UNIVERSITY OF NORTH DAKOTA

FROZEN FURY

NASA STUDENT LAUNCH INITIATIVE

CRITICAL DESIGN REVIEW

February 28, 2014

I). Summary of CDR report

Team Summary - Team Name and Mailing Address

University of North Dakota Frozen FuryWitmer Hall, 101 Cornell Street Stop 7129Grand Forks, North Dakota 58202-7129

- Location Grand Forks, North Dakota 58202

- Name of mentor, NAR/TAR number and certification level Dr. Timothy Young, NAR # 76791, Certification Level 2

- Launch Vehicle Summary Length: 112.7528 in Diameter: 6.00 in Span diameter: 19.00 in Mass: 688.8463 Oz Motor choice: Aerotech L2200G

- Recovery System Dual deployment upon separation of base section and payload section Drogue: 36 in. (3 seconds after apogee) Main: 72 in. (3 seconds after apogee)

- Rail Size The launch rail is constructed of steel tubing, and the rail for use by the rocket

with a bead system is 12 feet to the base platform. The length of the rail can be adjusted by moving a knuckle up and down on the rail so that the platform moves either up or down decreasing or increasing the length of the rail to adjust for conditions or for safety reasons. We plan to use 10 feet of the 12 foot rail, so we will have the knuckle two feet from the base, making the total distance traveled by the rocketed 10 feet total.

Launch Operations Procedures Checklist

Setting up Launch RailLaunch Rail Equipment:

Extension cord (200 ft) 6 foot tube 2 launch rails (2 Allen bolts

already attached) 1 Allen bolt

½ inch bolt (through angle iron and launch rail)

2 hex nuts (both on 2 inch bolt)

Stand: 3 legs 6 wing nuts Support angle iron

Bracket for support angle 2 / 2 inch bolts 2 hex nuts

Rocket stop: Glat back 2 / 2 ½ inch bolts 2 hex nuts

Blast plate Shims Ballast for stability

Launch Rail Assembly1. One of the removable legs is attached to the stand using two (2) wing nuts.2. The 6 foot tube is attached to the bottom launch rail using 2 inch bolts and hex nuts.3. The top launch rail and the bottom launch rail are slid together. The Allen bolt is used on the

top hole, and the 2 inch bolt with one hex nut in the bottom hole.4. The blast plate is placed on top of the base.5. The tube is screwed into the base, making sure that the support rail is aligned with the leg.6. The support beam is attached to the launch rail and secured with a hex nut.7. The remaining two legs are attached to the base with wing nuts.8. The support rail is secured to the leg of the stand with the brace.9. The stand is leveled.

Recovery PreparationEquipment:

Main parachute Large Nomex sheet 3 quick links Main shock cord

Drogue parachute Small deployment bag 3 quick links Drogue shock cord

Altimeter Bay: 2 Altimeters (one for redundancy) 2 9V batteries 4 washers 4 wing nuts Zip ties for battery

4 black powder ejection charges (3 – 3g, 1 – 4g main) Painters tape for friction fitting (as needed) Sheer pins Electrical tape

Folding Parachutes1. When the parachute is folded in a half circle, at least 3 team members begin to lay

out the chute2. One person holds the lines to prevent them from becoming tangled3. The other two individuals hold the parachute along the folded edges4. The chute is folded in half three (3) times5. Starting from the top, it is folded into thirds by folding the tip of the chute to the

middle, then folding down again6. The chute is placed into the bag.7. The chute’s rip cords are connected to the large quick link in the middle loop of the main

shock cord8. On the top of the chute, but still in the bag, the parachute rip cords and some of the

shock cord are carefully placed, to ensure they do not become tangled

Altimeter Bay1. The altimeters are calibrated, making sure that all parachute deployment numbers are

correct.2. Two (2) new 9-V batteries are placed on the altimeter board and secured.3. Charges are placed in the charge cups, threading the electric matches through the

holes. The charge for the main is placed on the bottom altimeter bay cup. The charge for the drogue is placed at the top of the altimeter bay cup.

4. The wires are connected to the altimeters, making sure the positive and negative wires are in the appropriate places.

5. The batteries are attached.6. The altimeter board is in place with wing nuts.7. The area is cleared of unnecessary personnel and the continuity is checked by using

the switch on the exterior of the rocket. If there is good continuity, two (2) beeps will be heard after the initial set of beeps. If the continuity is not good there will be

double beeps after the initial set of beeps.8. The switches are turned off until the rocket is placed on the rail.

Parachute Assembly in the Rocket1. The appropriate side of the main shock is attached to the bottom of the altimeter bay using a

quick link 2. The Nomex sheet is attached to the bottom of the altimeter bay also.3. The other end of the main shock cord is attached to the fin can. 4. The appropriate side of the drogue shock cord is attached to the top of the altimeter

bay using a quick link.

5. The drogue bag is also attached to the top of the altimeter bay.6. The appropriate side of the drogue shock cord is attached to the payload bay.7. The rocket is pushed together, slowly.

Motor PreparationEquipment:

Motor casing Motor grain

Motor retainer

Motor Assembly1. The motor is placed into the metal casing, making sure the motor is placed fully in its casing

and the motor closure is tightened2. The casing is inserted into the motor mount tube3. The rocket is secured with the motor retainer 4. The red safety cap is left on until the rocket is placed on the launch pad

After rocket is assembled1. The rocket is placed on the rail.2. The rocket stop is put on the rail at the appropriate height.3. Check to see if the altimeter is turned on and has the right number of beeps to

correspond to the altimeter working properly, as stated above.

