Illinois Space Society Student Launch 2014-2015 Maxi-MAV Proposal October 6, 2014 University of Illinois at Urbana-Champaign Illinois Space Society 104 S. Wright Street Room 321D Urbana, Illinois 61801
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Illinois Space Society Student Launch 2014-2015
Maxi-MAV Proposal
October 6, 2014
University of Illinois at Urbana-Champaign
Illinois Space Society
104 S. Wright Street
Room 321D
Urbana, Illinois 61801
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Contents 1. Team Composition ................................................................................................................................ 3
Major Subteam 1: Structures and Recovery ............................................................................................. 3
Major Subteam 2: AGSE .......................................................................................................................... 3
Minor Subteams ........................................................................................................................................ 4
NAR Section ............................................................................................................................................. 4
2. Facilities/Equipment ............................................................................................................................. 4
3. Safety .................................................................................................................................................... 5
Safety Plan ................................................................................................................................................ 5
Risk Mitigation ......................................................................................................................................... 6
NAR Personnel Duties .............................................................................................................................. 7
Law compliance ........................................................................................................................................ 8
Motor and Energetic Device Handling ..................................................................................................... 8
4. Vehicle and Recovery System .............................................................................................................. 8
Vehicle Definition and Summary ............................................................................................................. 9
Materials ................................................................................................................................................. 10
Vehicle Dimensions ................................................................................................................................ 11
Vehicle Construction Methods................................................................................................................ 12
Parachute System Design ........................................................................................................................ 13
Motor Brand and Designation ................................................................................................................. 16
Projected Altitude ................................................................................................................................... 16
Hatch and Payload Canister .................................................................................................................... 16
5. Autonomous Ground Support Equipment (AGSE) ............................................................................. 18
Robotic Arm............................................................................................................................................ 20
Arm Motors ............................................................................................................................................. 21
Gripper .................................................................................................................................................... 22
Ensuring Reusability of Robotic Arm ..................................................................................................... 22
Lifting System ......................................................................................................................................... 22
Launch Pad.............................................................................................................................................. 23
Ignition System ....................................................................................................................................... 24
Computing System .................................................................................................................................. 25
Software .................................................................................................................................................. 25
Computer Vision Considerations ............................................................................................................ 25
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Sensors .................................................................................................................................................... 26
Power System.......................................................................................................................................... 27
6. Project Requirements .......................................................................................................................... 27
7. Technical Challenges and Solutions ................................................................................................... 31
8. Educational Engagement..................................................................................................................... 33
Goals ....................................................................................................................................................... 33
Outreach Opportunities ........................................................................................................................... 33
9. Project Timeline .................................................................................................................................. 34
10. Community Support ........................................................................................................................ 35
11. Sustainability Plan .......................................................................................................................... 35
12. Budget ............................................................................................................................................. 36
Appendix A: Educational Feedback Form .................................................................................................. 38
Appendix B: ISS Safety Policy ...................................................................................................................... 39
3
1. Team Composition
Team Leader
David Knourek, Project Manager
Phone: (708) 497-8169
Email: [email protected]
Safety Officer Derek Awtry
The ISS Student Launch Team participating in this competition consists of about 30 students,
essentially split evenly into two major subteams.
Managers
Project Manager: David
Safety Officer: Derek
Structures and Recovery Manager: Jacqueline
AGSE Manager: Ian
Webmaster: Derek
Educational Outreach Director: David
Major Subteam 1: Structures and Recovery
The first main subteam of about 15 students is the Structures and Recovery team. This team
will be responsible for design and construction of the vehicle, as well as the recovery avionics and
parachute systems. The Structures and Recovery team will also be responsible for the system of
sealing and jettisoning the sample. The Structures and Recovery manager is Jacqueline. David,
Derek, Mike, and Kamil are key technical members for the Structures and Recovery teams.
Specifically, David is responsible for the design of the vehicle, and Derek is responsible for
construction procedures. Mike is charged with management of the recovery systems and Kamil is
in charge of the sample canister and hatch systems
Major Subteam 2: AGSE
The second major subteam is the Autonomous Ground Support Equipment team. This team
will be responsible for design and construction of a robotic system to contain the sample within
the vehicle, as well as systems to erect the rocket from the horizontal position and install the motor
igniter. Ian is the AGSE manager. Alex, Chris, and Rick are key technical personnel for the AGSE
systems. Alex is tasked with leading the design and construction of the robotic arm, and Chris will
manage the motor igniter installation system. Rick is responsible for the system which raises the
rocket from the horizontal loading position to the launch configuration.
All subteam managers are mainly charged with organizing their respective teams and
overseeing design and work meetings, however they are also integral to the technical design of
their systems. Although key technical members are listed for the major subteams, technical work
will be equally split between all team members. In this way, the team may draw on the experience
of past members while building the knowledge of new members.
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Minor Subteams
Minor subteams of 5 to 10 students will be responsible for web design, safety planning,
and educational outreach. Each student on these subteams is also a member of either the AGSE or
Structures and Recovery subteams. Derek will manage the web design and safety subteams, and
David will manage the educational outreach activities.
NAR Section
The ISS Student Launch Team will be working with members of Central Illinois Aerospace
(CIA) to facilitate test launches, mentor the team, and review system designs. Specifically, Mark
Joseph will be the main NAR mentor for the ISS Student Launch Team. CIA is section #527 of
the National Association of Rocketry. The CIA organizes bi-weekly launches at several locations
close to the university, depending on the time of year and launch field conditions.
2. Facilities/Equipment The ISS Student Launch Team has access to numerous facilities necessary to the
completion of the project. The team has permanent access to the Student Organizations office
within the Department of Aerospace Engineering in Talbot Laboratory. The office is electronically
locked at all times of day, requiring keycard access granted by the Aerospace Department. This
will ensure safe and regulated storage of all team equipment and materials. The office also has
basic hand and power tools, including electric drills and Dremel tools. Stored in this office are also
a variety of rocketry supplies acquired by the team throughout past instances of this and other
projects. This includes launch equipment, avionics hardware and recovery components such as
shock cord, Proline 4100, and quick links.
The team also has permanent access to several student project workshops with additional
power tools and general construction equipment. These workspaces are accessible by the team at
all times, seven days a week. The majority of construction will be completed in these student
workspaces. Before being granted access to these laboratories, students are required to complete
general safety courses and sign safety agreements. The team’s Safety Officer will also brief team
members on safe construction procedures.
As a leading research university, the University of Illinois also has a significant number of
state of the art facilities and knowledgeable personnel available during standard working hours.
These facilities include composite materials laboratories, 3D printing facilities, a fabrication
laboratory with laser cutting machinery, machine shops, and materials testing facilities. Students
working in these facilities may utilize the guidance of working professionals or in some instances
work independently.
Students also have access to modern computer equipment and software provided by the
University’s Engineering Workstations Laboratories located in numerous buildings throughout the
campus. These computer systems allow access to many engineering software packages. Most
importantly, students are able to access Matlab, Mathematica, Fluid Dynamics Software, Logic
Gate Simulations and CAD software such as Creo, Solidworks and NX. These systems are
accessible by all team members at all times.
Web hosting for this project is provided by the College of Engineering through the Illinois
Space Society website. This website may be updated either through Engineering Workstation
computers or personal computers. The website will comply with Architectural and Transportation
Barriers Compliance Board Electronic and Information Technology (EIT) Accessibility Standards.
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The team also has access to conference rooms in the Department of Aerospace Engineering
that may be used for presentations, meetings and phone conferences. These conference rooms are
equipped with reliable high speed internet and telephones with conference call capabilities. Video
equipment such as webcams are also available for the team to use during teleconferences and
presentations.
3. Safety
Safety Plan
The safety officer this year will be Derek Awtry. He is a student studying Aerospace
Engineering at the University of Illinois. He worked with the 2013-2014 SLI Structures and
Recovery team, and as such he has worked on projects similar to this in the past. He has reviewed
the responsibilities of the safety officer, and will be able to take on these responsibilities.
The safety officer will ensure that every single member of the team knows the risks
associated with their respective subteams. Each member in the structures and recovery team and
the AGSE team shall complete the necessary lab safety training, and will be aware of the risks
associated with the handling and disposal of hazardous materials. As such, Material Safety Data
Sheets (MSDS) will be provided for those who are working with hazardous materials. These
MSDS’s will also be provided on the team website. Personal Protective Equipment (PPE) will be
provided to and required by team members who are working with these materials or working in a
lab with machinery that poses risks to those team members. The Engineering Student Project Lab
(ESPL) will deal with larger machinery that the team members do not have the qualifications for.
The usage of this machinery requires completion of training courses provided by ESPL. In the
event that the safety officer or the team mentor cannot supervise a potentially dangerous situation,
the safety officer will ensure that more experienced team members who have worked in these
situations before, like the team leader, are able to supervise.
