Mars Rover PDR Team Rocket City Rover Presenter: Markus Murdy 1 Presentation Outline ● Introduction ● ● Systems Overview ● ● Butt Testing ● ● Hopping, McFerrin, Thibaudeau Integration ● ● Krause, Murdy, Rover Design ● ● McFerrin Rocket Design ● ● Murdy Suzuki Project Management ● Murdy Presenter: Markus Murdy 2 Team Organization Markus Murdy Team Lead Rocket Development Junior, Aerospace Eng. Dr. Francis Wessling Faculty Advisor Blake Krause Descent Control Rocket Development Sophomore, Aerospace Eng. Josh Thibaudeau Rover Chassis/Drivetrain Rocket Development Sophomore, Aerospace Eng. Ryo Suzuki Rover Chassis/Drivetrain Junior, Aerospace Eng. Ali Butt Software Development Graduate Student, Aerospace Eng. Ethan Hopping Rover Avionics Junior, Aerospace Eng Trey McFerrin Rover Avionics Sophomore, Mechanical Eng. Presenter: Markus Murdy 3 Acronyms CNC CONOP EEPROM FET FOS GPIO LI-ION MCU NAR NASA OD PCB PWM RBF SHC SPI SRB UAH USART Computer Numerical Control Concept of Operations Electrically Erasable Programmable Read-Only Memory Field Effect Transistor Factor of Safety General Purpose Input Output Lithium Ion Microcontroller National Association of Rocketry National Aeronatics and Space Administration Outside Diameter Printed Circuit Board Pulse Width Modulation Remove Before Flight Space Hardware Club Serial Peripheral Interface Solid Rocket Booster University of Alabama in Huntsville Universal Synchronous Asynchronous Receiver Transmitter Presenter: Markus Murdy 4 System Overview Trey McFerrin 5 Mission Summary • Rover and Rocket • Design, fabricate, test, and fly • Rocket releases Rover above 1000 feet AGL • Rocket and rover make controlled descent • Rover performs ground maneuvers • 10 foot straight • 90 degree turn • 10 foot straight • Score • Accuracy of ground maneuvers • Design Reviews Presenter: Trey McFerrin 6 Rocket Requirements • • Tripoli/NAR rules in place (required motor retention, no metallic objects on the exterior) Apogee • • • Recovery • • • Must reach at least 1000 feet Commercial altimeter must be used to determine apogee All components of rocket must return safely under a recovery system Maximum Descent Rate = <20 feet/second Motors • • • • Maximum motor class = K Minimum Thrust to weight ratio = 5:1 No Clustering No Staging Presenter: Trey McFerrin 7 Rover Requirements • Flight Operations • Must be fully contained into the rocket before deployment • Must return to ground safely with a recovery system • Ground Operations • Nominal Maneuvers: • Travel 10 feet, turn 90 degrees, and travel 10 feet • Required Maneuvers: • Must travel at least 3 feet, turn, then travel 3 feet • Place visible marker at landing and turn points • 10 minute limit from touchdown • No pyrotechnics • Fully Autonomous • 2 kg mass limit Presenter: 8 System Level Trade and Selection Rocket Rover • Tracked Vehicle • Constant Diameter Body • Proven Flight Heritage • Possibility of Payload binding in airframe • Fairings • Low ground clearance • Two Wheel Chassis • Payload Volume Flexibility • Fairings ejected away from payload, low jamming risk • Payload Canister • Inflatable Wheel Option • Additional Ground Clearance • Different ConOps • Adjustable Traction • Rocket ejects canister at apogee • Puncture Risk • More moving parts, reduced payload volume flexibility • Square Foam Wheel Option Pro Con Criteria • • Additional traction from treads Green Bullet • Competition Heritage • Ease of Fabrication • Foam corners provide additional bounce for navigating terrain Presenter: Trey McFerrin 9 Rocket Physical Layout Payload Fairing (Contains Rover) Dual Flight Computers Dual Recovery System 6” Payload Section Motor 79” Square Foam Wheels Chassis 10” 13.7” Dual Motors Presenter: Trey McFerrin 10 System Concept of Operations 2 3 1. 