When complete the stand will look similar to the picture below.

Igniter InstallationEquipment:

Igniter Tape

Igniter Installation1. Ask for confirmation from the range safety officer to begin.2. The red safety cap is removed and wedge cut out of it.3. The cap on the nozzle is replaced, threading the igniter through the wedge.4. The igniter is slid up the motor.5. Tape the igniter to bottom of rocket. Ensure the igniter is secure.6. The launch clips are attached to the ends of the igniter, looping the excess copper wire

around the clip to make sure they don’t fall off.7. The switch system is hooked up to the 12V battery.8. The continuity of the igniter is tested at the launch rail.9. The range safety officer is notified that preparation of the igniter is complete.

Launch ProceduresInstructions1. To check continuity, the main power button is turned on, the switch corresponding to

where the extension cord is hooked up is flipped, the key is turned to arm, the test button is pressed, and we listen for the tone indicating continuity.

2. Everyone checks for aircraft in the vicinity. After the “all clear,” begin countdown from 10 seconds.

3. At zero, the launch button is held down for 5 seconds.

TroubleshootingInstructions1. Unplug the battery/power source2. Only Team Lead, Safety Officer or Advisor may approach the launch rail.3. As walking towards the rail, check the extension cord.4. At the rail, check the wiring of the igniter on the gator clips. If needed, rewrap the

wires around the positive and negative clips. 5. If needed, add tape to clips to ensure the wires are secure.6. Check the igniter, make sure it is inserted completely in the motor, and there is tape to

secure it in place. 7. Attempt to launch rocket. If it still fails, replace igniter with a new one.

Post flight InspectionInstructions1. To assist in finding the rocket after it lands, use Rocket Hunter.2. Check to make sure no fires were started by the rocket and launch site, or at the landing site.3. Examine the area for harmful debris.4. Ensure that the ejection charges are spent before handling.5. Check to make sure the motor casing is still in the rocket.

Payload Summary - Payload Title

Hazard Detection Payload (3.1) Payload Faring/Deployment System (3.2.2.1) Liquid Sloshing Analysis Payload (3.2.1.2)

- Summarize experiment The Hazard Detection Payload will consist of a camera and the necessary

electronics to scan the ground during decent and relay any landing hazards in real time to a ground station. This payload will require static ground tests to determine the abilities the camera and software in identifying potential landing hazards.

The Hazard Detection Payload will be deployed by a faring system; the payload fairing system will consist of an altered payload bay that will be split into four sections. The faring system will deploy the Hazard Detection Payload shortly after apogee, when the payload bay parachute deploys. The deployment of the camera will be done through the separation of the four subsections of the cylinder encasing the payload. This mechanical system will require static ground tests to determine the force required to separate the payload cylinder. Problems with this system could arise if the drogue chute does not exert enough force on the system, or another potential problem could occur if the cylinder subsections do not separate enough to allow the hinges, that attach them to the body tube, to lock.

The Liquid Sloshing Analysis payload will be designed to collect and analyze fluid flow patterns in microgravity. The purpose of this project is to research liquid sloshing in microgravity to support liquid propulsion system upgrades and development. Collection of this data will be done through the observation of two tanks mounted in base of our rocket. The liquid in one cylindrical tank will be allowed to move freely and the other cylindrical tank will be controlled by a baffle system. The data for this payload will be collected by four cameras and stored via the onboard electronics. The four (4) cameras will be positioned inside the rocket airframe, and each oriented to focus on one of the two tanks. This project requires that we have at several dynamic ground tests to measure the liquid sloshing patterns, to determine liquid patterns in standard gravity. The data we collect in-flight can then be compared to this base data. One of the major challenges for this payload will be developing the appropriate software to analyze the video taken by the cameras in this payload bay.

II). Changes made since PDR Changes made to vehicle criteria

Component PDR CDR

a). Rocket Length 114 in 112.75 inb). Unloaded Mass 900.9002 Oz 688.8462 Oz

c). CP 77.6030 in 82.7776 ind). CG 59.9158 in 68.1631 ine). Safety Margin 2.4 2.44

The reason for the changes made to the rocket such as the length and mass are due to drastic changes to the design of our rocket, many fallacies were brought to our attention during the PDR review and presentation. Due to these fallacies, an almost complete overhaul of our rocket and its systems became necessary. As for the change in mass, this was due to the decrease in the mass of the payloads. The change in mass and its distribution caused changes in the CG and CP of the rocket. This led to changes in fin design and size, as well as changes to individual components of the rocket.

Changes made to payload criteria

Our payloads will be very similar to our designs in the PDR however we had to make many changes to size, position, and functions of the payloads. For the faring system we changed the original system, which was designed to split the nose cone in half. However, we have revised this system, in order to prevent the potential problems that could occur with the splitting of the nose cone, we will instead be separating the payload encasing cylinder. We have also altered the liquid payload, instead of using two half cylinders as tanks we will have two smaller full cylinders as tanks. We have also decided to place the tanks in the base section of the rocket instead of the payload bay.

