Presentation 2Vehicle Systems - Daedalus

1

Outline

• Structures

–Nosecone

–Body tubes

–Bulkheads

–Fins

–Tail Cone

• Recovery

–System Layout

–Testing

• Propulsion

–Ox Tank

–Plumbing

–Injector

–Chamber

–Nozzle

–Testing

•Hydrostatic

•Cold Flow

•Hot Fire

–System Validation

•Test data presentation

• Trajectory

–System Operating space (altitude)

–Flight Profile (engine test)

2

Slide Structure

ValidationDesign & Analysis Construction

3

Nose Cone

Design Discussion-Materials:

–Fiberglass sheet –60 minute cure epoxy resin

-High tensile and compressive strength

Anaylsis- Half-Power profile

-𝑦 = 𝑅𝑥

𝐿

- Fineness Ratio-STAR-CCM+

-Simulations @ Mach 0.8

FR = 3:1

Nose Cone

Construction-Wet-lay fiberglass strips into mold

halves, nose cone-Fill, prime, and paint

Flight Performance-Withstood flight loads as expected-Minor scratches from landing

Bulkheads

Recovery BulkheadConnections: • Recovery – well nuts• Payload – bolt/nut• Body Tubes – JB weld

Joint BulkheadConnections: • Body Tubes – JB weld

Thrust BulkheadConnections: • Body Tubes – JB weld• Top – Well nut• Bottom – Nut/Bolt

• Design

– Material

•Aluminum 6061-T6

– Considerations

• Attachment methods

–Well nut

–Nut/bolt

–Rivets

–JB weld

• Loading

• Ease of Assembly

– Layout

• 5 main bulkheads6

Body Tubes

• Analysis

– z+45°/-45° weave angle

–Fiber/matrix modeling difficulty

–Estimated Load

•~1250 lbf

–Flight Proven

• Construction– 0 ° (axial)

•Resistant to longitudinal bending

– 90 ° (hoop)

•Resists internal/external pressure

– 45 °

•Ideal to resist pure torsion

• Flight Results

– Weakened while finishing rough

surfaces, slight fracture upon landing

7

Fins & Stability

Airfoil Design• NASA SC-010• CFD optimization

Planform Design• RASAero optimization

Dynamic Stability• RASAero w/crosswind

8

Fins

• Construction– CNC aluminum bases– CNC fin mold– Cast foam fin cores – Fuse core and base with epoxy– Vacuum resin transfer process– Attach to body with ¼” bolts– Bondo fillet around the aluminum base

• Flight Performance– Withstood flight loads

• Design– Materials

• Carbon Fiber Cloth• High Density Foam• Aluminum Base• Epoxy

– Considerations• Light Weight• Resist Fin Flutter• Maintain Structural Integrity

Tail Cone

Design Discussion

-Lightweight & Heat Resistant

-Strong enough to hold fins

-Material: Al 6061-T6

-Made from rolled aluminum sheet, welded at seam

Analysis

-CFD in STAR-CCM+ → stagnation region

1.25 calibers14.5°

1.22 calibers

7.3°

Recovery System Overview

(1) Motor

Ignition

(2) Coast

(3) Apogee

(4) Drogue

Deployment

at Apogee,

Descent @

90 ft/s

(5) Main

Deployment at

1500’ AGL,

Descent @ 20 ft/s

(6) Landing

Dual-Deployment Recovery

System Key Features:

• Dual Deployment design to

minimize drift

• Single point of rocket

separation

• Integration of Advanced

Retention Release Device to

release main (ARRD)

11

Recovery System Overview

15’ Tubular Nylon

5’ Tubular Nylon

28’’ Tubular Nylon + 6’ Kevlar Y-Harness = 34’

Drogue Parachute

Configuration

Main Parachute

Configuration

Main

Shock Cord

Drogue

12

Initial Design Utilizing Line Cutters

• Preliminary Design Overview:–Dual Deployment system utilizing line cutters to deploy main parachute at desired altitude

