered Flight data is downloaded and stored for reduction Official altitude is recorded for competition

8. Vehicle CriteriaStructures Accomplishments since proposal: 4 inch mandrel delivered for subscale and 98mm motor tubes* Carbon fiber airframe manufactured in-house for subscale* Successfully flight tested subscale rocket** Verified in-house tube manufacturing as viable path forward for full scale rocket development Vacuum bag capability being matured* Work In Progress Developing procedures for in-house airframe manufacturing** Developing fiberglass laminated phenolic honeycomb core material for centering rings and bulkplates Preparing 6 inch mandrel for full scale rocket tubes* Strength testing carbon fiber tubes**

9. Vehicle CriteriaStructures Subscale Design Description (flight tested) 4 inches diameter & 68 inches overall vehicle length 10 lbs pad weight Carbon fiber airframe & phenolic coupler Four G-10 Garolite clipped delta fins Urethane 5:1 ogive nosecone 54mm phenolic motor tube ¾ inch plywood centering rings and bulkplates First Flight Performance: 0.99 calibur static stability margin – balanced (field) 0.28 drag coeffiecient 3540 feet altitude Many lessons learned

10. Vehicle CriteriaStructures Full Scale - Design Description (Baseline) 6 inches diameter & 102 inches overall vehicle length 32 lbs pad weight (with Aerotech L1150R loaded) Carbon fiber airframe & fiberglass coupler Four G-10 Garolite clipped delta fins 6 inch diameter fiberglass 5:1 ogive nosecone 98mm carbon fiber motor tube ¾ inch birch plywood centering rings & baseplates Baseline Performance Predictions: 1.43 calibur static stability margin – hand calculated 0.34 drag coefficient

11. Vehicle CriteriaPropulsion Accomplishments since proposal: Static test fired 4 motors Developed procedures for conducting static test firings** Validated subscale computer model with flight data (Cd)** Verified subscale model stability with hand-calculations** Baselined full scale competition motor – Aerotech L1150R*** Work In Progress: Optimizing full scale computer model Ordered full scale demonstration motor for verification test Baseline Performance Predictions: Thrust to Weight Ratio of 7.2 Velocity off the pad of 60 ft/sec Maximum Altitude of 5280 ft

12. Payload & Recovery Criteria Integrated Payload and Recovery Systems are closely linked Promotes commonality & improves reliability Reliability & Redundancy Bellerophon & Pegasus use mechanical release device (baseline) Mechanical releases triggered by altimeter activated servos Bellerophon & Pegasus use independent altimeters Altimeters have dedicated batteries & switches Pegasus Recovery System (Full Scale) Drogue: B2Rocketry 24 inch parachute(75 ft/sec decent rate) Main: B2Rocketry Cert-3 XXL parachute (15 ft/sec decent rate) D-Bag: B2Rocketry XXL deployment bag

13. Payload & Recovery Criteria Support Line Anchor Bellerophon Hybrid Lander Nosecone contains GN&C system Autonomous / manual override capable Drogue: B2Rocketry 24 inch parachute (75 ft/sec decent rate) Parasail: 2.75 AR & Spans 8 feet (15 ft/sec static decent rate) Control Lines Servos

14. Payload & Recovery Criteria Accomplishments since proposal: Flight tested prototype mechanical release device Flight tested prototype hybrid lander with R/C servos Work in Progress: Mature mechanical released device design Mature requirements for parasail configuration Building payload mass simulators for iterated subscale flight testing Developing hybrid lander ground test schedule to support flight test schedule Developing autonomous flight controller

15. Verification and Testing Approach A – Mission: Subscale rocket flight test Flight test mechanical release device with two parachutes (no parasail) Mass simulator for R/C parasail control & nosecone payloads Flight test of deployment bags B – Mission: Subscale rocket flight test Flight test mechanical release device with parachute/parasail (static) Mass simulator for R/C parasail control & nosecone payloads Flight test of deployment bags C – Mission: Subscale rocket flight test Flight test mechanical release device with parachute/parasail (static) Integrated Flight test of R/C parasail control system Mass simulator for nosecone payloads Flight test of deployment bags

16. Verification and Testing Approach D – Mission: Full scale rocket flight test – sub altitude Flight test of mechanical release device two parachutes (no parasail) Mass simulator for R/C parasail control & nosecone payloads Flight test deployment bags E – Mission: Full scale rocket flight test – 1 mile Flight Test of mechanical recovery mechanism with parachutes and parasail (static) Mass simulator for R/C parasail control & nosecone payloads Test deployment bags F – Mission “Full-Up”: Full scale rocket flight test – 1 mile Flight Test of mechanical recovery mechanism with parachutes and parasail Integrated Flight Test of R/C parasail control & nosecone payloads Test deployment bags

17. Verification and Testing Approach Flight Test Schedule: Dec.12-13, 2009: A – Mission Jan. 16-17, 2010: B – Mission Feb. 13-14, 2010: C – Mission/ D – Mission March 6-7, 2010: E – Mission March 27-28, 2010: F – Mission April 10-11, 2010: (Optional) Ground Test Schedule: In development to support flight test objectives

18. Safety Tools Safety Briefings: A now standard practice before conducting any construction project, and ground or flight test. Participating individuals are briefed of responsibilities, procedures, likely hazards, and actions to take in the event of an accident or hazard. Participants are briefed on the need and the proper use of safety equipment. Written Procedures: Developed for all construction projects, ground and flight tests. Improved knowledge base, effectiveness, and safety between leaving and incoming team members. MSDS: Available in the lab and audited once at the beginning of the semester

19. Safety Tools Existing Procedures: Static Motor Test Firing Stand Setup and Test Conduction Carbon Fiber Tubing Layup and Curing Launch Day Checklist Procedures in work: Black Powder & Ground Based Recovery Testing Parachute Folding Procedures Mechanical Release Testing Launcher Assembly and Usage

20. Risk Mitigation Identified risks to vehicle, schedule, & cost Potential outcome of failure Steps taken to mitigate those risks Need to rank risk from most likely to least

21. Recovery Risks: Risk Mitigation

22. Subscale Photos Bellerophon & Pegasus at the Childersburg, AL Proving Grounds

23. Questions/Discussion Recovery