Changes made to project plan

III). Vehicle Criteria Design and Verification of Launch Vehicle Flight Reliability and Confidence

- Mission Statement The primary objective of the 2013-2014 University of North Dakota Frozen Fury

rocket team is to design and construct a safe, stable rocket that will conduct research in liquid sloshing to assist in the understanding of liquid sloshing in microgravity. As well as develop a useful hazard detection system.

- Rocket Launch Success Criteria A successful rocket launch will consist of reaching an altitude at apogee within ±

3.00% of 7030.94 feet above ground level. This altitude is based on the altitude predicted by simulations.

- Payload Success Criteria A successful payload system will consist of the Hazard Detection Payload,

Payload Faring/Deployment System, and Liquid Sloshing Analysis Payload. The systems should operate successfully during and after the launch and be capable of determining the location of hazardous objects within the field of view of the rocket. The Liquid Sloshing Analysis Payload should provide detailed information

of the flow patterns of liquids in microgravity. The Faring system should successfully deploy the hazard detection camera.

System Level Design Review - Airframe Material

The 2013-2014 Rocket design is projected to have an airframe composed of a carbon fiber composite. Simulations have been conducted using RockSim for a 6 inch diameter and 112.75 inch length rocket. The simulations projected a peak altitude of 7030.94 ft. with both a carbon fiber and fiber-glass rocket (approximate dry weight 688.8463 oz.) using an Aerotech L2200G size motor.

- Fin Material Fins will be constructed out of the same material as the airframe (i.e. Carbon

Fiber). The innate strength of the material will ensure that the fins will not break upon landing, which is something that the Frozen Fury Team has experienced in the past.

- Bulk-Head/Centering-Ring Material Internal bulkheads/centering-rings will be constructed out of 0.5 in. cabinet

quality birch plywood purchased from a Grand Forks, ND local hardware retailer. The rationale behind choosing birch plywood is that it has a very clean face and very few knots. The use of higher grade wood ensures the bulkheads and fins will have uniform wood grain and will be structurally strong in order withstand the stress of flight. Bulkheads are cut from the plywood using a table saw, and then sanded to fit securely in the 6.0 in. diameter rocket body tube. The bulkheads are affixed inside the airframe with West Systems epoxy on both the superior and inferior edges for added strength. The plywood bulkheads make certain the rocket structure is rigid throughout its entire length.

- Motor type The current simulated motor type used for the 2013-2014 Frozen Fury Rocket is

an Aerotech L2200G. This motor has a moderate impulse and projects the design’s max altitude at approximately 7030.94 ft. It was also verified that the AeroTech L2200G motor was not of the Skid mark/metal filing variety so there would be no additional fire hazard with its use.

- Workmanship The quality of work is very important to maintain a successful program. The

team has plans to stay neat in the construction process and all tools and components will put away at the end of the day. This is propelling the team toward success by keeping our workspace clean day-to-day, which helps expedite work.

Subsystems - The subsystems that are required to accomplish our mission include: 36 in. drogue

parachute which will deploy 3 seconds after apogee, and the 72 in. main parachute which will deploy at 3 seconds as well. Both of these will be attached by nylon shock cords to the inside fuselage and will deploy based on altimeter readings. We have

chosen to separate the two sections to allow for the most stable decent possible for our Hazard Detection Camera payload.

Final Drawing

Verification Plan and Status - Purpose

The primary purpose of the 2013-2014 University of North Dakota Frozen Fury rocket team is to design and construct a safe, stable rocket that will conduct research in liquid sloshing to assist in the understanding of liquid sloshing in microgravity. As well as develop a useful hazard detection system.

- Manufacturing, Verification, Integration, and Operations Plan For the process of which we will be completing our rocket, we will be using

equipment provided by the Physics and Engineering departments at the University of North Dakota to manufacture and assemble our rocket. To verify this process we will do functional testing’s, such as doing multiple practice charges on the ground, payload data taken from rooftops and verified against actual results, and practice flights throughout the assembly process to see what areas we can improve in or modify. The integration of our payload and subsystems (i.e. parachutes) will be done concurrently with the assembly process to assure that proper size is accommodated for each component. Finally operations will be done once all tests assure us that we are ready to launch our finished product, and test its functionality.

- Confidence and Design Maturity The basis of our design is off of our 2012-2013 rocket that was done with the

SMD payload. This gave us a good starting point in determining how large a diameter of rocket we wanted, as well as the overall length of the rocket. The

reason why we’ve gone with our length is because we are unsure of how our payload will be incorporated, as in whether it will be more compact or lengthened out along our shaft which it will rotate about. We know from the 2012-2013 rocket that their design length was slightly smaller than needed, so from that, we determined that our finished rocket will be larger in length then that design

Mass Statement The mass of the vehicle was estimated by Rocksim to be 688.8463 Oz. with a

margin of 2.44; Rocksim has projected that our rocket will hit an altitude of 7030.94 ft with our specified motor. A list of the weights for each component and subsystems are as follows:

Nose cone: 11.6069 Oz Body tube: 14.2262 Oz Transition: 26.8820 Oz Body tube: 32.2460 Oz Liquid Mass: 28.3744 Oz Liquid Mass: 28.3744 Oz Drogue Parachute: 2.2767 Oz Fin set: 78.90 Oz Body tube:10.5152 Oz

Centering ring: 5.8017 Oz Centering ring: 5.8017 Oz Main Parachute: 5.5766 Oz Bulkhead: 4.8070 Oz Bulkhead: 4.8070 Oz Bulkhead: 4.8070 Oz Bulkhead: 4.8070 Oz Bulkhead: 4.8070 Oz

Subscale Flight Results Due to undesirable weather conditions; blizzards, high winds, and cold

temperatures we have not had a day that has been suitable for the launch of our scale model, since its completion. The model is complete and ready for launch, the first scale flight will happen the week of 03/02/2014. Simulations of the scale model predict a maximum altitude of 5000 ft. The Scale model will use an AeroTech H110 engine.

