1. FRR Presentation April 5, 2012 1

2. Eric P o Team Leader o Payload Manager o Documentation Manager Michael B o Building Team Manager o Safety Manager Sean K o Outreach o Materials Manager Jacob E o Launch Manager o Budget Manager Mike P o Technology Manager o Equipment and Facility Manager Michael G o Recovery Manager o Communications Manager Brian G o Technical Manager o MSDS Manager Lake Zurich Rocketry - Team Responsibilities 2 Lake Zurich High School

3. FRR – Final Launch Vehicle Dimensions Final Launch Vehicle Dimensions Launch Vehicle Specifications LengthDiameterMass 90.75 In6.16 In456.14Oz Center of Gravity Center of Mass Stability Margin 45.27 In64.91 In3.22 3

4. FRR – LV Key Design Features SystemRationaleCharacteristics A - Nose ConePart of payload - needs to be durableFiberglass with Ogive design B - PayloadEngineering experiment Designed to hold all components, deploy easily, able to maneuver, and be durable. C - Payload TubeLightweight and durable6" Carbon Fiber - fiberglass too heavy. D - Avionics BayStandard design for redundant ejection charges. Screws attach to payload tube, and shear pins to booster tube for ejection. E - AV Bay Collar Holds the arming switches - can be easily armed from outside of LV. 2" collar is adequate for arming switches and for vent hole for altimeter. F - Drogue Chute Design to eject with payload and allow LV to descend with wind. 28" Nylon chute that is attached with quick links to eyebolts in bulkplate on Avionics Bay. G - Main ChuteSlows the LV down to safe landing velocity. 108" Nylon chute that deploys at 1,000' to reduce impact of winds. H - Booster Tube Needs to be lightweight and durable to resist zippers. 6" Carbon Fiber - fiberglass was too heavy for the motor requirement. I - Cradle Designed to absorb some of the stress on tube from deployment of main. Connects to the shock cord at the edge of the booster tube. J - Motor MountStandard motor mount system for 54 mm motor.Using a K1050W motor from Aerotech K - Fins Attached to motor tube, and sized to provide stable flight. Fiberglass fins provide durable system BA C F E D GH I K J Launch Vehicle Key Design Features 4

5. FRR – Final Motor Choice – 1 of 3 Final Motor Selection - AeroTech K1050W Motor Subsystem Construction A - Centering Rings Made from ¼” birch plywood. Forward ring is doubled to increase strength for main chute deployment. Eye bolt is anchored into the forward centering rings for main chute shock cord anchoring. B - Fins Fins extend through the airframe, and are glued to the motor housing. This increases strength. C - Motor Tube Aluminum motor tube that holds the K1050 motor and slides into the kraft motor housing. Extends into the motor housing D - Retention Ring Holds the K1050 motor into the motor tube E - Anchor bolts and clips Used to clip over the retention ring, and holds the motor securely. 5

6. FRR– Final Motor Choice – 2 of 3 Final Motor Selection - AeroTech K1050W 6

7. FRR– Final Motor Choice – 3of 3 Motor Specifications Diameter: 54.0mm Length: 62.7cm Total Weight: 2203g Prop. Weight: 1265g Average Thrust: 1132.9N Maximum Thrust: 2172.0N Total impulse: 2426.4Ns Burn Time: 2.1s Thrust Curve Final Motor Selection - AeroTech K1050W 7

8. FRR – Rocket Flight Stability Margin Rocket Stability Margin LengthDiameterSpanMass (w/ motor) 90.75 in6.16 in15.66 in456.14 Oz MotorCGCPStability Margin K1050W45.2767 in64.9076 in3.22 CPCG 8

9. FRR– Thrust to Weight ratio and Rail Exit Velocity Thrust to Weight Ratio and Rail Exit Velocity Launch Information Thrust to Weight Ratio 8.936 Rail Exit Velocity68.87 ft/sec Launch Rail Length96" Rail Button Size Fits Standard 1" rail Flight Information (10 mph winds) PredictionLaunch VehiclePayload Time to Apogee 16.704 sec Maximum Acceleration 326.68 ft/s/s Maximum Velocity 566.59 ft/s Time to Landing109 sec.227 sec. 9