All involved team members will be briefed on precautionary measures before every test
and launch of the high powered rocket. This is to remind everyone of the potential hazards with
the launch and recovery of a high powered rocket.
The team will coordinate with the local Range Safety Officer (RSO) and our team mentor
whenever the team would like to launch the rocket, so that members comply with all safety rules
and regulations associated with launching high powered rockets. A safety code has been attached
to the bottom of this document which will be read to all team members by the safety officer and
understood by all, before any construction can be started.
In the event of injury to a person or persons working on the project, first aid kits will be on
hand for every potentially dangerous event. In the case where the injury is more serious, local
hospitals such as Carle and Provena are within 5 miles of the construction sites. In the event of a
fire, fire extinguishers will be closely on hand. First aid kits, hospitals, fire extinguishers will be
all identified each time before team members start the construction process.
The team mentor this year will be Mark Joseph (NAR 76446 Level 2). He is qualified both
based on his certification as well as having flown 15+ flights under that certification. Mark Joseph
has been the Team Mentor for this University’s Student Launch team in 2011-2012 and 2013-
2014, and as such he is experienced with our team as well as with high powered rocketry
competitions.
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Risk Mitigation
Table 3-1: Risk Identification Matrix
Risk Probability Impact Mitigation
Hazardous
Materials
Low to
moderate
Harmful injuries to
the body,
including but not
limited to burns,
rashes, scars, and
other potentially
permanent
damages
Material Safety Data Sheets (MSDS) and
Personal Protective Equipment (PPE)
will be provided to all team members
handling hazardous materials. The team
mentor will work with the safety officer
to ensure all team members are briefed
before handling any hazardous materials
so the team members know the risks
involved when dealing with these
materials. The safety officer and team
mentor will supervise all handling of
these materials as well.
Tools and
Machinery
Low to
Moderate
Heavy bodily
injury, possible
irreparable
damage
Each team member will be required to
take a general lab safety course, and team
members using tools they have not used
before will be trained under the
supervision of the safety officer and/or
more experienced members.
Black Powder Moderate Possible light to
heavy bodily
injury, including
skin burns
The black powder will only be used by
the team mentor and any other person
with the qualifications to handle such
hazardous material.
Electrical
Hazards, such
as electric
shock, short-
circuiting
Low to
Moderate
Possible bodily
burns or electrical
shock, possible
damage to
electrical
components of the
rocket or AGSE
Make sure every team member working
with electrical components such as circuit
boards/power cords know the necessary
grounding procedures and safety
precautions associated with these
hazards.
Battery Danger
(Lithium-Ion)
Low Possible bodily
burns, and scars.
Also damage to
the battery such as
acid leaks or fire
The safety officer will confirm all
batteries used are deemed safe and not
too powerful to cause damage to any part
of the AGSE or rocket vehicle. Also the
safety officer will ensure every member
working with the batteries know the
risks, and the things to do in the event of
catastrophe.
7
Testing
Dangers
Low to
Moderate
Potential bodily
injury, including
burns and
fractures, as well
as damage to the
rocket
Every test of the rocket, including launch
test, ignition test, and any other tests
relating to the rocket will be conducted
and supervised by the team mentor, and
all team members involved will be
briefed on the risks involved, and the
proper safety precautions to follow.
Testing of the AGSE will be supervised
by the safety officer and/or experienced
members that have worked with AGSE
equipment before.
Launch
Dangers
Moderate Potential bodily
harm, as well as
damage to the
rocket, payload,
AGSE equipment
or other the
surrounding
environment.
All launches will be conducted in
compliance with NAR High Power
Rocket Safety Code, FAA
Regulations, and all other laws,
regulations, or safety codes that pertain.
The launches will take place at locations
that have standing FAA waivers. All
team members will be familiarized with
the NAR safety code and will have
signed safety agreements. The team
mentor will be present to ensure safety
and proper motor handling. Safety and
flight readiness checklists will be created
and followed in order to reduce risk.
Rocket Motor
(Ammonium
Perchlorate)
Moderate Possible adverse
effects of the
motor chemicals.
All handling of the motor will be
conducted by the team mentor, and
precautionary measures will be taken
whenever the rocket motor will be in use.
Environmental
Safety
Low Damage to the
rocket via
overheating,
power tools, or
other
environmental
factors
The safety officer will work with the
team mentor and any other experienced
member of the team to ensure that every
modification to the launch vehicle will
not have any adverse effects on the
rocket.
NAR Personnel Duties
The team’s NAR mentor will be responsible for the acquisition of FAA permits for
airspace. The permits will provide assurance of clear skies at the launch and would ensure that
there will be no impact on commercial aviation. In addition, they will ensure the group’s
compliance with the NAR safety code, which has been attached in Appendix B. The Team mentor
will be in charge of handling all dangerous materials. This includes, but is not limited to, motor
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handling, construction, and transportation and work with ejection charges and black powder. The
mentor will also be informed of design decisions and construction work by the team, and given
the opportunity to provide feedback and suggestions to team members for safety purposes.
Law compliance
The group’s safety officer will be responsible for educating all involved team members of
the regulations regarding the use of airspace, Federal Aviation Regulations 14 CFR, Subchapter
F, Part 101, Subpart C; Amateur Rockets, Code of Federal Regulation 27 Part 55: Commerce in
Explosives; and fire prevention, NFPA1127 “Code for High Power Rocket Motors.” as well as all
applicable federal laws. This will be followed by having only the team mentor handle, purchase,
store and transport all explosives and the motors. There will also be fire extinguishers on hand in
all locations where construction or storage will take place. Environmental regulations will be
referenced during the course of this project to ensure compliance. The group’s safety officer is
responsible for finding these relevant regulations for the handling and proper disposal of hazardous
or environmentally harmful materials. The safety officer will educate all team members about
proper compliance and all necessary information involved with these materials.
Motor and Energetic Device Handling
All handling of the motor and other energetic devices will be handled by the team member
Mark Joseph who has NAR level 2 clearing. Mark Joseph will also transport and store the motors
for all the team’s launches. For insurance purposes, Mark Joseph will also be the sole owner of the
motor, as he is the only one legally allowed to operate the motor.
4. Vehicle and Recovery System The overall design of the vehicle was based on several parameters. First and foremost was the
criterion of recovery and reusability. Each part of the rocket has to be robust enough to undergo
multiple launches without failing structurally. This turned strength into a major concern when
making design considerations. In addition, the target altitude of 3,000 feet gave the team a general
idea of the motor size needed, which in turn helped determine the general dimensions of the rocket.
Finally, the rocket had to be designed around a maximum of four independent sections.
For the purpose of obtaining hands on, engineering work experience, it was the team’s decision
to design, build and implement a rocket from custom selected materials and components. A rocket
kit will not be purchased to compete in this competition. The team has been and will continue to
follow the concurrent engineering design process of: defining the task, doing background research,
specifying requirements, brainstorming solutions, selecting the best solution, selecting an
approach for implementation, building a prototype and finally, refining the original design. Several
weekly meetings have been and will continue to be carried out to sustain group communication
and avoid the malpractice of “over-the-wall” engineering. Throughout the early stages of this
process, the team has defined and established several engineering parameters such as the selection
of materials, vehicle dimensions, motor brand and designation, vehicle requirements and recovery
systems, parachute system design, and construction methods.
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Vehicle Definition and Summary
The main vehicle constructed for this project will be a single stage, single motor rocket
utilizing a dual deploy recovery system. The vehicle will jettison the sample canister 1000 feet
above ground level to comply with competition requirements. An initial model of the vehicle is
given below in Figure 4-1.
Figure 4-1: Model of the Rocket Constructed with the OpenRocket Software Package
The basic design of the vehicle is fairly standard for a high power rocket, with the addition
of several critical modifications allowing the sample to eject. The lower portion of the rocket, also
referred to as the booster, is constructed with 4 feet of 5.5 inch diameter airframe tubing. Attached
to the bottom of the booster are three fins, equally spaced 120 degrees apart. These fins will be
trapezoidal in shape, with dimensions custom designed to allow for an appropriate location of the
center of a pressure. Mounted to the inside of the booster tube will be a motor mount tube. This
tube is affixed to the inner walls of the booster airframe via three centering rings. Attached to the
bottom centering ring will be a motor retainer. This component ensures that the motor remains
fixed in place during the boost and motor burnout stages of the flight. The upper portion of the
booster airframe will contain the vehicle’s drogue parachute, to be ejected at apogee.
Inserted into the top of the booster airframe is the coupler, which acts as the primary
avionics bay for this vehicle. Capped by bulkheads on each side, the coupler provides an enclosed
environment for the recovery altimeters. The avionics and their power supplies will be mounted
on a payload sled. Rails composed of threaded aluminum rods will run the length of the coupler,
providing guides for the sled to slide on. The vehicle’s avionics will be activated via rotary
switches mounted on the exterior of the airframe. This avionics bay architecture was chosen
because the ISS Student Launch Team has successfully utilized such configurations in the past.