2. 3. 4. 5. 6. 7. Launch Apogee, Recovery deployment Deployment of Rover Landing of rover and rocket Rover travels 10 feet Rover turns 90 degrees Rover travels additional 10 feet 6 5 7 1 4 Presenter: Trey McFerrin 11 Rocket Design Markus Murdy and Blake Krause 12 Overview of Rocket (Numbers) Mission Profile Fins Apogee 2300 ft Number 4 Payload Deployment 1100 ft Root Chord 16in Inspiration Space Launch System Tip Chord 10in Motor Aerotech K1499 Height 4.5in Sweep Angle 45 deg Offset 3in Stability (dimensions from tip) Center of Pressure (no fins) 21.5in Center of Pressure (fins) 43.75in Center of Gravity 34.5in Stability (Separation) 1.49 (9.25in) Physical Specs Length Overall 79.5in Fairing Diameter 7.2in Fairing Length 10in Airframe Diameter 6in Airframe Length 55in Launch Weight 19.5 lbs Presenter: Markus Murdy 13 Overview of Rocket (Layout) Fiberglass Fairing~0”-30” Carbon Fiber Airframe~30”-76” Carbon Fiber Parachute Pods~44”-79” Nose Cone~ 0-10” Large Diameter Section~10-20” Small Diameter Section~10-20” Pod Nose Fairing Separation Cone~41” Plane~30” Transition from 7.2OD to 6.2OD~20-23” Fairing Separation Charge~1” Rover Descent Control~ 5-11” Mars Rover~ 12-27” Fairing Inside Coupler~ 22-36” Given Dimensions are from the tip of the nose Flight Computers ~ 43-51” Presenter: Markus Murdy Carbon Fiber Fin Set~ 61-76” Boat tail/Motor Retainer ~ 76-79” Rocket Descent Internal Motor Control~ 55-78” Support~ 55-78” Motor 14 Rocket ConOps Apogee: T+12 Seconds Altitude: 2300ft Motor Burnout: T+0.9 Seconds Recovery Deployment: T+12.5 Seconds Dual Parachutes from rear of SRBs Rover Deployment: T+50 Seconds Fairing Separation and Rover Separation/Deployment Altitude: 1100ft Landing: T+100 Seconds Liftoff: T+0 Seconds Weight: 19.5 lbs Presenter: Markus Murdy 15 Rocket Materials • Nosecone – • – Fiberglass LTM45 Carbon Fiber Prepreg • Fairings ‒ ‒ • Adhesives used Main Airframe and Parachute Pods – • ● Fiberglass Polycarbonate (rover pedestal) Fins – Polycarbonate Integrated Motor Retainer and Boat Tail • Epoxy – LTE45 (composites matrix) – 3M DP100 (attachments) Rail Buttons – Large Rail Buttons (15/15 Rail) – CNC turned aluminum button in-house Motor retention – Integrated Motor Retainer/Boat Tail – 2 part assembly – Male part is fixed in the airframe – Female part screws onto the bottom – Injection molded in-house Presenter: Blake Krause 16 Rocket Recovery System ● ● ● Parachutes will be sewn in-house to meet desired specifications Overall diameter 5.25ft, Spill Hole diameter 1.5ft Harness – Parachute Swivel Quick Link From calculations, maximum deceleration is 10m/s^2, recovery system must withstand 250lbf with Factor of Safety – Commercially available ½” tubular Nylon (1000lb test, FOS 4) – Each parachute has 8ft of shroud line from chute to #500 ball bearing Swivel (500lb test, FOS 2) – 20ft of shock cord from swivel to hardpoint on rocket – Shock cord will be mounted to airframe part of integrated boat tail motor retainer with ¼” Quick Links (880lb Test, FOS 3.5) and ¼” Forged Eye-Bolt (500lb test, FOS 2) – Parachute protection will be provided by Nomex sheets Presenter: Blake Krause Shock Cord Quick Link 17 Rocket Recovery System Deployment Method ● ● • Altimeter controlled ejection ● First Deployment at apogee ● Back up Deployment at 1500ft Drogue Primary Secondary PerfectFlite Stratologger – Both boards can fire both charges – Independent 9V Batteries Main Charge Installation – Pack latex glove finger with appropriate black powder amount – Twist emath leads, insert emath into black powder pile – Tie off glove finger – In parachute