P07110 – Vertical Test Stand

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Concept Review

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Last year, a Senior Design team designed and built a horizontal rocket test stand. Many useful lessons were learned from this effort and there exists the potential for improvement with this design. We have been given the task to improve upon the current horizontal stand and data acquisition system, as well as the challenge to design and build a vertical test stand.

Some problems that have been encountered:• The data acquisition system is extremely time consuming to set

up • The calibration and rail systems do not work as efficiently as

they could and need to• The orientation of the rocket does have an effect on its

performance, so a vertical test stand is essential

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• We went to a closed linear bearing for better support• We performed analysis to verify that the rails would not deflect too much

� ¾” rails are sufficient• The current rod connecting the rocket and load cell is susceptible to

buckling� Using a thin-walled structural shape would solve this problem (i.e. If a

1”x1”x0.0625” thick aluminum square section is used, the maximum length for a200lbf load is 130”.)

• Data Acquisition system will be more efficient and easy to use• Ignition system will be controlled by three simple switches

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• Temperature readings at the fuel grain are necessary for other METEOR teams

• The plan is insert K thermocouple wires between the steel rocket body and the fuel grain

• Temperatures within this region are not expected to be beyond the limits of these thermocouples

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• Vertical Thrust Reading• Lateral Force• Plume Removal• Option for Roll Movement• Acceleration Readings on Rocket Body• Rocket must be restrained safely• Pressure & Temperature Readings• Simple Set Up• Need Amplifiers for Sensors• “Plug & Go” Data Acquisition System/Terminal

Blocks

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Rails on Rails

Orthogonal Frame

Ethan2

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Ball-Bearing

Axis PivotTube

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Single Cantilever

Gimbal

Double Cantilever

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A B C D E F G H IEthan1 Ethan2 Brian1 Brian2 Brian3 Kevin1 Kevin2 Kevin3 Mike1

(Benchmark)Rails on Rails

Orthagonal Frame

Axis Pivot Ball-Bearing TubeSingle

CantileverGimbel

Dual Cantilever

Selection Criteria Rating Rating Rating Rating Rating Rating Rating Rating Rating

Axial Force Measurement 0 0 0 0 0 0 - + 0

Lateral Forces 0 + 0 + + 0 - + -

Plume Removal 0 0 0 0 0 + + + 0

Safety 0 + + - + + - - 0

Ease of Construction/Use 0 + + + - - + 0 +

Torsional Force 0 0 0 - + + 0 + 0

Ability to be Modified for Different Rocket Sizes 0 - - 0 - - + + +

Cost 0 0 + 0 - + + 0 +

Sum +'s 0 3 3 2 3 4 4 5 3

Sum 0's 8 4 4 4 2 2 1 2 4

Sum -'s 0 1 1 2 3 2 3 1 1

Total Score 0 2 2 0 0 2 1 4 2

Rank 7 2 2 7 7 2 6 1 2

Continue? No Yes Yes No No Combine No Combine Revise

Concepts for Vertical Stand

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Gimbal & TubeCombination

Thrust Bearing Cone

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Selection Criteria Weight Rating Weighted

Score

Rating Weighted

Score

Rating Weighted

Score

Rating Weighted

Score

Rating Weighted

Score

Axial Force Measurement 15% 3 0.45 2 0.30 5 0.75 1 0.15 5 0.75

Lateral Forces 15% 3 0.45 2 0.30 4 0.60 1 0.15 4 0.6

Plume Removal 5% 3 0.15 3 0.15 3 0.15 3 0.15 3 0.15

Safety 25% 3 0.75 1 0.25 5 1.25 1 0.25 4 1

Ease of Construction 5% 3 0.15 4 0.20 2 0.10 5 0.25 2 0.1

Ease of Use 5% 5 0.25 3 0.15 4 0.20 2 0.10 4 0.2

Torsional Force 15% 0 0.00 0 0.00 3 0.45 0 0.00 2 0.3Ability to be Modified for Different Rocket Sizes 10% 1

0.103

0.302

0.203

0.305

0.5

Cost 5% 3 0.15 5 0.25 1 0.05 5 0.25 2 0.1

Continue?

BConcepts for Vertical Stand

FH I AAC

Yes

Total Score

E2 Orthagonal Frame

Gimbal with Tube Dual Cantilever Thrust Bearing

Cone

2.45

Rank 3 4 1

No No Yes

3.70

5 2

1.90 3.75

No

1.60

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Amplifier and Power Regulator Circuits

Battery Packs

Sensor Plugs Power Switches RS232

Future RS232Op-Amp Power

Sensor Power

Sensor Plugs Future Sensor PlugsRS232

Inside The “Box”

Faceplate

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Input from Load Cell

Output to A/D Converter

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Oxidizer Purge

Ignition

12 V12 V Power for Purge and Oxidizer solenoids

12 V

RL Circuit for Ignition

Power for Ignition

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Item Notes Budgeted CostElectrical Plugs and Connectors Connects sensors on horizontal and vertical stands to DAQ. $50.00Custom PCB Boards Connects sensors on horizontal and vertical stands to DAQ. $100.003 x USB or Serial DAQ Units Interface between the test stand sensors and the computer(s). $100.001-3 x Older Laptop Computer(s) Reads data from the DAQs. Hope to get these donated if possible. $1,200.00Misc. Electrical Components Restistors, capacitors, inductors, and ICs used in the DAQ circuits. $30.00

500 lbf Load Cell Already have this item from last year. $0.004 x 25 lbf Load Cells Needed for lateral force measurements. $2,000.00K Type Thermocouple Wire For temperature mearsurements on the rocket body. $60.00Thermocouple Amplifiers / Junctions Transforms the thermocouple signals into something readable by DAQ. $300.00Pressure Sensors METEOR project already has these. $0.00

Rails / Bearings for Horizontal Stand Materials to improve horizontal test stand for more testing. $650.00Universal Joint Provides freedom of motion in the vertical test stand. $250.00Bearings Reduces friction in the movement of vertical test stand. $300.00Shaft Coupling Provides the capability to test with or without roll capability. $100.00Metal Stock Needed to build the structure of final test stand. $1,200.00Metal Cutting Tools Cutting tools the ME machine shop does not have but are needed. $75.00

Total: $6,415.00

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