Recovery Subsystem Description of Hardware

- Parachute Both of our parachutes will be made out of a nylon material. Main – 72 in. Deployment at 700 ft. Style: Round. Drogue – 36 in. Deployment 2 seconds after apogee. Style: Cross.

- Harnesses

The shock cords are made of rip-stop nylon. The shock cord’s length will be large enough to ensure that none of the rocket’s structural components will collide during decent.

- Bulkheads Internal bulkheads/centering-rings will be constructed out of 0.5 in. cabinet

quality birch plywood. Birch plywood is has a very clean face and very few knots. The use of higher grade wood ensures the bulkheads uniform wood grain and will be structurally strong in order withstand the stress of flight. Bulkheads are cut from the plywood using a table saw, and then sanded to fit securely in the 5.75 in. inner diameter rocket body tube. The bulkheads are affixed inside the airframe with West Systems epoxy on both the superior and inferior edges for added strength. The plywood bulkheads make certain the rocket structure is rigid throughout its entire length.

- Attachment Hardware Shock cords and parachutes are all attached with quick links for ease of

assembly and removal. The quick links will also be attached to eye bolts which are epoxied into place on the altimeter bay’s bulk head. Sheer pins will be used in conjunction with small amount of friction fitted tape at the separation points.

Electrical Components - Altimeters

We will be using two Perfect Flight StratoLogger Altimeters. They will each be connected to a 9 volt battery, and be located in the Altimeter bay. They are set to go off 2 seconds after apogee to release the drogue, and at 700 ft. to release the main parachute.

Kinetic Energy

- Using the equation for kinetic energyK=12

mv2, where m is the mass and v is the

velocity of the rocket we can calculate the kinetic energy of the rocket. For the kinetic energy when the rocket lands m=600.097 Oz and v=44.903 ft/sec.

- Calculations:

600.097 Oz( 0.0625 lb1 Oz )=37.506 lb , K=1

2(37.506 ) ¿

Drawings

- Drogue Parachute

- Main Parachute

Test Results At this current point in time we do not have test results for the full scale rocket, but here is a list the tests we plan on conducting.

- Black Powder Charges Testing We plan to test the charges that will separate the specific chambers of the rocket.

Prior to these testing, the entire rocket will need to be built to ensure the weight of the rocket is the same as in flight. This includes that the parachutes, blast protection bag (of the parachute), and the shock cords will all be packed inside their respective chambers. This will most likely be one of the final tests before launch.

- Main Parachute Once parachute is constructed, we will test the strength of the material to ensure

no rips will occur and everything was sewn correctly. We will also test the parachute

by dropping it a various heights to ensure it will work properly and the vehicle will have a safe landing.

- Drogue Parachute Once parachute is constructed, we will test the strength of the material to ensure

no rips will occur and everything was sewn correctly. We will also test the parachute by dropping it a various heights to ensure it will work properly and the vehicle will have a safe landing.

- Drogue Parachute Force for Fairing Deployment System Once we can verify the Drogue Parachute will function properly, we will need to test

the integration of the Fairing Deployment System Payload. Since the Fairing Deployment system will rely on a specific amount of force to push the nose cone forward from the drogue parachute, we will need to figure out this exact amount of force and ensure that the drogue parachute can perform the task, while not interrupting the deployment.

Mission Performance Predictions - Our performance predictions come from the software RocSim 9 the predictions are as

follows Altitude: 7030.94 ft Maximum Velocity: 794.661 ft/sec Maximum Acceleration: 510.392 ft/sec/sec Weight: 688.84 Oz Maximum Thrust: 3100.821 N CP: 88.7776 in CG: 68.1631 in Static Stability Margin: 2.44

Flight Profile Graphical representations Altitude:

0 20 40 60 80 100 120 140 1600

1000

2000

3000

4000

5000

6000

7000

8000

Altitude Feet

Altitude Feet

Velocity:

0 20 40 60 80 100 120 140 1600

100

200

300

400

500

600

700

800

900

Velocity Feet / Sec

Velocity Feet / Sec

Acceleration:

0 20 40 60 80 100 120 140 1600

100

200

300

400

500

600

Acceleration Total Feet/sec/sec

Acceleration Total Feet/sec/sec

Weight:

0 20 40 60 80 100 120 140 160540

560

580

600

620

640

660

680

700

Mass Ounces

Mass Ounces

Thrust:

0 0.5 1 1.5 2 2.50

500

1000

1500

2000

2500

3000

3500

Thrust N

Thrust N

Static Stability Margin:

0 20 40 60 80 100 120 140 1600

0.5

1

1.5

2

2.5

3

3.5

4

4.5

Static stability margin Calibers

Static stability margin Cal-ibers

Drag Force:

0 20 40 60 80 100 120 140 1600

50

100

150

200

250

300

350

400

450

Drag force N

Drag force N

Payload Integration - For the payloads that require electronics those electronics will be contained in areas

separated from the actual payload itself. As for the liquid payload the entire payload will be contained in one removable cylinder that will allow for easy removal this is shown below.