–Both main and drogue are ejected from the vehicle at apogee

• System Concerns–A pre-mature deployment of the main parachute at Waco launch

–Redundant line cutters on same zip-tie proved to be faulty in conditions that are difficult to test

• More reliable and testable solution is desired

Line Cutter V3 Key Dimensions

Length 5.25”Weight 3.75 ozCharge .75 grams Pyrodex p

13

Current Recovery System

Ejection Pod Showing E-match to Pyrodex Charge

Binding Posts connect E-Match to Electronics BayU-Bolt

U-Bolt ARRD

Recovery Bulkhead: Top View

•Recovery Bulkhead–Redundant Ejection Charges connected with

binding posts to electronics bay•7 gram charge Pyrodex P•4 x (4-40 Shear Pins)

–2 (U-Bolts) distribute opening force across entire bulkhead

–ARRD mounted through bulkhead

14

ARRD (Advanced Retention Release Device)

• ARRD implemented as alternative to line cutters–Link between drogue and main parachute from apogee to 1500’ AGL

–Activated by pyrodex P charge–Installed through the recovery bulkhead

• Advantages of ARRD vs. Previous Designs–Main parachute is kept in the recovery bay –Electronic wire no longer required to run from bulkhead to main parachute

–Utilization of deployment bag keeps the recovery bay organized

ARRD Key Dimensions

Length w/o shackle 2.125”Diameter 1.375”Weight 2.75 ozPyrodex P Charge .25 grams

15

Opening Force Calculation

• Impulse Momentum Theory –Transfer of momentum between vehicle and

displaced air mass provides opening force –Function of inflation time

• Force as a function of inflation time–Deployment inflation window: 100 ft/s–Estimate Opening Force: 380-450 lbf

0

200

400

600

800

1000

1200

0 0.5 1 1.5 2 2.5 3 3.5

Op

en

ing

Fo

rce

[lb

f]

Time [s]

Opening Force vs. Inflation Time

Recovery System Max.

Load Ratings

Tubular Nylon Shock Cord 4000 lb

Fruity Chutes Swivel 3000 lb

3/8” Quick Link 6000 lb

Kevlar Y-Harness 6000 lb

ARRD 2000 lb

Parachute

Inflation

Window

16

NP-915 Icarus II

Summary Specifications

ISP 220 s

avg 𝑚Prop 2.47 lbs/s

Burn time 11.8 s (8.4 liq)

Peak Thrust 915 lbf

Average Thrust 542 lbf

Impulse 6411 lb-s

Exhibition Engine – 70% FR 20% Hydrotest Verified 20% Cold Flow Verified 30% Static Test Verified

Completion pending infrastructure improvements

Hybrid Engine

Liquid Oxidizer:

Nitrous Oxide

Solid Fuel:

HTPB

Oxidizer

• Nitrous Oxide–Vapor pressure dependent on ambient temperature

–Two phases in oxidizer tank: Liquid and gas

• Climate Control–Controlling fill tank temperature

–Regulate engine performance

Predicted ThrustTemp: 85 F

Predicted ThrustTemp: 60 F

0

200

400

600

800

1000

1200

0 20 40 60 80 100 120

Pre

ssu

re (

psi)

Temperature (°F)