compartment, navigate ematch leads through bulkhead ports – Tape emath leads to prevent contaminate, note either drogue or main Presenter: Blake Krause 18 Rocket Recovery System Deployment Method • • Arming Process • Check to ensure no one is in the immediate blast area • Turn on PerfectFlite, install ematch drogue leads in screw top headers, then install ematch main leads in screw top headers • Check that each ematch has good continuity • Insert Remove Before Flight Pin • Do Not Point blast end of parachute pod at anything other than ground Safety • Absolutely no open flames in charge prep area • Same person installs charges each time • E-match leads are twisted until installed in the headers • Pulling the Remove Before Flight Pin is the last item on the launch checkout ● Charge Sizing (FFFFG Black Powder) ● For 2in ID tube, 25in long: ● 𝑁 = 𝑃𝑉 ● Calculations are derived from NASA Advanced Rocketry Workshop Handbook 16𝑝𝑠𝑖∗337𝑖𝑛 𝑅𝑇 = ( 3 𝑖𝑛∗𝑙𝑏𝑓 266 𝑙𝑏𝑚 ∗3307°𝑅 )(454𝑔𝑟𝑎𝑚𝑠 Presenter: Blake Krause 1𝑙𝑏𝑓) =2.8 grams 19 Rocket Motor Selection ● ● ● Primary motor: AeroTech K1499 ● 75mm, 2 grains, adjustable nozzle ● On Campus Availability ● Thrust to Weight Ratio: 18.7:1 ● Faster liftoff for windy conditions Backup motor: Cesaroni J410-RL ● 38mm, 6 grain ● Thrust to Weight: 5.11:1 ● Smaller liftoff G-load (6 vs 20) Flight simulations – Open Rocket and RockSim – Estimated Apogee – K1499 = 2200 ft – J410 = 1180 ft Presenter: Blake Krause 20 Rover Design Joshua Thibaudeau, Ethan Hopping, Trey McFerrin 21 Rover Design Overview Top View (with component callouts) Axle Subassembly (Inflatable option) Front View (with dimension callouts) Motor subassembly and mounting fixture Presenter: Joshua Thibaudeau 22 Rover Design Overview (Assembly) Front View showing wheels at different rotation angles (foam wheel option) Isometric View (foam wheel option) Top View with Chassis, Motor Assembly, and Axle/Gear Assembly (inflatable option) Presenter: Joshua Thibaudeau 23 Rover Mechanics ● ● ● Polycarbonate Rover Chassis ● Impact Resistance ● Availability and Machinability Electronics Mounting ● Prototype: PCBs mounted to open plates on chassis (as in rendering) ● Final Unit: PCBs enclosures added Drive Gear Ratio ● ● ● Found through experimentation with prototype Wheel Options to be Evaluated ● Inflatable Wheels ● Square Foam Wheels (as in renderings) Rover Mass is estimated at 1.4 kg Presenter: Joshua Thibaudeau 24 Motors, Drivetrain Black & Decker Electric Screwdrivers • Easily sourced and Replaced • Designed for durability • Integrated Planetary Gearbox • Flight heritage • Appropriate speed range for rover Image Credit: Target • Reasonable Power Requirements • Product powered from alkaline batteries Voltage (V) 6 Stall Current (A) No-Load Current (A) 3 0.5 Motor, Drivetrain Specifications Presenter: Ethan Hopping RPM Torque (in-lbs) 120 20 25 Electrical Block Diagram 3.3V Regulator 6V RBF 6V Rail 3.3V Rail Data/Control MCU Hotwires Magnetometer Motor Controllers Rotary Encoders Motors Pressure Sensor Non-corruptible EEPROM memory is built into MCU Presenter: Ethan Hopping 26 Rover Ground Operations String spools Mass 1 Stage 1 • Release parachute • Drop first marker • Drop first mass anchor Marker 1 String 1 10 ft. Stage 2 • Drop second marker • Turn 90 degrees • Drop second mass anchor String 2 Mass 2 Rotary encoders Stage 3 • Ground operations complete • Stop, wait Marker 2 10 ft. Presenter: Ethan Hopping 27 Motor Control Presenter: Trey McFerrin 28 Angle Measurement: Magnetometer • Purpose: Determine the orientation of the rover against the earth’s magnetic field • Selection: HMC5883L • Characteristics: • Resolution: 4.35 milliGauss • Earth’s magnetic field