For vehicle safety, it is critical that recovery electronics function properly, and a proven system
provides the best opportunity to ensure flight safety.
Above the coupler is the upper airframe tube. The lower portion of this tube serves as the
storage location for the vehicle’s main parachute, which will eject at 1,100 ft. above ground level.
The center of the upper airframe is the storage location for the sample to be contained in the
vehicle. Much like the avionics bay, this portion of the rocket is capped at each end by bulkheads,
sealing the sample and other payload materials from the rest of the rocket. This system is described
in more depth in the Hatch and Payload Canister portion of this report.
Above the payload sample canister is the sample parachute, which will be used to safely
recover the sample canister after being jettisoned. Inserted into the top of the upper airframe will
be a 21 inch long ogive nose cone for aerodynamic purposes.
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Materials
In designing the rocket itself, team members researched various materials for construction
of the main body and fins. Initially, aircraft plywood and balsa wood were considered as possible
materials for the fins while Blue Tube, carbon fiber, and fiberglass were evaluated for possible use
in the main body. Each material was later assessed in regards to its respective advantages and
disadvantages as seen in Table 4-1 below. 5 represents the best possible score in a category, while
1 represents the poorest possible score in a category.
Table 4-1: Material Trade Study
Material Strength Cost Ease of Use Safety
Aircraft Plywood 3 3 3 4
Balsa Wood 1 5 5 4
Blue Tube 4 3 4 4
Carbon Fiber 5 1 2 3
Fiberglass 4 3 2 1
Team members first settled on a material for the main body of the rocket. Research into
fiberglass revealed that there are many safety hazards when working with it. The dangers of
inhaling fiberglass particles during construction were a major safety concern. Additionally the
team desired a shift away from the heavy and expensive fiberglass airframes constructed in the
past. The team then debated between carbon fiber and Blue Tube. It was ultimately decided that
the added strength of carbon fiber was unnecessary and did not justify its much higher cost. In
addition, Blue Tube is easier to work with than carbon fiber. Its heat capacity is sufficient to protect
against the heat output of the motor, and its reinforced cardboard makeup poses fewer safety
concerns when it is being cut. These benefits, combined with its relatively high strength at an
affordable price, led Blue Tube to emerge as our chosen material for the main body.
Focus then shifted to deciding between balsa wood and aircraft plywood for the fins. Team
members decided that the material would have to be moderately strong and relatively easy to work
with, especially because fins require extensive shaping and sanding before being attached to the
rocket. Although balsa wood is extremely easy to cut and shape, it was almost immediately ruled
out due to its low strength. Aircraft plywood, on the other hand, was found to be an excellent
material for fins that fits both our main requirements: moderately strong and relatively easy to
shape. As a bonus, aircraft plywood is not high in price and does not present any unacceptable
safety hazards. Due to structural concerns and the reusability requirement, however, the fins will
also be lightly reinforced with carbon fiber. A thin skin of carbon fiber will add an immense
amount of strength to each fin without adding significant weight.
Centering rings and bulkheads will be composed of high strength plywood, as this is a
relatively cheap, strong material that is easy to work with. The vehicle’s nose cone will be a
commercially available Poly-propylene plastic nose cone, to ensure the quality of this important
aerodynamic component.
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Vehicle Dimensions
The vehicle dimensions were generally determined based on the approximated total
weighted value of the flight vehicle and the target apogee of 3,000 feet. Specific dimensions were
determined based on keeping the flight vehicle stable in its flight direction. Minimal axis deflection
is desired to avoid any horizontal lift generated through the center of pressure due to gusts of wind.
Minimizing drag force and keeping the center of gravity 1 to 2 calibers above the center of pressure
was an essential factor. In the end it was determined that the rocket will in total have a mass of
13,619 grams and a total length of 298 cm. Dimensions and mass are defined into specific
components in Table 4-2 below.
Table 4-2: Vehicle Component Summary
Component Material Dimensions [cm] Approximate
Mass [g]
Nose Cone Poly-propylene 53.3 cm 324 g
Body Tube Blue Tube 122 cm x 14 cm 1344 g
Sample Container Plywood 21.4 cm x 13.6 cm 43.8 g
Booster Tube Blue Tube 122 cm x 14 cm 1341 g
Coupler Blue Tube/Plywood 45.7 cm x 13.6 cm 530 g
Motor Mount and Casing Blue Tube 61 cm x 8 cm 1742 g
Centering Rings (3) Plywood
13.6 cm (outside
diameter) x 8 cm
(inside diameter)
135.9 g
Fins Plywood
Root: 49 cm
Tip: 31 cm
Height: 16 cm
435 g
Avionics -- -- 454 g
Parachutes and Attachment
Hardware -- -- 3629 g
Sample -- -- 113.4 g
Sample door and Electronics Blue Tube/Electronics -- 170.1 g
Motor Retainer -- -- 454 g
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Motor -- 39.5 cm x 75 cm 2935 g
Additional Materials (Carbon
Fiber, Epoxy, etc.) -- -- 1635.8 g
Vehicle Construction Methods
The manufacturing and assembly of the flight vehicle will be broken down into several
individual sections and will take place periodically throughout the project after all designs have
been finalized. Safety has been the primary factor while determining these construction techniques.
Safety equipment such as gloves, safety glasses, and earplugs will be worn when necessary
throughout the build process. Members of the team building the flight vehicle will rotate in turns
to insure a small group of students is working at any given time. Work instructions will be written
before all build meetings and all work will be documented at the end of build meetings to eliminate
any progress confusion for following build meetings. The projected construction techniques are
subject to change as the team approaches obstacles in the manufacturing process.
An assortment of tools will be used from basic office supplies to power tools. Basic
supplies will include: pencils and pens, masking tape, mixing sticks, sandpaper of assorted grit, a
ruler, drafting squares, a level, an X-Acto knife, a C-clamp, razor saw, threadlocker and rubbing
alcohol. Power tools will include: a drill and bits, a Dremel tool and a palm sander. Epoxy will be
used for bonding major areas of the flight vehicle. The amount applied will be determined by the
structural integrity and consequential drag effects while in flight. Since there are many hazards
associated with exposure to epoxy fumes, great caution will be used when handling this resin
system.
Before construction, all parts will be inventoried, weighed, cleaned and labeled. All parts
will then be checked for proper fitting. General construction practices will include marking all hole
locations, confirming all hole and insert sizes, and double checking locations before drilling.
Surfaces that will have epoxy applied will be sanded with 60 grit or coarser sandpaper and later
cleaned with rubbing alcohol.
The projected plan is to begin with the construction of the motor mount. While constructing
the motor mount tube and centering rings several things will be accounted for. Motor retention
will be ensured by a screw-on motor retainer or the old fashioned method of screwing a metal plate
to the base of the rocket. If Aero Pack retainers are chosen, the position of the centering rings will
have to be adjusted.
Three center rings will be used for additional support and ease of alignment. The location
of the center rings will be marked on the motor mount and body tube in three different locations:
the top ring slightly below the motor mount tube, the middle ring to be aligned with the top of the
fins, and the bottom ring to align the retainer with the bottom of the rocket.
Rail button positions will be marked on the airframe. The rail buttons will be attached
before the motor mount is fixed inside of the rocket. T-nut interfaces will be created on the inside
of the rocket.
The motor mount will be inserted into its marked location in the booster airframe at a later
time. The inside of the booster airframe and the fin slots will be sanded. Epoxy will be applied to
the top of the center rings. For the bottom center rings, epoxy will be applied through a hole for
the top ring and through a fin slot for the middle ring.
13
The avionics bay will be assembled through many subparts. The bulkheads will have
threaded rod rails, eyebolts for parachutes, charge cups, and terminal blocks. A switch band will
be created and attached next. Finally, a sled will be created by marking out electronics, attachment
placement, and attaching tubing to the bottom for the rail guides.
There are also several methods being considered for the construction of the fins, which are
composed of aircraft grade plywood wrapped in a carbon fiber skin. The flight vehicle will be
constructed with through-the-wall fins. These must be able to fit between the middle and bottom
center rings. A fair amount of epoxy will be applied between the fins and the body tube for support.
Internal fillets for the fins will be used since the fins must be fit tight to the motor mount tube and
the center rings must fit snug to the top and bottom of the fins. Fin alignment will be insured
through the use of a fin guide jig which will be specified at a later time.
A CAD model of the hatch system will be created before construction of the hatch occurs
to ensure proper dimensions and verify predicted alignment. The hatch door mechanism will be
constructed with the same techniques of measuring and marking all parts as described above to
ensure proper fitting. In addition, any amount of Blue Tube removed on the airframe for the
purpose of receiving the payload sample will be mimicked on the opposite side to maintain a
balance of weight and ensure stability. The two ends will be sealed using the same techniques
mentioned below in the Hatch and Payload Canister section.