N2O Vapor Pressure v. Temperature

Fuel: HTPB

• HTPB–Solid Fuel Grain–Regression rate–Geometry

•5 in OD•3.5” ID•2.3” Pre-Combustion Chamber•21.3” Fuel length

–Predictability

𝑟𝑎𝑣𝑔 = 𝑎𝐺𝑙𝑖𝑞𝑢𝑖𝑑 (𝑎𝑣𝑔)𝑛

ABS Pre-CC

Fiberglass Insulation

Fiberglass Insulation

HTPB Fuel Grain

𝑟𝑎𝑣𝑔 = 0.115 in/s

Full Burn

𝑟𝑎𝑣𝑔 = 0.068 in/s

Partial Burn

Propellant

• Solid HTPB and Liquid Nitrous Together

–Ideal FO ratio of ~0.154

–Looking for equivalence ratio of 1

•Φ𝑎𝑐𝑡𝑢𝑎𝑙

Φ𝑠𝑡𝑜𝑖𝑐ℎ= 1 where Φ𝑎𝑐𝑡𝑢𝑎𝑙 =

𝑚𝑓𝑢𝑒𝑙

𝑚𝑜𝑥𝑖𝑑𝑖𝑧𝑒𝑟

Tank & Plumbing

Luxfer T144ATank Specifications

Icarus

Requirement

Service Pressure 3600 psi 1000 psi

Volume 1100 in3 -

Max Nitrous Mass

(@ 95°F)23.4 lb

(0.02 lbm/in3)

22 lb18.9 lbs. vs. 46.9 lbs.

Composite

OverwrappedSolid Aluminum

structure

0

10

20

30

40

50

0 20 40 60 80 100

Ma

ss (

lb)

Temperature (°F)

Maximum N2O(l) Mass v. Temperature

Tank & Plumbing

Plumbing Specifications

Minimum Thickness 0.100”

Service Pressure 5200 psi

Weight 1.22 lb

Minimize

• Weight

• Length

• Leaks

Ball Valve Actuator

BVA Specs

Servo Torque 611 oz-in

4 Bar Linkage Output 1100 oz-in Transferable between engine systems

Injector

Specifications

Orifice Area 0.0675 in2

𝑚 2.1 lbs/s

Increase Regression Rate ~20%

Best Mixing

-Result of vortex injection-Localized Increase

Combustion Chamber

Specifications

Operating Pressure 400 psi

Test Pressure 520 psi

Length 30 in

OD 5.5 in

Thickness 0.25 in

Factor of Safety >2

Nozzle

Specifications

ε 4.5

At 1.1 in2

Ve 7461 ft/s

𝒎 2.75 lb/s

Hydrostatic Testing Process

Injector to Tank - pressure tested to 1400 PSICap coin in place

Tank to Chamber & Nozzle- pressure tested to 400 PSI

Surface Area: 12.75 in2

Service pressure: 400 psiExperiences 5100 lbf

Cap Area: 19.63 in2

Test pressure: 260 psiProof pressure: 375 psi

Hydrostatic Testing Results

Issues with various gasket materials

Buna O-ring seal

Verified April 28, 2016

Heat affected

zone failure

V1

V2

V1

V3

Engine Testing: Cold Flow

• Oxidizer runs through engine system without ignition

• Allows for complete testing of system and infrastructure before static fire

Predicted

Recorded

Data Time of cold flow

272-241.7 = 30.3 sec

Static Engine Testing Results (Video)

Static Engine Testing Results

32

Daedalus Performance

OV

ER

FIL

L

10k Target Flight

SpacePort, NM Daedalus [Icarus] 100 MC

Value ±𝟏𝝈

LoadedWeight

107.3 lb -

Mass N2O

14.5 lb -

Apogee 9838 ft ±3.5%

Peak Mach

0.65 ±1.5%

Peak Accel.

6.12 G ±2.0%

Rail Exit 94 ft/s ±3.0%

10k Target Flight

SpacePort, NM Daedalus [Icarus] 100 MC

Value ±𝟏𝝈

LoadedWeight

107.3 lb -

Mass N2O

14.5 lb -

Apogee 9838 ft ±3.5%

Peak Mach

0.65 ±1.5%

Peak Accel.

6.12 G ±2.0%

Rail Exit 94 ft/s ±3.0%

05/10/16: Empirical Load Cell

SpacePort, NM Daedalus [Icarus] 100 MC

Load CellPressure

Trans.

Mass N2O 25 lb 25 lb

Apogee 11,619 ft 20,393 ft

Peak Mach

0.56 1.04

Peak Accel.

2.9 G 5.0 G

Rail Exit 65 ft/s 87 ft/s