10. FRR – Mass Statement Mass Statement SystemMass oz.Mass lbs. Booster Tube124.37.77lbs. K1050 Motor77.74.86lbs. AV Bay52.03.25lbs. Payload Tube40.82.55lbs. Payload84.55.28lbs. Nose Cone33.32.08lbs. Recovery37.52.34lbs. Paint6.00.38lbs. Total Mass456.1 oz.28.51lbs. 10

11. FRR – Recovery Systems – 1 of 3 Recovery Systems Recovery Sub-Systems Drogue Chute 28" - LOC Precision LP-28 - Rip-stop Nylon Main Chute 108" - Rip-stop Nylon Shock Cord 1/2" Tubluar Kevlar - 7500 lbs rated - Drogue and Main 30' length Payload Chute 42" Round Custom (8" vent in top for added stability) Nomex Used to protect all parachutes from heat of ejection charge Eye Bolts Used to hold the shock cords to bulk plates - AV Bay and Payload U-Bolts Used to hold the shock cord to bulkp late in the booster tube Quick Links Used to attach shock cords to eyebolts 11

12. FRR – Recovery Systems – 2 of 3 Recovery Systems Avionics Bay and Recovery Components Redundant AltimetersDrogue Chute - Payload Tube Arming SwitchesMain Chute - Booster Tube 2 - Forward EyeboltsMain Shock Cord 2 - Aft EyeboltsDrogue Shock Cord Batteries4 - Quick Links 2 - Forward Charge cupsShock Cord 'Cradle' 2 - Aft Charge cups4 - Black Powder Charges GPS Recovery deviceFoil Frequency Barrier Altitude Sensor for verificationEjection charge terminals We are using a dual event recovery system (DERS). The drogue parachute will be 28 inches in diameter, and will deploy at apogee. The main parachute will be 108 inches in diameter, and will deploy at 1100 feet. This will slow the descent rate to approximately 16.21 ft/sec. 12

13. FRR – Recovery System – 3 of 3 Recovery Systems Ejection Charge Sizing Shear Pins Shear pins will be used to securely connect all sections that ejection charges will be separating. We will use 1/16” shear pins that require an average of 50 Lbs of force to shear. We are planning on using a minimum of 3 shear pins per section which will then require 150 Lbs. of force to shear, but additional testing is required to make sure this is suitable for the ejection charge sizes we have specified. Shock Cord Cradle To prevent a ‘zipper’ to the Booster tube when the Main chute deploys, the team has created a ‘Shock Cord Cradle’ that will reduce some of the stress created on the forward edge of the booster tube Ejection Charge Sizes Sub-System Charge Size (Grams) Shear Pin Size Drogue Chute Ejection1.5 gr. 1/16" Qty - 3 Main Chute Ejection2.0 gr. 1/16" Qty - 4 Payload Release Mechanism 1.25 gr. 1/16" Qty - 3 13

14. FRR – Kinetic Energy Kinetic Energy Kinetic Energy Predictions (ft/lbs) Altitude (10 mph winds) Booster Tube (mass = 11.94 lbs) Payload/AV Bay (mass = 3.55 lbs) Payload (mass = 7.36 lbs) Drogue Descent767 ft/lbs227 ft/lbsNA Main Descent48.77 ft/lbs7.12 ft/lbsNA Landing48.77 ft/lbs7.12 ft/lbs55.77 ft/lbs 14

15. FRR – Predicted Altitude and Wind Drift – 1 of 2 Launch Vehicle - Predicted Altitude and Wind Drift Altitude Predictions Wind (mph)Altitude 04489' 54479' 104444' 154385' 204303' Launch Vehicle Wind (mph) Range at Apogee Range at Landing 00' 5-341'311' 10-653'707' 15-965'1200' 20-1257'2020' 15