is approximately 300 milliGauss • Max sampling rate: 160 hz • I2C output • Flight heritage on past UAH Space Hardware Club projects. • Calibration: • A hard iron calibration will counter the effects of the motors’ permanent magnets. • If soft iron distortions are noticed, the magnetometer will be moved further from interfering materials. If the problem persists, a soft iron calibration may be implemented. Presenter: Trey McFerrin 29 Pressure Sensor • Purpose: Detect Launch/Landing • Selection: MS5611 • Characteristics: • Accuracy: 13.5 feet • Resolution: 0.33 feet (at up to 100 hz sampling rate) • SPI or I2C Interface • Flight Heritage on past Space Hardware Club projects Presenter: Trey McFerrin 30 MCU • Purpose: Track flight sequence, Control ground operations • Selection: Atmel ATxmega256A3BU • 8 bit • Flight Heritage on past Space Hardware Club projects • Built in Hardware Modules Used • 1x I2C (Magnetometer) • 1x SPI (Pressure) • 1x USART (debug) • 1x Timer/Counter (Motor Controller) • 8x GPIO (5x Hotwires, 1x SPI Chip Select, 2x Encoder) Presenter: Trey McFerrin 31 Rover Power: Battery Selection – – Requirements: – Capacity: 1034 mA-hr – Nominal Voltage: 6.0V – Surge Current: 5.8A Battery Selection: 4x SF123A Li-ion cells (series-parallel) Characteristics: - Capacity: 2700 mA-hr (2.61 times margin) - Nominal Voltage: 6.0V - Surge Current: 6.0A - Single Use - Meets Requirements - Readily Available - Flight Heritage on past UAH Space Hardware Club projects Mounting method – – - Selection Rationale: - – 6V Mounted to PCB via battery holder with retention clip GND Protection circuits ● Short Circuit Protection: Fuse ● Over-discharge protection unnecessary for non-rechargeable cells Presenter: Trey McFerrin 32 Rover Power: Power Budget Device Motors (x2) Hotwires MCU Pressure Sensor Magnetometer Rotary Encoder Current (mA) 6000 2000 20 1 5 5 Time (s) 600 20 3600 3600 600 600 Time (hr) 0.167 0.006 1.000 1.000 0.167 0.167 Duty Cycle 100% 100% 100% 100% 100% 100% Capacity Needed Capacity Available Capacity Margin Presenter: Trey McFerrin Capacity (mA*hr) 1000.0 11.1 20.0 1.0 0.8 0.8 1034 2700 2.61 Source Experimental Experimental Datasheet Datasheet Estimate Estimate mA*hr mA*hr mA*hr 33 Rover Power: Distribution – 6V Rail – – Supplied directly from batteries Powers: – Motors – Hotwires – – 3.3V Rail – – – Supplied by Linear Regulator from 6V bus Powers: – MCU – Sensors Connections: 15A Anderson Powerpoles – – – Controlled by TO-220 MOSFETs Battery Board to Motor Controllers, MCU Motor Controllers to Motors Remove Before Flight Switch – Connects battery to voltage rails Presenter: Trey McFerrin 34 Rover Markers ● ● Markers are Expo Dry-Erase Marker Caps ● Lightweight ● High Visibility Release via Hotwire Image Credit: Expomarkers.com Presenter: Trey McFerrin 35 Software Overview • Detect Launch • Determine altitude relative to ground reading • Detect Rover Deployment • Detect Rover Landing • Release Parachute • Initiate Ground Operations • Guide rover through ground operations • Calculate traveled distance and turn angle • Control Motors • Provide fault tolerance in event of momentary power loss • Store ground pressure and flight state in non-corruptible EEPROM memory Presenter: Ethan Hopping 36 Software Flowchart State 2: Deployment Detect State 0: Power up, Integration Batteries Installed Measure Deployment Switch State No power until removal of RBF While Deployment switch closed False True Measure Deployment Switch State State 1: Launch Detect Measure ground altitude, store in memory While altitude < (ground +error bound) False Proceed to Stage 3 True Measure altitude Proceed to Stage 2 Presenter: Ethan Hopping 37 Software