Finishing the build process will include priming and painting with the possible application
of decals. Pressure relief holes in the airframe sections will determined and drilled to allow
pressure to equalize in flight.
Parachute System Design
A full multi-parachute system has been designated to recover our flight vehicle. The tumble
system was ruled out with reusability and safety in mind. The instability of the flight vehicle is
associated with a high risk of damage or complete destruction and also raises questions over the
safety of any bystanders watching below. While the streamer recovery system is an option that is
more stable and produces more drag upon descent, the team determined that it would not produce
enough drag to safely allow main parachute deployment.
The parachutes that the team will utilize for each falling section of the rocket will be sized
to ensure that no individual piece will impact the ground with a kinetic energy greater than 75 ft-
lbf. Initial parachute sizing will be determined through computer modeling of the rocket which
includes descent rate after parachute deployment and the drift of the rocket. In addition to the
models, the team will compute by hand the desired area of the parachute with commonly used
rocketry equations, taking into account the mass of the section landing and the desired descent
speed. Following testing of each parachute, the team will adjust the sizing if needed to stay within
the requirements of the mission. In particular, the kinetic energy on landing will be the driving
requirement.
The team will purchase a parachute on the market rather than manufacturing one. This will
ensure quality in expectation of performance in addition to allowing for relatively easy
replacement should the system get damaged during testing. To conserve resources, the team is
considering the use of a parachute used previously in a similarly sized rocket. The team will first
determine whether the use of this component allows the rocket to fit within the requirements of
the recovery system. This is a 96 inch Iris Ultra parachute manufactured by Fruity Chutes. This is
a high quality commercial parachute constructed of materials that are simultaneously lightweight
14
and durable. Benefits of using this parachute are the fact that this parachute has been tested and
that members of the team are already familiar with it.
The configuration of the parachute system will be as follows: The drogue parachute will
be stored in the booster airframe above the motor and below the avionics bay. At apogee, altimeters
in the payload bay will send signals igniting black powder ejection charges. These charges will be
located on the bottom bulkhead of the avionics bay. The parachute will be attached to the bottom
bulkhead and the motor casing via Kevlar shock cords. Forged steel eye bolts will be secured to
both attachment points, and steel quick links will be used to attach the shock cord to the eyebolts.
This is a system commonly used by the ISS Student Launch Team, and it has been determined
through numerous launches and flight tests that the steel and Kevlar components have the
necessary strength to withstand the loadings of ejection.
The main parachute will be stored in the lower portion of the upper airframe, and operate
similarly to the drogue parachute. The parachute will be attached to the upper bulkhead of the
avionics bay and the lower bulkhead of the sample canister via the same quick link - eye bolt -
shock cord interface utilized for the drogue parachute. The main parachute will be deployed by
ejection charges at 1,100 feet above ground level during descent. The primary difference between
the main and drogue parachute systems is that the main parachute attachment to the sample canister
will utilize a Defy Gravity Tether. This is a small connective component that contains a small
reloadable pyrotechnic charge allowing for the separation of previously connected components.
The application of this tether system is discussed below.
Above the payload sample canister and below the nose cone is the sample parachute. This
parachute is connected to bulkheads on the nose cone and payload canister via the same hardware
configuration as the previously mentioned parachutes. This parachute will be ejected at 1,000 feet
above ground level during descent. Upon determination that this parachute has successfully
deployed, the Defy Gravity Tether will be released to disconnect the sample canister from the main
portion of the vehicle. These ejection and release systems will be controlled by a Telemetrum and
a Stratologger altimeter in the sample canister.
Shear pins will be used to connect all portions of the vehicle where separation is desired.
The number, size and spacing of shear pins will be determined through testing and calculations
during the charge testing phase of construction and verification. Additionally, a radio frequency
transmitter will be attached to the main parachute shock cord in order to track the location of the
vehicle.
Several images given below illustrate the deployment procedure.
15
16
Motor Brand and Designation
The initial motor selected for this vehicle is the Aerotech K780R-P. Several factors
contributed to the selection of an Aerotech motor. Aerotech is a highly regarded motor
manufacturer whose products are often utilized in high power rocketry. Additionally, Aerotech
motors are readily available and numerous in variety. Due to previous dealings with this
manufacturer during past projects, the ISS Student Launch Team has acquired experience with
Aerotech products and hardware compatible with these motors.
The specific motor model was selected in order to launch the vehicle to the targeted altitude
of 3,000 feet above ground level. After modeling the critical components of the rocket, motor
simulations were undertaken in an iterative manner. Several motors were simulated in an attempt
to select the proper choice for the vehicle’s altitude target. The projected altitude is discussed
further in the following section.
Projected Altitude
While the team targeted the goal of reaching the required 3,000 feet, speculation and
calculations predicted apogee to fall in the region of 2,800 to 3,400 feet. Calculations were
simulated via OpenRocket, which predicted 3,209 feet, and will be later calculated by hand to
verify accuracy. The margin of error is due to several factors such as imprecise drag calculations,
friction of the launch rail, and unpredictable atmospheric conditions on launch day. The mass of
the rocket may also vary which greatly affects the actual altitude compared to the predicted one.
More accurate altitude predictions are highly dependent on the finalization of many system details.
Hatch and Payload Canister
Students researched several design concepts for storing, sealing and ejecting the recovered
sample. It was decided that having the cargo bay be an existing portion of the rocket body was the
optimal solution. Having a separate container hold the payload sample within the body and eject
was also considered, however the team encountered several issues with designing a system to close
and seal the hatch and payload container door simultaneously. Separately ejecting the payload
without damaging any of the electronics controlling the closing system was also a considered
factor.
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The three main design considerations for the hatch system were an articulating arm, a
rotating hinge, and a sliding door mechanism. The sliding door system was selected by the team
as the best option.
The articulating arm mechanism was the first concept explored by the design team. In this
configuration, the hatch door would be manually opened during initial setup. An articulating arm
attached to both the door and the inside of the airframe would close the door after sample loading.
This technique would allow for a simple process of creating a secure seal. However, space
concerns are a major factor in this system design, and it was determined that an articulating arm
system would occupy too much volume within the vehicle.
The next mechanism considered was a rotating hinge mechanism. In this system, the hatch
door would rotate on a barrel-style hinge. After the loading of the sample, the hinge would be
rotated using a DC motor or Servo motor, thus shutting the hatch and sealing the payload. This
system also would allow for a simple build procedure. However, this option is quite restrictive as
there are few locations where the hinge motors may be mounted. This system did not allow for
sufficient adaptability throughout the future of the design process.
The final mechanism discussed by the team, and the design finally selected, was a sliding
door system. In this configuration, the hatch door would be composed of the same Blue Tube as
the airframe in order to maintain consistency with the vehicle body. This door will be mounted
flush with the inner walls of the airframe, with an area slightly larger than the hole being covered,
in order to ensure a proper seal. Two lightweight, plastic gear racks will be mounted onto the inside
of the door, with these gear racks mounted onto a set of motorized gears on the inside of the
payload canister. Motors will be attached to small brackets running across the diameter of the
rocket. Once the sample is loaded and sensed in the payload bay, these motors will drive the gears,
moving the gear racks and hatch door down into a closed position. The motors will continue to
drive for the duration of the flight so the hatch remains locked shut. The design of this sliding
doorway mechanism allows space for the avionics of the rocket to be protected on the sides of the
payload canister throughout the flight. This is the most secure method of sealing the payload, as it
is the easiest to lock shut. This method does contain several complex mechanisms, however
sufficient ground tests will be completed to ensure the canister will seal reliably.
For the electronic systems of the sample canister, the team will utilize two continuous-
spin Servo Motors. Attached between these two motors will be a metal D-shaft acting as a
drivetrain for the gear system. Two small gears will be on the shaft and the teeth will mesh with
the gear racks on the hatch door. To detect when the sample is loaded into the payload bay, a
small pressure sensor will be used. Once triggered, the sensor will send off a small electrical
signal to the motors, causing the motors to spin and thus lowering the door.
To allow the AGSE robot system to clear the doorway, there will be a small delay
between the pressure sensor detection and the motor starting. Rather than using a microcontroller
or Arduino to accomplish this, members of the team are investigating the design and fabrication
of a basic logic chip to use. In order to do this, the University of Illinois’ Micro and
Nanotechnology Laboratory will be used with the aid of a research graduate student. Backup
plans are also in place to use a commercial microcontroller in the event that a custom made chip
does not provide sufficient reliability. A lightweight battery pack will be used to power the entire
system
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5. Autonomous Ground Support Equipment (AGSE) The rocket will initially be placed on the launch rail in the horizontal position. It will be
supported by the launch pad and another support bar attached to the launch rail part way down on
the ground facing side, opposite of the rocket. The master switch will be turned on and the pause
button will be activated immediately. The master switch will be hardwired into the AGSE system
and will act as an emergency kill switch. This switch will cut power to all systems. The AGSE
systems will remain paused until the Launch Control Officer gives the command to proceed. Once
the procedure begins, the robotic arm which is on a 25 inch high platform, will begin to follow
preprogrammed instructions. It will acquire the payload sample that will be placed in a
predetermined spot on the ground using two lasers. The arm will position itself over the sample
and then close around the sample, capturing it firmly. The sample will then be lifted and held over
the open payload hatch of the rocket. From this position, the payload will be placed into the hatch.