16. FRR – Predicted Altitude and Wind Drift – 2 of 2 Payload – Range Predictions with Wind Drift Payload (Separated at Apogee +- 4500') Wind (mph)Range at ApogeeRange at Landing Altitude Deployment to Stay within 2500' Range 00' Apogee 5-341'1474'Apogee 10-653'2300'Apogee 15-965'3196'3900' 20-1257'3630'3400' 16

17. FRR – Test Plans and Procedures – 1 of 2 Test Plans and Procedures TestProceduresStatus Altimeter Deployment Test Altimeters are depressurized and then pressurized to test for proper ejection altitudes of the parachutes Complete Battery Connection Test The batteries are connected to the various subsystems to test for functionality Complete GPS Location Test (Astro)GPS is tested in various locations for verification of accuracyComplete Altitude Test (Redundant Altimeter) Redundant Altimeter unit is taken to various heights to test for accuracy Complete Ejection Charge Test Ejection charges are ignited in a safe environment to test for proper ejection Complete Ejection Test Elements of the launch vehicle are tethered to a zip-line. The ejection charges are then detonated to test for proper separation of elements. Complete RockSim Verification Test Data from subscale launch vehicle and from RockSim are compared to test the validity of RockSim Complete Altitude Test (Ejection Altimeters) Altimeters are pressurized to various altitudes to test the accuracy of flight data Complete Subscale Launch Measurements of stability and strength were taken from the subscale flight to verify the integrity of the launch vehicle’s design Complete Parachute Drop Tests Both the drogue parachute and the main parachute are dropped from various heights to test for parachute functionality Complete Altimeter Continuity Test The continuity of the altimeter terminals are tested to verify proper wire connections Complete Integration TestThe payload fits into the payload bay as designedComplete 17

18. FRR – Tests and Procedures – 2 of 2 Test Plans and Procedures Flight testing Para-wing testing – concluded the design was too unstable – switching to a round/vented parachute Release mechanism Static Line testing Ejection charges Shear pins Recovery systems Full-scale launch vehicle test flight(s) RC signal strength Telemetry Checklists Component Integration Additional Testing Completed since CDR: 18

19. FRR – Additional Scale Model test flight Additional Scale Model Test Flight Launch Details Launch Date: February 28, 2012 Launch Location: Richard Bong State Park Launch Conditions: 52 degrees partly cloudy 5-10 mph from NW launch at 11:45 AM CST Launch Objectives and Results: Retest DERS Verify shear pins in actual test flight. Verify range of payload electronics. Checklist verification All verifications successful. 19

20. FRR – Full-Scale test flight - 1 of 4 Full-Scale Test Flight Launch Details Launch Date: March 17, 2012 Launch Location: Richard Bong State Recreation Area GPS coordinates: Lat: 42 Deg, 37 Min, 44.06 Sec N Long: 88 Deg, 10 Min, 17.83 Sec W Launch Conditions: 73 degrees partly cloudy 10-15 mph from NW launch at 2:45 AM CST Launch Objectives: Verify RockSim predictions Test a dual event recovery system with redundant altimeters. Use checklists for prep, launch, flight, recovery, and analysis. Verify payload integration Verify that our GPS system worked correctly. Determine if our construction techniques were suitable to meet SLI requirements. Collect data for analysis. 20

21. FRR – Full-Scale test flight - 2 of 4 Full-Scale Test Flight 21

22. FRR – Full-Scale Flight Test – 3 of 4 Full-Scale Test Flight Flight and Recovery Observations: Launch was straight and smooth with no indications of any issues. The nose cone ejected with the payload while still climbing – at about 2823 feet. This caused the drogue and payload chutes to partially shred due to extreme wind force. Main chute deployed as planned – at 1100’. The payload chute acted like a streamer, and only partially slowed the payload descent. This caused the payload to land with KE outside of guidelines. The LV landed within guidelines. Data Analysis: The dual deployment system worked as designed. We had good signal connection with the RC components from the ground. We were at a maximum of 3,027 feet from transmitter to receiver. Both altimeters worked for the redundant charges. The Garmin Astro worked perfectly, and gave us accurate recovery data. 22