Flowchart State 4: Ground Operation Drop Marker State 3: Landing Detect Drive Forward Measure Distance Travelled False False While alititude >(ground+error bound) While distance< (10ft) True Measure Distance Travelled Stop, Drop Marker True Begin Turn Sequence Measure altitude Measure Angle While distance<(90 deg) False True Measure Angle Delay to ensure rover is on ground within altitude measurement uncertainty End Turn Sequence Drive Forward Measure Distance Travelled Cut Parachute While distance< (10ft) False True Measure Distance Travelled Proceed to Stage 4 Program Stop Presenter: Ethan Hopping 38 Rover Payload Integration Layout ● The payload section will be two fiberglass fairings ● Rover sits on two ‘half moon’ pedestals, one in each fairing ● ● With the current foam wheels, the wheels will be compressed into the rocket’s fairings. The volume these compressed wheels will take up is less than the volume remaining in the fairing with the mechanical assembly in place. Parachute/Shock Cord is stowed in the larger diameter section of the fairings above the Rover Descent Control Rover Presenter: Ali Butt 39 Rover Payload Integration Process 1. Check battery charge status, string tension, condition of markers and weights 2. Wrap/Tape rover wheels with embedded hot wire release device 3. 4. With the fairings in the horizontal position, place the rover in the fairings, making sure it is firmly seated on the pedestal Place folded parachute/shock cord around the upper section of the rover, this corresponds to the larger diameter in this section 5. Connect hot wire release devices for wheel/ parachute release 6. Close fairing blast cap nose cone with monofilament 7. Insert inside shoulder section of fairings into rocket’s main airframe 8. Place rocket at 45deg from vertical to check lateral stability 9. 10. Lift rocket by fairings to check fairing/airframe connection, this reduces risk of drag separation during ascent Remove RBF switch once on pad Presenter: Ali Butt 40 Testing Ryo Suzuki 41 Rover Testing: Hardware ● ● ● Ground testing of all competition aspects (angle, distance, impact, safe descent) will be done on a variety of surfaces in multiple conditions. The system will be tested integrated with the rocket in a full scale launch before competition. At the full scale test the entire competition travel path will be practiced from power up to measurement of angle and distance traveled. Presenter: Ryo Suzuki 42 Rover Testing: Avionics • Power system • Verify lack of excessive voltage sag during motor and hotwire operation • Observe connection reliability through initial testing • Ensure flight software correctly resets after momentary power loss • Flight sequence • Simulate launch in vacuum chamber. Ensure flight software advancement through landing state. • Ground Operations • Angle measurement: Verify measured heading (magnetometer) against external compass • Distance measurement: Verify measured distance with measuring tape • Software Sequence: Demonstrate full autonomous ground run with no glitches Presenter: Ryo Suzuki 43 Rocket Testing ● Parachute Deployment Testing ● ● ● Payload Deployment Testing ● ● ● ● ● Ground test demonstrating proper ejection charge size/parachute packing Vehicle Roof Rack tests on quick ascent/descent in surrounding hills Tethered drop with fairing/body tube assembly from 20ft shop balcony Rocket flight demonstrating fairing stability and proper airframe separation Ground fairing separation charge test demonstrating proper charge sizing Follow-up flights with mass simulator to demonstrate fairing separation Flight Tests ● ● Flight tests at the Phoenix Missile Works Range in Childersburg, AL. The 1 mile