Launch Concerns and operation procedures

Analysis of Current Item of FunctionAnalysis of Item of

Function After Actions Taken

Item or Function

Potential Failure Mode

Potential Effect(s) of

FailureSeverity Potential

Cause

Expected Occurrenc

e

Preventative

Recommended Action

Completion

Battery Wiring

Altimeters fail, and parachutes never deploy

Unsafe return results in damages

10

Wiring from the batteries to the altimeters wiggle loose over the flight

4

Solder end of wires, use bindings to keep the wires from wiggling during the flight

Shake test, and addition of hot glue over joints

 

Motor retainer

Motor retainer comes loses during flight

Rocket could become unstable

8

Unpredicted flight path, could crash land

2

Ensure plenty of epoxy is used on holes, ensure bolts are fastened tightly

Light test to inspect for any holes or gaps between the surfaces.

 

Structural Failure

any of the fins or structure of the rocket fail.

Energetic deconstruction.

10Cracks or unsecure surfaces

3Inspection of gluing areas.

Allow proper time for drying

 

Exterior paint failure

paint could strip off due to high velocities.

Striping of paint from the rocket.

1

High velocities over the rocket skin, and an uneven coat of paint

1

Even coats of paint, and consider limiting velocity of rocket

Paint Rocket evenly, uses of proper paint on specific materials.

 

Fins

Fins come lose or break off during flight

Rocket will go off course of projected flight pattern

4Fins not secure to body.

2

Use plenty of epoxy when attaching the fins.

Inspect to make sure there are no holes or gaps between the body and the fins

 

Nose cone

Nose cone separates in flight

Entire chamber will deconstruct

8Surfaces not tightly sealed

4

Inspection and test all surfaces remain tight during flight

Testing in wind tunnels

Updated list of Hazards Listing of Personal Hazards

The following is a list of the most common personal hazards when constructing the rocket. During this phase, communication to other team members of the potential risks will be essential to ensure their safety.

Personal Hazards Mitigations StatusSkin contact when gluing parts together using epoxy and resin

Wear protective glovesHave necessary safety equipment

Debris getting into eyesWear protective goggles when cutting or sanding parts

Have necessary safety equipment

Breathing powder when mixing hardener with epoxy and resin

Wearing mask to cover mouth and nose when mixing ingredients

Have necessary safety equipment

Skin irritation cause by cutting material (example: carbon fiber)

Wear long sleeves, gloves and eye protection

Have necessary safety equipment

Injury from small explosive (example: ejection charges)

Only have experienced team member handle explosives. Inform any other team members of risks, and to keep enough distance

Complete

Injury from using powered equipment

Only have experienced member use machines Complete

The MSDS information for the following products we will be using. The MSDS will not be attached to the CDR for paper conservation, but the information can be found in the links below.

West Systems Epoxy Product Name: WEST SYSTEM® 105! Epoxy Resin. Product Code: 105 Chemical Family: Epoxy Resin. Chemical Name: Bisphenol A based epoxy resin. http://www.westsystem.com/ss/assets/MSDS/MSDS105-resin.pdf

West Systems Hardener Product Name: WEST SYSTEM® 205! Fast Hardener. Product Code: 205 Chemical Family: Amine. Chemical Name: Modified aliphatic polyamine. http://www.westsystem.com/ss/assets/MSDS/MSDS205.pdf

West Systems High Density Filler Product Name: WEST SYSTEM! 404" High-Density Filler. Product Code: 404 Chemical Name: Calcium Metasilicate, silicon dioxide blend. http://www.westsystem.com/ss/assets/MSDS/MSDS405.pdf

West Systems Fiber Glass Product Name: WEST SYSTEM® 727 Episize! Biaxial 4” Glass Tape, WEST

SYSTEM 737Episize Biaxial Fabric, and WEST SYSTEM 738 Episize Biaxial Fabric with Mat.

Product Code: 727, 737, or 738. Chemical Family: No information. Chemical Name: Fibrous Glass. http://www.westsystem.com/ss/assets/MSDS/MSDS745.pdf

Ammonium Perchlorate – Obtained from Sciencelab.com Product Name: Ammonium perchlorate Catalog Codes: SLA2725 CAS#: 7790-98-9 RTECS: SC7520000 TSCA: TSCA 8(b) inventory: Ammonium perchlorate CI#: Not available. Synonym: Chemical Formula: NH4ClO4 http://www.sciencelab.com/msds.php?msdsId=9922929

Carbon Fiber MSDS Number: 439-3227-00SU-C000-12 This product is not classified as a Hazardous Chemical as defined by the OSHA

Hazard Communication Standard. Statement of Hazard: May cause temporary mechanical irritation of the eyes, skin

or upper respiratory tract. Carbon fibers or dust are electrically conductive and may create electrical short-

circuits which could result in damage to and malfunction of electrical equipment and/or personal injury.

http://www.tapplastics.com/uploads/pdf/MSDS%20Carbon%20Fiber %20Sheet.pdf

When using any of these products, every team member will understand the dangers and make sure they are following proper safety measure.

The following link is from the OSHA site precautionary measures for the use of power tools.

http://www.osha.gov/doc/outreachtraining/htmlfiles/tools.html

Environmental Concerns

The following is a table of environmental concerns and how we plan to mitigate them.