23. FRR – Full-Scale Flight Test – 4 of 4 Scale Model Test Flight On-board Altimeter Data Data Analysis and Conclusions By looking at the flight data and observations, the following conclusions can be made: Apogee was reached in 13.85 Sec. Apogee altitude was approximately 2823 Ft. RC Signal Strength was strong. GPS was accurate Flight was stable The team believes that the nose cone ejected early due to an increase of pressure in the payload tube. To keep this from happening again, the team has now added shear pins to the nose cone, and have also added larger vent holes in the payload tube. 23

24. FRR – Recovery System Tests – 1 of 2 Recovery System Tests Multiple tests and Verifications: Static Line tests: Completed using an exact scale model of the actual LV system. Verify ejection charge sizes Verify shear pin size and placement Verify recovery deployment and shock cord Flight tests: 6 test flights for verifying the DERS Some early failures that enabled the team to make modifications. Release Mechanism for Payload: Added during CDR. Tested and verified with static line testing and flight tests. 24

25. FRR – Recovery System tests – 2 of 2 Recovery Systems Avionics Bay and Recovery Components Redundant Altimeters Drogue Chute - Payload Tube Arming SwitchesMain Chute - Booster Tube 2 - Forward EyeboltsMain Shock Cord 2 - Aft EyeboltsDrogue Shock Cord Batteries4 - Quick Links 2 - Forward Charge cupsShock Cord 'Cradle' 2 - Aft Charge cups4 - Black Powder Charges GPS Recovery deviceFoil Frequency Barrier Altitude Sensor for verification Ejection charge terminals 25

26. FRR – Summary of Requirement Verifications – LV Summary of Verifications – Launch Vehicle RequirementDesign ElementVerification 5,280 feet AGLMotor K1050WAltitude will be under 5280’ Maximum total impulse of 2,560 Nsec (K)Motor K1050WAerotech testing results Remain subsonicMaximum Velocity =.504 machRockSim and LV test 1 All sections to have GPS tracking deviceGarmin Astro in payload and AV BayCompleted – flight test Must be have a stabilty margin of between 2.0 and 2.50 (RockSim) Stability margin – 3.22RockSim analysis and inspection Must have at least 1 sub-scale test flightScheduled for 1-14-2012Completed Must have at least 1 test flight of full-scale LVScheduled for 3-17-2012Completed LV must meet flight review by RSOPending approvalInspection by RSO Ready to launch within 2 hours of waiverPending test flightsCompleted Ready mode for one hourElectronics tested to achieveCompleted Utilize Launch and Safety checklistCompleted - see PDRInspection and analysis DERS - Drogue and Main chutesCompleted in designInspection and Testing Separate Arming Switches - no higher than 6'Completed in designInspection and testing Redundant Altimeter SystemsCompleted in designCompleted Electronics protected from freq. interference Completed in design - a foil barrier on surface of forward bulkplate Analysis and testing Removable Shear pinsCompleted in designIncluded in design and tested No more than 75 ft/lbs of KE per sectionMaximum KE = 55.77 ft/lbsRockSim analysis and LV Test All sections within 2,500 feet of launch padChute size and deployment affectRockSim analysis Utilize Recovery checklistCompleted - see FRRInspection and Analysis Ready for re-launch in same day - no repairsPending test flightsTesting Collect experiment data for analysisTelemetry data being stored on laptopTesting Must have flown and recovered a min of 15 flights at K Class or greater Both Mentors have achieved thisCompleted 26

27. FRR – Payload Design – 1 of 6 Payload Design Payload Objectives Direct the payload to a specific landing location Gain telemetry from our payload such as speed, GPS coordinates, and altitude Land the payload SAFELY Gain video telemetry to accurately direct the payload Payload Success Criteria To have a successful payload, our team has brainstormed a list of requirements that our payload shall meet. They are: Land the payload within 50 feet of a designated location Land the payload SAFELY Gaining information from the payload during the payload’s flight 27