The weight of the payload will trigger a pressure sensor and allow the vehicle door to close and
seal. After the payload is secure, the winch system located under the launch pad will start to lift
the vehicle into the launch ready position. The launch rail and vehicle will rotate into the final
position of 5 degrees from vertical, pointed away from spectators. A pin will then lock the rail into
place and the power to the winch will be turned off. The ignition system will then raise the igniter
through the small hole in the launch pad blast deflector and into the motor of the vehicle. After the
igniter is in place the pause switch will then be reactivated and will remain as such until the vehicle
is deemed ready to launch by a final command from the Launch Control Officer.
The construction of the AGSE section will be further split into two groups, one to work on
the robotic arm and end effector, and another to work on the erection of the launch platform,
ignition system, and the support structure of the whole AGSE system. These two subgroups will
be constructing and assembling their projects simultaneously after the final designs have been
finalized and reviewed. The materials and tools that will be used have been researched to minimize
the chance of a fault as well as ensure safety throughout the construction and use of the AGSE.
Several different tools will be used with numerous materials to manufacture the AGSE
components. The robotic arm will mainly consist of ABS and PLA plastic, with aluminum or an
equivalent metal used for the structurally dependent components. The launch platform, ignition
system, and and steel because of the environment these components will be exposed to structure
will primarily be consisted of aluminum, along with the stresses involved. 3D printers located on
campus will be used for a large majority of the plastic components due to their ability to produce
custom parts in a rapid manner. Available resources to manufacture the metal components include
a variety of basic tools such as saws and drills. Heavier machining equipment available on campus
will be used as necessary. Other aids such as tape measures, T-squares, and sanders will be
available when needed as well. When using any of the power tools, safety glasses and ear
protection will be strictly enforced to ensure a safe environment for the team.
Figures 5-1 and 5-2 given below provide conceptual drawings of the system in both the
initial loading and final launch configurations.
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Figure 5-1: The AGSE system in its initial configuration.
Figure 5-2: The AGSE system in the final, raised configuration.
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Robotic Arm
To retrieve the payload, an autonomously operating robotic arm will be used. The arm will
be placed on a frame that is 12” by 12” and 25” tall. The arm will have three degrees of motion
with three segments and a gripper. There will be 180 degrees of motion allowed in the joint
connecting the box to the first segment, 180 degrees of motion in between the first and second
joint, and 180 degrees of motion in between the second and third joint. There will be no movement
between the third segment and the gripper. There will be a servo mounted on the frame that will
connect to the first joint of the arm via a belt to allow the first joint to move. There will be a second
servo in the first segment with a belt to move the second joint and a servo at the third joint to rotate
the third segment. The payload sample will be placed on the ground next to the frame and the
rocket will be on the other side of the frame. The robotic arm will reach across the frame and
down to retrieve the payload. The third joint will then rotate 90 degrees, the second joint will be
rotated just under 180 degrees, and the bottom joint will rotate just over 90 degrees to position the
sample over the hatch. The dimensions of the arm are 9” for the first segment, 18” for the second
segment, and 7” for the third segment including the gripper. The arm will be 3D printed out of
ABS or PLA to minimize the weight of the AGSE system. A model of the system is given below
in Figure 5-3.
Figure 5-3: The robotic arm picking up the sample from the ground.
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Arm Motors
In order for the arm to function properly, all three degrees of freedom need to have at least
180 degrees of rotation. Servos have been chosen to drive these joints because they will have a
minimum of 180 degrees of rotation. The base servo and the servo powering the second joint will
be comprised of the same high torque servo: a JR DS8411 Digital Ultra Torque Servo. Gear and
roller chain systems will be used to scale the torque of the servos as necessary. The final joint and
the gripper require significantly less torque than the first two joints. They will use a Generic High
Torque Full Rotation Servo by Sparkfun. All of the servos will be controlled using a servo control
board designed and produced by Adafruit, Inc. This servo control board will allow for simple angle
inputs to be sent to the servos. Consequently, the servos can be set to the exact positions needed
for picking up and depositing the sample with a single command to each servo. This control board
will also transmit the necessary power required by the servos to operate. Figure 5-4 given below
shows the arm system in the sample insertion position, which is the orientation used to place the
sample within the vehicle.
Figure 5-4: The robotic arm in position over the theoretical location of the rocket.
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Gripper
The end effector that will be used for the robotic arm is a two finger gripper. Other grippers
contemplated for the task were a “three finger gripper” and a “vacuum gripper”. The three finger
gripper was ruled out because of its weight and the added load it would put onto the rotating joints.
The vacuum gripper was rejected because of its inaccuracy and complexity. The two finger
gripper was concluded to be the best for the task because of its simplicity. Considering the size
and shape of the payload and the precision requirements for the task, the two finger gripper would
be the most efficient. The minimal weight of the gripper would add very small strain to the arms
and will help the arm move quickly with less wasted power. This end effector will have curved
fingers and will be programmed to complete the payload pickup and placement accurately. The
opening ends of the two fingers on the gripper will be semi circles with equal radii which would
allow for a tighter hold on the circular surface of the payload. The insides of those ends may
include rubber pads to make the grip better if it is determined to be necessary. This feature will be
tested after construction begins to determine the optimal configuration that gives a grip of the
payload without any slipping.
Ensuring Reusability of Robotic Arm
One of the main criteria for this project is to ensure the reusability of the entire system. The
launch of the K-class motor will create high temperatures and release harmful gas. The emissions
from the rocket engine will hit the launch pad and radiate out in all directions. This will be harmful
for the AGSE system including the robotic arm.
The robotic arm will be placed approximately seven feet away from the launch pad so that
the arm can place the payload into the compartment directly under the nose cone. To optimize the
length and degrees of freedom, the robotic arm will be placed on a platform 12” x 12” x 25” tall.
Since the robotic arm is approximately seven feet away from the launch pad, the emissions from
the rocket engine should not be that dangerous. However, for the sake of safety with the valuable
robotic arm, a heat/dust shield plate will be attached onto the side of the robot arm’s stand facing
the launch pad. An aluminum plate will be used as it will provide sufficient protection from debris
and because it is cost-effective.
Other options included having the arm roll away from the launch on wheels, lowering the
arm lower than the launch pad, covering the arm with protective material, or attaching the shield
plate on a rotating plate with the arm and having the plate rotate so that the shield will be in between
the rocket and the arm. Having the heat shield plate attached onto the box platform was the simplest
and most cost-effective way to protect the arm.
Lifting System
To raise the rocket and launch rail to vertical, two major lifting systems were explored:
lifting the rail and rocket directly at the launch pad and lifting the rail and rocket from a distance
by utilizing a pulley system. Although the latter option involves much smaller torques, the former
option was chosen because of its simplicity and robustness. A standard DC motor will be placed
beneath the blast shield on the launch stand. A gearbox connected to the motor will be used to
manage the torques involved with the system. A standard ANSI type 25 or 35 roller chain
connected to the gearbox will run to another gear situated at the base of the launch rail. The motor,
once activated, will turn the gears to the lift the rocket, applying about 250 ft-lbs of torque on the
base of the launch rail. This has been calculated to be more than sufficient to raise the rail given
the planned rocket mass and mass distribution.
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A hard stop barrier will be situated in the path of rotation to stop the motion of the rail and
rocket at 5 degrees off-vertical. A pressure sensor on the barrier will be activated at 5 degrees to
cut power to the motor, preventing the rail and rocket from rotating any further and locking it in
place through the use of a lock-pin system.
Figure 5-5: Close up look at the lifting mechanism that will raise the launch rail.
Launch Pad
The launch pad will be based off a regular launch pad used in high powered rocketry. There
will be a blast shield attached to the pad that will be made out of steel due to its high melting point
as well as its availability. The launch pad blast deflector will be made 2 feet in diameter and will
stand 20.5 inches off the ground. It will be supported by three legs made out of steel that are set
up in a tripod fashion. The legs will extend out one foot in each direction from the center of the
base. There will also be a blast shield in place to protect the ignition system and the motor that is
used to lift the vehicle into a launch ready position. There will be a small hole placed in the base
of the launch pad to allow for the ignition system to be raised into the motor of the vehicle from
below the pad. The launch rail for the vehicle will be a standard 1515 launch rail designed to guide
a rocket utilizing 1.5 inch rail buttons. The rail will be made out of aluminum and be 12 feet in
length. The vehicle will then sit a short distance off of this launch pad.