Environmental concerns Mitigations Status

Dissolution of rocket fuel into open water causes contamination of water source.

Careful planning of launch locations and recovery area.

Launch area are open fields, away from water sources.

Fume inhalation of hazardous fumes due to proximity to rocket.

Observe proper distances for spectators and keep minimum crew around rocket.

Complete

Ignition produces sparks capable of setting fire to dry grass and other flammable material.

Keep flammable material away from rocket and ensure the launch rail is metal.

Complete

Upon recovery, ground destruction may be discovered, such as loose rocket propellant.

Prior to launch, all rocket components will be checked so that all materials are secured and contained to minimize potential ground damage.

Pending

Potential hazard to wildlife if small rocket pieces are ingested.

Team will function as cleanup crew at impact and launch site to ensure all rocket parts are recovered.

Complete if necessary. Will bring bag to gather all pieces.

Rocket ash can have hazardous effects on the ground below the launch pad.

An adequate blast shield will be used and when clean up occurs proper disposal of the cleaning materials will take place.

Blast shield will be brought with to launch site.

Safety and Environment (Vehicle) - The Safety Officer is Nicole F.- Analysis of Failure Modes

- The following is a list of potential failure modes for the rocket. This includes the expected severity and plans for mitigating the risk.

Severity Ranking of Identified Hazards: 10 to 8: Catastrophic: A condition that may cause injury, total loss of rocket, or severe damage to systems

and equipment during launch or testing procedures. Constitutes a loss of greater than 50% of total cost. 7 to 5: Critical: A condition that may cause injury, damage to rocket, or damage to systems and equipment

during launch or testing procedures. Constitutes a loss between 15-50% of total cost. 4 to 2: Moderate: A condition that may cause minor injury, minor damage to rocket, or minor damage to

systems and equipment during launch or testing procedures. Constitutes a loss between 2-15% of total cost. 1: Negligible: A condition with no injury to persons, superficial damage to rocket, or superficial damage to

systems and equipment during launch or testing procedures. Constitutes a loss between 0-2% of total cost.

IV). Payload Criteria Testing and Design of Payload Experiment

- Hazard Detection Camera: The Hazard Detection Payload will consist of a camera and the necessary

electronics to scan the ground during decent and relay any landing hazards in real time to a ground station. This payload will require static ground tests to determine the abilities the camera and software in identifying potential landing hazards.

- Faring system: The faring system will be designed to deploy the hazard detection camera; this

system will be all mechanical and consist of few moving parts. The system will draw the needed force from the deployment of the payload sections parachute. It will do this through a simple system consisting of a tether running from the chute to two pulleys the tether is then attached to a rod. Upon the deployment of the chute the force from the air resistance will cause the rod to push the nosecone up 1.5 inches, this will then allow the segmented cylinder housing the hazard detection camera to separate. The four segments will be attached to the body tube by locking hinges so; when the segments separate they will be folded back towards the body tube and away from the nose cone, revealing the hazard detection camera.

- Liquid Sloshing Payload: The slosh liquid payload comprises of two tanks each partly filled with a non-

hazardous liquid. These payloads are intended to provide information that can give insight into the effect of sloshing of rocket fuel as it is depleted during flight. One of the tanks contains slosh control devices and while the other does

not. The flow patterns developed during the rocket flight will be recorded on camera to be used for further investigations.

Perforated disc baffles are intuitively installed one on each of two locations (1/3 and 2/3) along the height of the sloshing fluid tank. The perforated disc pattern has been selected because it is the easy to fabricate and could substitute for in-flight adjustable baffle system. The tank has hole located at the center of the top side that will serve both filling and emptying purposes.

The design essentially reduces amount of space available for the free surface of fluid to move. The perforated discs, hopefully, will damp out the fluid movement otherwise due to sloshing and also redistribute the fluid flow pattern. Since the purpose of the payload load is to collect data that will shed light on the liquids slosh pattern during flight, the quantity of liquid is small enough not to have any significant effect on the rocket’s flight trajectory.

Tanks are fabricated from Plexiglas the parts being held by epoxy. The materials have been selected because of they are light weight and have strength sufficient to bear the loads.

- Integration of Slosh Liquid Payload The flanged bases of the tank sit on a centering ring to which they are coupled

by means of bolts or screw keeping it firm during flight. The tanks are placed parallel to each and have the same net weight for correct weight distribution and will sit on the same centering ring.

Production Diagram of Slosh Payload

Safety and Environment (Payload) The Safety Officer is Nicole F. Analysis of Failure Modes

The following is a list of potential failure modes for the payloads. This includes the expected severity and plans for mitigating the risk.

Severity Ranking of Identified Hazards:10 to 8: Catastrophic: A condition that may cause injury, total loss of rocket, or severe damage to systems and equipment during launch or testing procedures. Constitutes a loss of greater than 50% of total cost.

7 to 5: Critical: A condition that may cause injury, damage to rocket, or damage to systems and equipment during launch or testing procedures. Constitutes a loss between 15-50% of total cost.

4 to 2: Moderate: A condition that may cause minor injury, minor damage to rocket, or minor damage to systems and equipment during launch or testing procedures. Constitutes a loss between 2-15% of total cost.