28. FRR – Payload Design – 2 of 6 Payload Design Payload Systems: RC controlled fan – to provide the payload with controlled movement RC controlled directional fins – to change the course of the payload Video camera – to help the pilot guide the payload Telemetry system – to help collect data to analysis the descent GPS locator – to assist in the recovery of the payload should it go off course Parachute – will use a ‘vented’ chute to provide flight stability. Payload release mechanism – for safety – remotely controlled release of the payload when the RSO gives approval. 28

29. FRR– Payload Design – 3 of 6 Payload Design – Fan and Directional Fins Payload fan Fan and Directional Fins The fan drives the payload forward. It is controlled by the Payload Pilot using an RC transmitter. The directional fins change the course of the payload. They are also controlled from the ground by the Payload Pilot. Combined, this system will enable the Payload Pilot to steer the payload to a desired landing zone. Directional Fins 29

30. FRR– Payload Design – 4 of 6 Payload Design – Electronics Electronics Sled Payload Electronics: RC System – houses the RC receiver. Controls the fan and directional fins Transmits telemetry data. Sends a live video feed so the Payload Pilot can see where the payload is going. Activates the release mechanism. Video Camera and Locator 30

31. FRR – Payload Design – 5 of 6 Payload Design – Electrical Diagram Electrical connections 31

32. FRR – Payload Design – 6 of 6 Payload Design – Release Mechanism Payload Release Mechanism Release Mechanism: The release mechanism is a container holding the payload parachute, and keeps the entire payload attached to the LV by the drogue chute shock cord. It remains this way until given permission by the RSO to release the payload. When approved, the Payload Pilot will activate an RC controlled ejection charge that separate the release ‘cup’ from the payload. The ‘cup’ will remain attached to the drogue chute shock cord for the descent. Once released, the parachute for the payload will deploy. The ejection charge contains 1.25 grams of black powder, which has been verified to be adequate to eject the release cup. 32

33. FRR – LV Key Design Features SystemRationaleCharacteristics A - Nose ConePart of payload - needs to be durableFiberglass with Ogive design B - PayloadEngineering experiment Designed to hold all components, deploy easily, able to maneuver, and be durable. C - Payload TubeLightweight and durable6" Carbon Fiber - fiberglass too heavy. D - Avionics BayStandard design for redundant ejection charges. Screws attach to payload tube, and shear pins to booster tube for ejection. E - AV Bay Collar Holds the arming switches - can be easily armed from outside of LV. 2" collar is adequate for arming switches and for vent hole for altimeter. F - Drogue Chute Design to eject with payload and allow LV to descend with wind. 28" Nylon chute that is attached with quick links to eyebolts in bulkplate on Avionics Bay. G - Main ChuteSlows the LV down to safe landing velocity. 108" Nylon chute that deploys at 1,000' to reduce impact of winds. H - Booster Tube Needs to be lightweight and durable to resist zippers. 6" Carbon Fiber - fiberglass was too heavy for the motor requirement. I - Cradle Designed to absorb some of the stress on tube from deployment of main. Connects to the shock cord at the edge of the booster tube. J - Motor MountStandard motor mount system for 54 mm motor.Using a K1050W motor from Aerotech K - Fins Attached to motor tube, and sized to provide stable flight. Fiberglass fins provide durable system BA C F E D GH I K J Launch Vehicle Key Design Features 33

34. FRR – Payload Integration and Interfaces - 1 of 3 Payload Integration and Interfaces Payload Integration: Payload Containment Tube is attached to the nose cone. The tube is divided into different levels, with each level holding payload components. GPS tracking unit RC batteries and Servos Telemetry components Fan and directional fins Wireless Video camera with retractable arm Parachute cup with release charge The Payload Containment Tube slides inside the payload airframe tube. At the end of the Payload Containment Tube is the Parachute cup, which also houses the Release Ejection Charge. The entire payload system is secured to the payload airframe tube at the nose cone with shear pins. Payload Interfaces: RC Interface Control of fan Control of directional fins Activate release ejection charge Telemetry Interface GPS Interface TeleMetrum Video Interface To monitor on ground AV Bay Interfaces: Altimeters Redundant altimeters activate DERS ejection charges GPS Garmin Astro 34