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Ignition System
The autonomous ignition system for the vehicle will sit completely under the launch pad.
The mechanism to raise the igniter is inspired by a ball screw. The blast shield will have a hole for
the igniter to rise through into the motor of the vehicle. The igniter will sit on a small L-shaped
platform, attached to a wooden rod. The rod will ensure that the entire length of the igniter is
inserted into the motor of the vehicle in an upright fashion. The other side of the L platform will
be attached to a ball screw. A DC motor will then be used to rotate the ball screw. The platform
will be attached to a ball nut that is threaded on the ball screw. There will also be two rails on
either side of the flat base of the L platform that will keep it from rotating around the screw. This
will cause the ball nut and platform to move upward along the ball screw. The DC motor will
continue to run until the sensor is tripped which indicate that the igniter is completely in the motor
of the vehicle. The DC motor will be encased to shield it from the exhaust of the vehicle.
Figure 5-6: Close up look at the system that will raise the igniter into place.
Another design option using a lever to raise the igniter to the motor was previously
considered. There would have been a small DC motor to pull a wire down which would cause the
half of the lever with the igniter towards the motor. Since the igniter would not be raised straight,
but instead would have moved in an arc, that idea was decided to be less effective than the ball
screw inspired design. A spring loaded system was also considered but deemed less precise and
would be less reliable in ensuring that the igniter was correctly positioned.
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Computing System
The Raspberry Pi was chosen as the main control computer for the AGSE system. It is a
very inexpensive option at about $35, while still being more than powerful enough for our
applications. The Pi is a single board mini-computer, with a visual interface and its own operating
system. It runs on Linux distributions, with the recommended OS being Raspbian. Several
programming languages are used with these boards, mainly Python or C, with support for BBC
BASIC, Java, Perl, and Ruby. There are three variants for us to choose from. Model A has 256MB
RAM, one USB port, and no Ethernet port. Model B and B+ have 512MB RAM and an Ethernet
port, the difference between B and B+ being that the latter has 4 USB ports over the former’s 2.
All the models have the processing unit, using an ARM1176JZF-S (ARMv6k) 700 MHz.
Raspberry Pi uses an SD card for storage and booting, but Model B+ has been upgraded to use a
MicroSD card. In terms of power requirement, Raspberry Pi uses a base 5v micro USB, with total
power requirements depending on how many USB ports are in use. A 2500 mA power source will
provide sufficient power for the Raspberry Pi. Lastly, it has an HDMI video output for our visual
interface during the construction and testing period. For these reasons, the team has decided to go
with the Raspberry Pi over other options such as an Arduino Mega. Despite the Arduino being marginally less expensive at $30, the Pi offers much more versatility, interactivity, and processing
power.
Software
The AGSE system will only follow a set of preprogrammed movements and will not be
required to perform any kind of complex decision making. This simplifies the system to the most
feasible configuration given the competition constraints. All commands will be sent from the
Raspberry Pi computer to the various components in sequence, usually after confirmation of the
completion of the previous task. A built in pause switch will be included in accordance with
competition requirements. This switch will halt the actions of the system without cutting full power
to the system. A separate mechanical “kill switch” will also be included separate from this
function. The AGSE system will be started with the pause switch activated for safety reasons.
The actual programming of robot movements will require extensive testing but will work
by setting positional commands to the servos in the robot arm. This sequence of commands will
accomplish the final goal of placing the payload safely into the rocket. This will be written in
Python, as several members of the team have experience using this language.
Computer Vision Considerations
The team has considered using computer vision to autonomously locate the sample for
pickup. Computer vision is the concept of receiving and interpreting a visual feed, usually from
one or more cameras, and using algorithms to glean information from it.
There are a few methods for acquiring information from images. One involves calculating
the difference in one pixel from the pixels around it, and if the difference is greater than a given
threshold, the pixel is marked. This method finds edges of the objects in the video feed, but is not
very useful for finding the sample as the function would mark all edges and there is no way to
distinguish the edges of the sample from the edges of anything else in the video feed. The system
would have to use a function to find areas of a certain color, specifically the color of the sample,
and then ascertain how the robotic arm should move in order to get to the marked object. The main
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issue with this method is if the sample is of a color that is relatively common with the background.
In this case it would be difficult to distinguish the sample object from garbage that is marked by
the program. There is also an issue in finding how far the object is from the camera. Both of these
issues can be overcome, but the calculations for these would also be prohibitively CPU intensive.
It took 1.6848 seconds to process the single image pictured below on a home computer, which is
unacceptably slow for our purposes. The computers that would be used in any proposed system
for the AGSE would also likely have even lower performance.
In conclusion, while this method for acquiring the sample is more robust than methods
such as pre-programming the robotic arm to retrieve the sample from a pre-set location, the time
and effort of development required to implement this method prohibits its use, and it requires a
more powerful processing platform than the team will be capable of using on this project.
Figure 5-7: Example image with edges highlighted.
Sensors
To have the robotic arm parts, lifting system, and ignition system working accurately and
precisely, the system must utilize endstops and or other sensors. These devices will communicate
to the systems its position and when to stop.
For the lifting system, the team will be using a motor at the point of rotation to lift up the
rocket from the horizontal state to a vertical state. One important factor of this process is to make
sure the rocket only goes to the vertical state five degrees off of vertical, no more and no less. To
get these exact measurements, a magnetic endstop, specifically a Hall Effect sensor, will be used.
A Hall Effect sensor works as a switch that will tell the computer if the mechanism is at a given
position. With this system, a transmitter can be attached onto the rail and a receiver can be attached
onto the hinge. Once the sensor responds to a certain distance, the motor at the hinge will stop
turning, placing the rocket in its vertical position. Other possibilities are to use stepper motors on
the lifting device so that team members can pre-program the distance or angle travelled. However,
because of the large torque that the motor will have, magnetic Hall Effect sensors are the best fit.
The ignition system will also use a Hall Effect sensor. The igniter will be attached to a
platform which will be elevated up to the bottom of the launch pad by a ball screw so that the
igniter can be pushed into the rocket. It is also important to have a sensor here so that the ball
screw motor will stop when it has served its function. A magnetic Hall Effect sensor will be used
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as the team put a magnetic transmitter on the bottom of the launch pad and a receiver on the
platform to which the igniter is attached. The device will send a halt signal to the motor when the
desired distance between the bottom of the launch pad and elevated platform is achieved.
Again, the robotic arm system will require hall sensors so that the motors will stop before
the mechanical limitations are reached. The arm needs three of these sensors for the three degrees
of freedom that will bend. For all of the degrees of freedom, one part of the arm will contain a
magnet that will transmit a magnetic field to a magnetic receiver that can determine if we are at
the position that the arm section must stop at. By pre-programming the desired values, it allows us
to prevent the arm from exceeding its limitations as well as gives us the opportunity to home the
robot if needed.
Some other sensors that are possibilities include optical sensors and mechanical sensors
but the magnetic Hall Effect sensors seem to be the best option. Compared to the other devices, it
is generally more simple, accurate, and cost-effective, as well as easy to apply. One problem that
the magnetic sensors may have is interacting with other hall sensors. If the magnets interact with
other Hall Effect magnetic receivers that are not intended for the specific device, it may cause
confusion about the angular positioning. Our team can possibly pre-program the individual devices
to only react to the magnetic field intended for the certain device.
Power System
The AGSE system will draw power from an 11.1 V Lithium-ion battery with a maximum
current of 15 A. The nearly 90 Wh battery capacity will be more than sufficient to power all AGSE
systems for the duration of any competition attempt without any recharging. This closed cell
Lithium-ion battery was chosen for the battery as it provides a reusable option that will perform
safely in the environment around the rocket during launch. In order to provide power to the servos
and Raspberry Pi, which all require a 5V power source, a 12V to 5V DC-DC converter will be
included in the power system. The lifting motor requires a 12V power supply so it will not require
any conversion.
The battery and DC-DC conversion board will be located within the base of the robot arm
stand. They will be protected from the rocket exhaust at this location by the same shield that
protects the robot arm, and the entire assembly will be located approximately 7 feet from the
burning motor, leaving it not significantly adversely affected.