1: Negligible: A condition with no injury to persons, superficial damage to rocket, or superficial damage to systems and equipment during launch or testing procedures. Constitutes a loss between 0-2% of total cost.

Analysis of Current Item of FunctionAnalysis of Item of Function After

Actions Taken

Item

or F

uncti

on

Pote

ntial

Fai

lure

Mod

e

Pote

ntial

Effe

ct(s

) of

Failu

re

Seve

rity

Pote

ntial

Cau

se

Expe

cted

Occ

urre

nce

Prev

enta

tive

Reco

mm

ende

d Ac

tion

Com

pleti

on

Liquid Sloshing Analysis Payload

Liquid tankTank comes loose during flight

Sloshing data not collected, changing stability of rocket during flight

8

Tank not properly secured to bulk plate

3

Tightly fasten bolts, add epoxy if needed

Conduct shake test

Cameras Cameras fail to collect data

No results for experiment

3

Camera comes loose during flight, no power

3 Camera mounting

Test recording, conduct shake test

WiresWires come loose during flight

Power loss. No results for experiment

3

Wire get caught on objects during flight

3

Feed wires through tube or secure them to wall

Conduct shake test

Baffles Baffles come loose from tank

Experiment is ruined 3

Baffles not properly secured

3

Test baffles after placed in tank

Conduct shake test

Liquid tank Water leaking out

Sloshing data not collected/ damage or electronics

6Top and bottom of tank not secure

2

Inspection of seals. Add epoxy if needed

Conduct shake test to see if water spills out

Faring Deployment Payload

Drogue Parachute

Drogue Parachute fails to deploy

Fairing system is not given any force to push forward the nose cone

7

Walls of nose cone will not fall out, Hazard detection camera view ground

2

Testing of force provided by drogue parachute is sufficient

Have a backup system to ensure nose cone will move forward

HingesHinges break or become damaged

Nose cone area exposed during flight

8

High forces acting around hinge causing to break off rocket

5

Proper securing of hinges. Add extra epoxy if necessary

Conduct tests in wind tunnel

Walls

Walls of nose cone come apart during flight

Nose cone area exposed during flight

9

High forces acting on walls cause them to separate

5

Use tight seals to help secure the lips of the walls

Conduct tests in wind tunnel, test mechanics of system to ensure they are hold walls tight, squeeze test

HingesFail to lock walls of nose cone

Hazard Detection Camera's view is blocked, no data collected

3

Defective hinge, or damaged during flight

2

Test locking mechanism on hinge

Test after integration of Hazard detection camera

Hazard Detection Camera Payload

Cameras Cameras fail to collect data

No results for experiment, system cannot detect hazard

3

Camera comes loose during flight, no power

3 Camera mounting

Test recording, conduct shake test

WiresWires come loose during flight

Power loss. No results for experiment

3

Wire get caught on objects during flight

3

Feed wires through tube or secure them to wall

Conduct shake test

Electronic communicating between camera to ground station

Communication loss between rocket and ground station

No data sent/ received, cannot detect hazards

3Body of rocket prevents communication

4

Testing of equipment at various distances

Testing after integration of all systems

Updated list of Hazards

The lists of personal hazards when constructing the payload are similar to those of constructing the rocket. Thus, all the information on the list of updated hazards can be found in: III) Vehicle, Safety and Environment (Vehicle).

Environmental Concerns

The following is a table of environmental concerns for the three payloads and how we plan to mitigate them.

Environmental concerns Mitigations Status

Potential hazard to wildlife if small payload pieces are ingested.

Team will function as cleanup crew at impact and launch site to ensure all rocket parts are recovered.

Complete if necessary. Will bring bag to gather all pieces.

Batteries become broken cause an exposure to chemical waste (Ex: lead mercury, and cadmium)

While wearing gloves, member will clean area. For alkaline batteries use lemon juice. For acid base batteries, use baking soda with water.

Complete if necessary. Will bring proper cleaning supplies.

V). Project Plan

Budget Plan: - The following is a chart of the cost of the entire rocketry project. As we have

found ways to save money, such as grants or by using previously owned materials, we added it to the funded column. This way we know how much money is needed for the rest of our expenses.

EXPENSES QUANTITY PRICE PER UNIT COST FUNDED EXPENSES OUTSTANDING

Travel / Gas Van

(mileage and gas)

1 $700.00

$700.00

yes - Space Grant

Sub Cost $700.00 0

Lodging May 13,

2014 - Billings, MT

4 $85.00

$340.00

yes - Space Grant

May 14, 2014 –Salt Lake City, UT

4 $85.00

$340.00

yes - Space Grant

May 15, 2014 - Salt Lake City, UT

4 $85.00

$340.00

yes - Space Grant

May 16, 2014 - Salt Lake City, UT

4 $85.00

$340.00

yes - Space Grant

May 17, 2014 - Salt Lake City, UT

4 $85.00

$340.00

yes - Space Grant

May 18, 2014 - Salt Lake City, UT

4 $85.00

$340.00

yes - Space Grant

May 19, 2014 -Billings, MT

4 $85.00

$340.00

yes - Space Grant

Sub Cost $2,

380.00 0

Rocket

Supplies

Air Frame ( in) 2 $40

4.00 $8

08.00

$808.0

0 Centering

Ring 3 $7.00

$21.00

$21.00

Motor 1 $14 $1 $1

Mount Tube .00 4.00 4.00

Nose Cone 1 $49.45

$49.45

$49.45

Stiffy Tube 2 $9.95

$19.90

$19.90

Tube Coupler 2 $8.