35. 35 R/C Signal Components ComponentFunction HiTec Optic 2.4 Transmits the commands for moving the fins and power to the fan HiTec- Optima 9 Receives the fan and fin movement information from the tramsmitter HiTec-HS-45HB Moves the directional fins per the signal received Telemetry Components ComponentFunction TeleMetrum transmits the telemetry data to the ground using Radio signal. TeleDongle Receives the GPS signal from the payload, and configures it into the laptop. Additional Payload Components ComponentFunction WiVid L-5801-B Transmits positioning video to Payload Pilot Garmin Astro 220 Assists in recovery of Payload - back up for GPS data E-Flite 300 EFLM1150 Adjustable speed fan for forward movement E-Flite 300 EFLM1150 powers all of the R/C controls on the Payload Horizon R/C landing gear Moves the camera to the desired view point for pilot control LOC Precision / Custom-made Custom vents to propel the Payload forward Custom Made Adjusts the air flow to turn the Payload on descent Payload Integration and Interfaces FRR – Payload Integration and Interfaces - 2 of 3

36. FRR – Payload Integration and Interfaces - 3 of 3 Payload Integration and Interfaces Component Frequencies ComponentLocationFrequencyWattageRange HiTec Optic 2.4Payload2.4 GHz390 mA1 Mile RC Optima 9Payload2.4 GHz AFHSS325 mA1 Mile WiVid L-5801-BPayload5.8 GHz500 mW2 Miles TelemetrumPayload 300-348 MHz 391-464 MHz 782-928 MHz 25 mA1 Mile Garmin Astro DC 40 AV Bay 5 Miles 36

37. FRR – Summary of Verifications – Payload TestProceduresStatus Drop TestThe vented chute will be tested from 250’ for flight stability and responsiveness to pilot commands. Planned Battery Connection TestThe batteries are connected to the various subsystems to test for functionality Complete GPS Location Test (GPS Unit)GPS is tested in various locations for verification of accuracyComplete Altitude Test (GPS Unit)GPS unit is taken to various heights to test for accuracyComplete Speed Test (GPS Unit)GPS unit is moved at various speeds for verification of accuracy Complete Flight Path Test (GPS Unit)GPS unit’s flight path is tested during the drop test to verify accuracy Complete GPS Location Test (Garmin Astro) GPS is tested in various locations for verification of accuracyComplete Altitude Test (Altimeter)Altimeter is taken to various heights to test for accuracyComplete R/C Transmitter and Receiver Operating Distance Test R/C Transmitter and Receiver are taken to their furthest operating distance to verify that the will operate at over 1 mile Complete Thrust TestThe payload is placed on a scale and has its thrust steadily increased to verify that it can propel the payload in flight Complete Wiring TestThe subsystems are connected to corresponding wire connections to test if each responds accordingly Complete Stress TestThe payload is run for an hour to verify that it can withstand the stresses of flight Complete Camera TestCamera images are compared to known ground features to ensure that the camera is functioning Complete Final TestThe completed payload is tested for functionalityPlanned Summary of Verifications - Payload 37

38. FRR – CDR Feedback Items CDR Feedback Items Feedback Items and Resolution: Calculate the KE for each section of the vehicle. Added to the FRR and also the Milestone Fly Sheet. Describe the release mechanism in greater detail. Added to the FRR and also added to this presentation. Ensure that the main does not deploy at apogee ejection event. The team has tested and verified that the shear pins will hold the main in place until the ejection event for the main occurs. Describe the algorithm that controls the UAV Our UAV is controlled remotely from the ground through an RC controller. How far will the UAV drift in a 20 mph wind from its ideal release point. The team has decided to alter the design by using a standard round but vented parachute. This will significantly reduce any chance of the payload landing outside the 2500’ perimeter. In addition, to reduce this landing range, the team calculated that in a 20 mph wind, the payload should not be released until 3400 feet. Describe the mechanism that turns the UAV. More information was added to the FRR, and also this presentation, regarding the entire payload fan and directional fin system. The team is still testing the deflection of the fins to determine how much force is created. 38

39. 39 Thank you! Can we answer any of your questions?