diameter field provides a large downrange area to aim flight tests 4 flight weekends before competition, first weekend of each month Presenter: Ryo Suzuki 44 Flight Operations • Arrive at launch site Preliminary • Unload equipment Activities • Motor Preparation • Recovery Packing and Charge Installation Pre-Launch • Final Rocket and Rover Avionics Checks Integration • Integration of Rover into Payload Fairing 45 Presenter: 45 Flight Operations Launch pad Launch • Arming Recovery Charges • Installation Motor Igniter • Removal of RBF Pins ( 1 on Rover, 3 on Rocket) • Ascent • Rocket Recovery Deployment at Apogee • Rover Deployment (1100 feet) • Controlled Descent and Landing • Rover Performs Autonomous Ground Operations On ground • Data Analysis, Verification of Altitude Post Flight 46 Program Schedule Electrical orders received here Presenter: Markus Murdy 47 Program Budget (Hardware) Rover Hardware Budget Item 3D Printing Microcontroller Pressure Sensror (Launch Detect) Accelerometer (Landing orientation) Rotary Encoders (Distance Measurement) Magnetometer MOSFET (hotwire control) Motor Controllers Motors+Drivetrain Printed Circuit Boards Battery Dry Erase Markers (rover markers and design work) String (Distance Controller) Fiberglass Resin Total ( 10% margin) Trade UAH Machine Shop Digi-Key Digi-Key Digi-Key Digi-key Digi-Key Digi-Key Digi-Key Target Sunstone PCB Amazon Description ABS plastic Canister for Fortus 360 ATXMEGA128A1 BMP180 Pressure Sensor ADXL345 Triple Axis Accelerometer EMS22A Magnetic encoder, 3.3V HMC5883L Magnetometer BUK952R3-40E N-channel MOSFET LMD18201 H-Bridge Black & Decker Alkaline Screwdriver 4.5"x4.5" double layer pcb 123A (12 pack) Amazon Amazon UAH Machine Shop Expo Dry Erase Markers, 4 pack Nylon Kite String LTE45 Qty Sub Total Total Costs 1 $ 360.00 $ 360.00 6 $5.17 $31.02 4 $4.80 $19.20 4 $6.93 $27.72 4 $21.31 $85.24 4 $3.30 $13.20 16 $2.29 $36.67 4 $15.25 $61.00 4 $9.99 $39.96 4 $67.00 $268.00 1 $21.99 $21.99 1 1 1 $4.72 $7.95 $55.00 $4.72 $7.95 $55.00 $1134.74 Rocket Development Budget Description Certification Hardware Launch Fees Rocket Tubing Rocket Motors: Perfect Flight Module Descent Control Rover Descent Control Rocket Total ( 30% margin) Source Apogee Rockets Description Misc. parts for fabrication Rocketry Warehouse Wildman Rocketry PerfectFlite UAH SHC UAH SHC 6” G10 Airframe 48” J1055 (Flight Testing Motors) Stratologger altimeter Stock Parachute Stock Parachute Presenter: Markus Murdy Quantity 2 1 per day, 3 days 1 9 2 1 2 Price Each $ 50.00 $ 50.00 $ 168.00 $ 70.00 $ 71.96 $ 12.00 $ 12.00 Total Costs $ 100.00 $ 150.00 $ 168.00 $ 630.00 $ 143.92 $ 12.00 $ 24.00 $ 1,596.00 48 Program Budget (Travel and Summary) Team Travel Budget Description Rate Unit Quantity Hotel (3 rooms) $ 85.00 /Night∙Room 4 Nights∙3 Rooms $ 1,020.00 Meals $ 60.00 /Day∙Person 5 Days, 10 people $ 3,000.00 Van Rental $ 100.00 /Day 5 Days $ 500.00 $ 4,520.00 Total Team Budget Summary Description Expenses Prototyping & Rover Hardware $ 1,134.74 Rocket Development $ 1,596.00 Travel $ 4,520.00 Total $ 7,250.74 Presenter: Markus Murdy 49 Summary ● Prototype Rover design is well underway for testing of: ● Wheels ● Drivetrain & Motor ● Motor Controllers ● Ground Navigation Systems ● 2 team members flew at most recent rocket launch ● Finalize mold designs over winter break, cut molds in January ● Additional team members in process of building L1 cert rockets ● ● ● L1 certs at January launch, begin L2 cert work Lots of assembly testing in January and February Prototype rocket flight testing is targeted for January and February launch windows Presenter: Markus Murdy 50
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