25 $1

6.50 $1

6.50 Parachute

96" 1 $89.95

$89.95

$89.95

Drogue 36" 1 $20.95

$20.95

$20.95

1000 Series Rail Beads 2 $2.

65 $5.30

$5.30

Shockcord (per yard) 6 $1.

10 $6.60

$6.60

Casing 1 $450

$450.00

previously own

Motor Aerotech L220G

4 $215.00

$860.00

$860.0

0

Rocket Kit 1 $40.00

$40.00

scrapped from previous rocket

PerfectFlite 2 $99.95

$199.90

previously own

Sub Cost $2,

601.55 $1,911.65

Misc.

Supplies 1/4" by 6'

Plywood 1 $15.00

$15.00

$15.00

1/8" by 6' Plywood 1 $15

.00 $1

5.00 $1

5.00

Nuts 20 $0.25

$5.00

$5.00

Washers 20 $0.25

$5.00

$5.00

Eye Bolts 4 $1.50

$6.00

$6.00

Xacto Knife 1 $1.97

$1.97

$1.97

Batteries 6 $5.00

$30.00

$30.00

Paint & gloss 6 $10.00

$60.00

$60.00

Paper towels 1 $3.

99 $3.99

$3.99

Plastic cups 1 $5.99

$5.99

$5.99

Sub Total $147.95

$147.9

5 Payload

Supplies

Arduino Mega 2560 2 $58.95

$117.90

$117.9

0 Mego Protoshield for Arduino 2 $14

.95 $2

9.90 $2

9.90

D2523T Helical GPS Receiver 2 $79

.95 $1

59.90

$159.9

0

Copernicus II DIP Module 2 $74

.95 $1

49.90

$149.9

0

Xbee Pro 900 Wire antenna 4 $42

.95 $1

71.80

$171.8

0

Xbee Pro 900 U.FL Connection 4 $42

.95 $1

71.80

$171.8

0 LinkSprite JPEG Color Camera TTL Interface 2 $49

.95 $9

9.90 $9

9.90

Open Log 2 $24.95

$49.90

$49.90

TEMT6000 Breakout Board 2 $4.

95 $9.90

$9.90

Mini Photocell 2 $1.50

$3.00

$3.00

Light to Frequency Converter - TSL235R 2 $2.

95 $5.90

$5.90

Polymer Lithium Ion Battery - 6Ah 1 $39

.95 $3

9.95 $3

9.95

CamOne Infinity w/ gps module 2 $19

9.00 $3

98.00

$398.0

0 2 in. Plexiglas glass tube 48" long

1 $50.00

$50.00

$50.00

Sheet of Plexiglas 1 $30.00

$30.00

$30.00

Hinges 4 $5.00

$20.00

$20.00

CamOne GPS Module 2 $50.00

$100.00

$100.0

0 Sub Total $1,

607.7 $1

,607

5 .75 Other

Expenses

T-shirts 9 $15.00 $135

$135.0

0

Sub Total $135

$135.0

0

Total Cost $7

,572.25 $3,802.35

Timeline: February

- 10 - Full Scale Test Launch (tentative)- 28 -CDR reports, presentation slides, and flysheet

posted

March- 3-7 -CDR Presentations- 12 -Full scale test launch- 13 - Flight Readiness Review Question and Answer

Session

April- 18 -FRR reports, presentation slides, and flysheet

posted- 21-25 -Present FRR (tentative dates)

May- 14 -Arrive in Salt Lake City, Utah- 15-16 -Launch Readiness Reviews

-Flight Hardware and Safety Check (tentative)- 17-18 -Launch Day

June- 2 -Post the -Post Launch Assessment Review (PLAR)- 13 -Winning USLI team will be announced

Educational Engagement Plan and Status - Schools: Valley Middle School and South Middle School.

- Dates of the Events: March 28th 2014 and April 16th 2014 respectively.- Location of Events: Classrooms and auditorium of participating schools.

Plan: For Valley Middle School we will be going into the classroom of a local 8th grade teacher who is currently covering physical sciences that relate to space exploration. Around March 28th, the classes will be covering basic physics principles such as gravity and momentum. We will be coming in and giving a brief lecture about those topics and then following up with hands on experiment. The experiment will be simple, but incorporates some of the material covered in the lecture. We are thinking of doing a momentum experiment that momentum is affected by mass and velocity by having kids experiment with rolling balls at a target and seeing if a heavier ball or a faster ball effects momentum more.

For South Middle School, we are planning on going in and doing something similar to what was done at Valley Middle School, except that we will be focusing more on the trajectory since it pertains more to what they are currently doing. The experiment that we plan on doing with them, following the brief lecture, is have them find the optimal angle to maximize distance for a projectile. We will do this by having them use old film canisters and filling them up with water and antacids to create the force necessary for liftoff. From there the students will experiment with the angle to see what works best to maximize the distance. Afterwards, we will have a contest to see who can get their projectile closest to a target. The students will use their knowledge from the previous experiment to try and get their projectile closest to the target.

- Number of Students: If all goes according to plan, we will reach about 125-150 students depending on attendance on those days. We are still in talks with teachers to see if they would be interested in more presentations in the future if it fits into their curriculums.

VI). Conclusion