6. Project Requirements Vehicle Requirements
Requirement Solution
Vehicle shall deliver the payload to, but not
exceeding, 3,000 feet
The motor selection and ballast masses will be
refined to ensure the vehicle’s projected
altitude is 3,000 feet as designs change
The vehicle shall contain a commercially
available barometric altimeter that reports
vehicle altitude via a series of beeps
Current design includes the use of a
Stratologger altimeter, which fits these
requirements
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The launch vehicle shall be designed to be
recoverable and reusable
Designs focus on reliability and durability to
ensure reuse of the vehicle
The launch vehicle shall have a maximum of
four independent sections
The current design includes four independent
sections. No need for additional sections is
anticipated
The vehicle shall be limited to a single stage The vehicle contains only a single stage
The vehicle shall be capable of being
prepared for flight at the launch site within 2
hours
Vehicle design and construction will include
systems to streamline launch day preparation,
such as the avionics bay payload sled
The vehicle shall be capable of remaining in
launch-ready configuration at the pad for a
minimum of 1 hour
All on board components will have sufficient
battery life to operate for over an hour
The launch vehicle shall be capable of being
launched by a standard 12 V direct current
firing system
The vehicle’s ignition system will use the
motor igniter sold with the motor, specifically
designed for use with the standard system
The vehicle shall use a commercially
available solid motor propulsion system using
APCP certified by the NAR, TRA or CAR
The vehicle will use an Aerotech motor
certified by one of these entities
The total impulse shall not exceed L-Class The vehicle will utilize a K or L class motor
An inert or replicated version of the motor
must be provided to ensure the igniter
installer will work
The team will produce such a system and
bring it to the LRR
Pressure vessels must meet safety criteria The vehicle will not house any pressure
vessels
Subscale model shall be launched and
recovered prior to CDR
The team will construct, launch and recover
such a model
Full Scale Vehicle shall be flown before FRR The team will complete construction and
launch the full scale vehicle prior to FRR
Each team will have a maximum budget of
$10,000 to spend on the AGSE and rocket
The budget will be carefully tracked to remain
below the limit
Vehicle Prohibitions: Forward Canards,
Forward Firing Motors, Titanium Sponge
motors, Hybrid Motors, Cluster Motors
None of these systems will be implemented on
the vehicle.
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Recovery Requirements
Drogue parachute must deploy at apogee with
main parachute much lower
The vehicle will deploy a drogue parachute at
apogee and a main parachute at 1100 feet
above ground level
Ground ejection tests shall be performed for
both drogue and main parachutes
These tests will be completed prior to flight
testing
Each independent section of the vehicle shall
have a maximum kinetic energy of 75 ft-lbf
Parachute systems will be carefully designed
and tested to ensure the vehicle lands slowly
enough to meet requirements
Recovery electrical circuits shall be
independent of payload electrical circuits
Recovery electronics will operate on
independent power sources controlled by
independent switches
Recovery system shall contain redundant
commercial available altimeters
The vehicle will utilize redundant Stratologger
and Telemetrum altimeters for recovery
system usage
A dedicated arming switch shall arm each
altimeter from the exterior of the rocket
External rotary switches will be used to
independently arm each altimeter
Each altimeter shall have a dedicated power
supply
Each altimeter will be powered by an
independent battery power source
Arming switches shall be capable of being
locked on
Rotary switches used for the vehicle are
capable of locking in on position
Removable shear pins shall be used for main
and drogue parachute compartments
Shear pins are included in the vehicle design
An electronic tracking device shall be
installed in the vehicle
A radio frequency transmitter will be used to
track the vehicle
Any rocket section or payload component
which lands untethered to the launch vehicle
shall carry a tracking device
The telemetrum altimeter in the jettisoned
sample canister utilized GPS capabilities
The recovery electronics shall not be
adversely affected by other electronic devices
during flight
Electronics shall be tested to ensure recovery
electronics are not interfered with by other
devices
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Recovery system electronics shall be shielded
from other transmitting devices
Electronics shall be located in isolated
compartments capped with bulkheads.
AGSE Requirements
Launch vehicle must be placed
horizontally on the AGSE
The launch vehicle will be placed onto the rail in
the horizontal position and left to erect
autonomously
A master switch will activate power to all
autonomous procedures and subroutines
The AGSE system will include a master switch
which controls all power distribution
A pause switch will halt all AGSE
subroutines, allowing other teams to set
up
The AGSE system will include a pause switch,
enabling the safe pause and resumption of all
AGSE activitiy
One team member is required to remain
at the launch site with the launch services
official to answer questions
A team member with in depth knowledge of all
rocket and AGSE systems will be chosen to
remain at the pad
The rocket will jettison the payload at
1,000 feet AGL during descent
The rocket will be designed to eject the nose
section including the payload when the main
parachute is deployed at 1,000 feet AGL
All AGSE systems should be fully
autonomous
All AGSE components will operate free from
human intervention after the procedure is started
The AGSE system will be designed to
theoretically be operable in the Martian
environment
The AGSE system will not include
magnetometers, sound based sensors, GPS,
pneumatics or air breathing systems
The launch vehicle must have a space to
contain the payload and seal the payload
containment area
The rocket payload bay has been designed to
accommodate the given payload size as well as
seal the vessel completely after the payload is
placed inside
The payload will not contain any means
to grab it outside of its original design
The payload will remain unmodified by the team
and will be kept in its original state
The payload must be placed outside of
the mold line of the rocket
The team will place the payload near the robot arm
stand, well outside the mold line of the rocket
The payload container must utilize a
parachute for recovery and contain a GPS
or radio locator
The payload section will utilize its own parachute
and a GPS locator built into one of the altimeters
for recovery
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Each team will be given 10 minutes to
complete the autonomous portion of the
competition
The team will ensure the full autonomous portion
will take significantly less than 10 minutes as a
safety measure
A master switch which controls power to
all parts of AGSE must be easily
accessible
The AGSE system will include a master kill
switch which directly can cut power to all systems,
placed in a safe location
A pause switch which terminates AGSE
actions must be included and easily
accessible
A pause switch will be placed on the AGSE
alongside the master kill switch which will
terminate all AGSE procedures
An orange safety light must be included
which indicates power is on, flashing
when active and solid while paused
The team will include and orange safety light on
the main AGSE system to display the current state
of the system
An all systems go light must be included
to verify all systems have passed safety
verifications and the rocket is ready to
launch
The team will include an all systems go light that
verifies that the system has passed all verifications
and is prepped for launch
7. Technical Challenges and Solutions Implementing a theoretical design into a tangible manufactured product always proposes
technical challenges. It is inevitable for unforeseen challenges to appear during the build process
of the team’s flight vehicle and AGSE system. Some challenges however, could be foreseen
allowing the team to implement proper countermeasures should these challenges arise.
Challenge Solution
Quick assembly on launch day Create and follow launch day check lists for all team
members to follow. Make sure all components are easily
assembled beforehand
Imprecise parachute deployment Perform detailed charge testing before and after
construction of the flight vehicle to ensure correct sized
charges for proper deployment
Imprecise altitude prediction Collect data on several test flights to ensure proper
motor selection and ballast characteristics
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Fins could break during flight or
upon ground impact
Ensure fins are properly attached. Simulate stress and
strain on CAD
Parts not fitting as expected during
assembly
Assemble all components via CAD, then ensure scaled
down prototype parts fit properly
Hatch mechanism not functioning
as predicted
Create scaled down version of hatch mechanism before
implementing on flight vehicle to ensure operational
capabilities
Hatch seal failure during flight Simulate vibrational forces on a CAD system to ensure
force handling capabilities
Hatch door closing before payload
sample is inserted into canister
Investigate failsafe options to remotely reset the system
and re-open the door in the event of an AGSE
malfunction
Dropping the sample after the robot
has picked it up
The end effector will be made to tightly grip the sample
and ‘encase’ it so that it can’t fall out of the fingers
Getting the rocket from the
horizontal to vertical position
The mechanism will consist of a high torque motor that
can handle the weights involved
Locking the rocket in the vertical
position
The hinge will have a spring assisted piston that will
drive into a hole to lock the system when it is in the
correct position
Inserting the igniter into the motor
without destroying the mechanism
inserting it
The whole mechanism will be placed in a 2 foot span
below the blast plate to protect it from the blast. The
igniter will then rise through a small hole in the plate
Keeping the igniter on a straight
path into the motor so that it is not
broken.
A lever system would cause the igniter to be inserted at
a slight angle. Using the ball screw method allows the
igniter to be inserted straight into the motor
Robot reaching both the ground and
the rocket.
The robot was designed with calculated arm sections so
that it will be able to reach over to the ground as well as
reach the payload compartment
Electrical motors having not enough
torque
Calculations were made with estimated weights and arm
section lengths so that the approximate torque could be
determined
The blast destroying the AGSE
equipment
Any sensitive equipment will be placed either below the
blast plate or behind a blast shield to protect it
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Positioning the equipment at the
same spot every time
All the individual systems will be rigidly but not
permanently attached so that they will be in the same
position every time
Making sure that the sample will be
located at the same place every time
outside of the mold line
Lasers will be pointed at the ground so that the sample
can be precisely positioned at the spot where the robot
will pick it up
8. Educational Engagement
Goals
Throughout the duration of Student Launch, the ISS Student Launch Team intends to
actively engage educators and students throughout the state of Illinois. The purpose of these
activities will be to not only teach the community about the principles behind rocketry and flight,
but also to inspire support and participation in the future of spaceflight technologies. As the theory
behind rocketry is conceptually too abstract for younger students, engagement activities will
revolve around hands-on demonstrations of the basic principles of rocketry. Due to the nature of
this project, the team will also be able to demonstrate robotic theory to the community, which is
an area of great interest to young students.
These activities will be distributed continuously throughout the project, and as such the
outcome of activities will be evaluated in order to improve future events. Students, educators and
team members will be asked to respond to surveys requesting feedback for the events. The main
focus of this feedback will be determining the interest level of those involved, and the
understanding of principles demonstrated by the team. This will allow the team to adjust
presentations for future activities in order to better educate the community. An initial draft of this
feedback form is given in Appendix A. Through the team website the team will also implement a
contact system wherein participants of outreach events may request further information or
demonstrations from the team.
Outreach Opportunities
The Illinois Space Society and the College of Engineering offer numerous opportunities
for educational engagement activities. Particularly, the Illinois Space Society features an
Educational Outreach team which has established relationships with many local schools. This
offers a convenient starting point for engagement activities. Particularly, the team intends on
contacting schools in Mahomet, Urbana and Champaign Illinois to offer educational services to
students. Additionally the team intends on offering hands on demonstrations to students at the
University High School on campus and the High Schools previously attended by team members.
This allows students to both give back to the local community and the institutions that have
previously educated the team. These activities typically take the form of optional after school
classes for students, or interaction with school science clubs. Additionally, the ISS Student Launch
Team has contact with local Boy Scout groups through previous engagements, and the team plans
on capitalizing on these opportunities for additional engagement.
Another major opportunity for engagement is the College of Engineering’s Open House on
March 13th and 14th. As this is only several days before the educational engagement deadline, the
team will strive to complete the required engagement activities before this time. Nevertheless the
team still intends to participate in the Engineering Open House. This is a large event held every
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year and attended by thousands of students and community members. Although not all of these
attendees may be directly engaged by the ISS Student Launch Team, the Open House still provides
an important opportunity to interact with the community. The team plans on operating continuous
activities in order to facilitate indirect interactions with the community. However the team will
also use this event to provide direct interactions with students and educators. In order to do this,
the team hold scheduled demonstrations at advertised times in order to allow structured hands-on
demonstrations.
9. Project Timeline The following table presents important milestones along with their required or expected
dates of completion.
Milestone Completion Date
Proposal Due October 6th
Selection Notification October 17th
Team Web Presence Established October 31st
Vehicle and AGSE Design Definition Complete October 31st
PDR Report, Slides and Flysheet November 5th
PDR Presentation November 7th-21st
Subscale Test Flight Completed December 20th
CDR Report, Slides and Flysheet January 16th
CDR Presentation January 21st - February 4th
Vehicle Construction Complete February 20th
AGSE Construction Complete February 20th
Recovery System Ejection Testing February 21st
Full Scale Test Flight Complete February 28th
Engineering Open House Educational Outreach March 13th-14th
FRR Report, Slides and Flysheet March 16th
FRR Presentation March 18th-27th
Travel to Huntsville April 7th
Launch Readiness Reviews April 7th
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LRR and Safety Briefing April 8th
Rocket Fair and MSFC Tours April 9th
Launch Day, Banquet April 10th
Backup Launch Day April 12th
Post Launch Assessment Review April 29th
Winning Team Announced May 11th
10. Community Support The team has plans in place to solicit support from the community in the case that external
services are required. A primary source for rocketry specific expertise is the Central Illinois
Aerospace chapter of the NAR. This group provides access to launch fields as well as launch
equipment. Additionally, members of the CIA are highly interested in ISS Student Launch Team
projects due to involvement in past endeavors, and are available to provide guidance and criticism
to the team.
The team also has access to a world class educational system with leading experts in
aerodynamics, structures, composite materials, controls and dynamics. When necessary the team
will endeavor to involve these educators to obtain relevant information regarding technical design
issues.
In terms of monetary sponsorship, the team intends to contact interested technological
companies to support the cost of traveling to the launch. In the past the team has partnered with
technology based websites and aerospace companies to provide funding and support for the
project. Additionally, the team intends to solicit industry support in acquiring certain materials.
Most notably, the ISS Student Launch Team has had previous contact with companies willing to
supply excess carbon fiber and other composite materials for educational purposes. While seeking
community support, the team will focus on discussing the merits of the project, both in terms of
educational and real world research value. The team will explain the history of the ISS Student
Launch Team as well as details of the current endeavor. As a means of encouragement for potential
sponsors, the team plans on placing company logos on team apparel and the vehicle itself, as well
as placing sponsor mentions on the team website.
11. Sustainability Plan The ISS Student Launch Team is committed to ensuring a bright future of rocketry in the
local community. Most notably the team intends to create a learning environment beneficial to the
project in future years. Team members are chosen by interest rather than experience, and as such,
over half of the ISS Student Launch Team members are in the first or second years of their college
education. These members are assigned the same duties and responsibilities as more experienced
members, to ensure that the younger students are able to carry out the project in future years. Team
members from previous years are able to draw on past experience to both avoid previous mistakes
and replicate success of past teams. Passing this knowledge down to younger team members will
streamline the build and design processes for years to come, and this shared knowledge will only
grow with time.
36
The ISS Student Launch Team has the benefit of recruiting members from the entirety of
the Illinois Space Society. This is a campus group composed of about 150 students interested in
space flight and rocketry. Historically the Student Launch Team has been able to recruit members
from the overall ISS club in order to participate in this competition. However new members are
also recruited via personal relationships with current members as well as via University run
Student Organization listing.
In terms of funding sustainability, the team again is fortunate to be able to rely on the
overarching Illinois Space Society. Combined society funds and project grants from the University
allow for the continuation of the ISS Student Launch Team’s participation in this project.
Additionally, the team intends on pursuing lasting relationships with corporate partners that will
continue into future years. Success of the project as well complete and professional presentation
and documentation will highly increase the chances of continuing relationships with industry
sponsors.
The ISS Student Launch Team will also reach out to the community to educate and inspire
future generations with regards to science and rocketry. Most specifically, the team will seek to
interest middle and high school students with regards to engineering and rocketry. As the vast
majority of students at the University of Illinois come from central Illinois or the suburbs of
Chicago, these are important areas of interest to the educational efforts of the team. The team
intends to involve these students in science and engineering, in the hopes that they will then pursue
education and careers in these fields.
12. Budget All anticipated costs for the Illinois Space Society’s Student Launch project are summarized
below in Table 12-1. Costs are broken down by major MAV system, and have been calculated
using our current baseline design for all components.
Table 12-1: Summary of Expenses
Item Cost [USD]
Rocket Structure 298
Motors 453
Recovery and Parachutes 464
Sample Canister System 470
AGSE Robot Arm 814
AGSE Igniter Placement 80
AGSE Lifting System 1350
AGSE Launch Pad 450
Subscale Rocket 120
Educational Outreach 100
Structure Total 4,599
Travel and Accommodations 2,462
Total Cost Incurred by the Illinois Space Society 7,061
All expenses for this project have been accounted for with some margin built in for
unexpected increases in cost or required replacement/backup items. The total cost of $3,998
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excluding travel also satisfies the stated requirement of a total project cost of less than $10,000.
This summation can be found in Table 12-3.
Table 12-2: Summary of Total Project Costs
Build Cost Amount [USD]
Items to be Purchased 4,599
Items Already Owned by ISS 643
Total Project Build Cost 5,242
These costs will be covered from a variety of funding sources available to the Illinois Space
Society. Several organizations such as the Engineering Council and the Design Council provide
funding to on campus groups to facilitate participation in competitions of this caliber. Corporate
sponsorship will be utilized where available to reduce direct costs to the Society, but all costs have
been included in this budget to meet the stated requirement of $10,000 for the total Maxi-MAV
system. A summary of the funding sources the Illinois Space Society will be using to fund this
project are summarized below in Table 12-3.
Table 12-3: Summary of Funding Sources
Funding Source Amount [USD]
Illinois Engineering Council 1,500
Illinois Design Council 2,000
Student Organization Resource Fee 3,500
Corporate Sponsors 1,975
Total Funding 8,975
This funding surplus will allow the Illinois Space Society to manage any small increase in
costs. Any budget overruns or replacement parts that need to be purchased will not remove the
Illinois Space Society’s ability to compete in this event.
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Appendix A: Educational Feedback Form
Illinois Space Society Student Launch
Educational Feedback Form
How interesting was the demonstration? (circle one)
Not Interesting…….A Little Interesting…….Very Interesting…….Super Interesting
How much did you learn from the demonstration? (circle one)
Nothing…….A Little…….A Lot
What did you learn from the presentation?
What was your favorite part about the demonstration?
What was your least favorite part?
Do you have any questions to ask the team?
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Appendix B: ISS Safety Policy
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