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TEAM ROCKET:
CRITICAL DESIGN
REVIEW 2010
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Table of Contents
I.
II.
III.
IV.
V.
Summary of CDR Report .......................................................................................................... 3
Changes Made Since PDR......................................................................................................... 3
Criteria ....................................................................................................................................... 4
Activity Plan ............................................................................................................................ 25
Conclusion ............................................................................................................................... 26
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Team Summary
Team Name: Team Rocket
Location: Clear Lake High School
Team Official:
-Cynthia Wood
Mentors:
-Lee Spinner
-Harold Larson
Launch Vehicle Summary
Length: 85.75”
Diameter: 4.02”
Body Tube Material: Kraft Phenolic
Fin Count: 3
Fin Material: G10 Fiberglass
Motor: Plugged K550
Recovery subsystem: The rocket will use a dual deploy system with redundant
altimeters. Black powder ignited using low current electric matches will be used as
ejection charges.
Payload will be held in the nose cone and upper section of the rocket.
There will be two electronics bays: one containing the payload and one containing the
recovery subsystem.
Payload Summary
The scientific payload will include a vortex tube with two thermocouples that will take
readings of the temperature in vents at the sides of the rocket. The nose cone will direct
airflow into the vortex tube.The thermocouples will have to measure the temperatures of
the air exiting the two different vents of the vortex tube; a basic Arduino system will be
used to measure and record these temperatures changes. The Arduino will be
programmed with a timer so that every temperature sent back to it by the
thermocouples has a corresponding time. The Arduino will then transfer the
temperatures sent to it by the thermocouples into voltages between 0 and 5 volts, so it
can ‘understand’ the data it is being sent. It will be programmed to transfer the voltages
back to a temperature that humans can understand and record this temperature.
II) Changes made since PDR
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Team Rocket changed the motor choice again, to one with a higher average
thrust and higher impulse so it will have more stability off the rail
The nose cone design has also been altered to avoid drag and because
funneling the air into the piping for the vortex tube was thought to be
unnecessary.
The team added an extra fin to maximize the stability of the rocket.
A GPS tracking device was added.
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III) Vehicle Criteria
Design and Verification of Launch Vehicle
Mission Statement
The team’s goal is to safely and successfully launch the rocket to an altitude of
approximately one mile while carrying the scientific payload, a vortex tube. The team’s
rocket will use a plugged K500 motor, and will safely return to the ground using a dual
deploy system- a drogue chute will deploy at apogee, and a main chute at 700 feet.
During the ascent stage of the team’s flight, a ducted nose cone will feed air into a
vortex tube, and the temperatures of the air as it exits the two vents of the tube will be
measured and recorded. The team hopes to use this data to determine whether a
vortex tube can be successfully operated by the air moving relative to a rocket.
Launch System:
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Nose cone Public Missiles - PNC-3.90 - Plastic nose cone, Material: Polystyrene
PS
o Nose shape: Hollow Ogive, Len: 14.0000 In., Dia: 4.0000 In. Wall
thickness: 0.1250 In.
Body Tube: Public Missiles Ltd. - PT-3.9 - Airframe tube, Material: Kraft phenolic
o OD: 4.0200 In. , ID: 3.9000 In.
o Three Total with lengths of 16”, 28”, and 24”
o 1” body tubes will be glued to the center of each coupler to serve as
placeholders.
Bulkhead Public Missiles - BP-3.9 - Was BP-06, Material: Birch (four, two
surrounding each coupler section)
Tube coupler: Public Missiles Ltd. - CT-3.90 - Coupler: tube, Material: Kraft
phenolic
o OD: 3.9000 In, Len: 7.0000 In.
o One for each electronics bay (payload and recovery)
Body Tube: Public Missiles Ltd. - PT-3.9 - Airframe tube, Material: Kraft phenolic
o OD: 4.0200 In. , ID: 3.9000 In. , Len: 8.0000 In.
Fin set: Public Missiles - FIN-C-09 - Fins, Material: G10 fiberglass
o Planform: trapezoidal, Root chord: 10.0000 In., Tip chord: 2.0000 In.,
Semi-span: 5.0000 In., Sweep: 8.0000 In., Mid-Chord: 6.4031 In. Misc:
Location: 0.8750 In. From the base of Body Tube: Thickness: 0.0930 In.
Profile: square
Centering ring Public Missiles - CR-3.9-2.1 - Was PML CR-14, Material: Aircraft
plywood (Birch)
o OD: 3.9000 In., ID: 2.2800 In., Len: 0.1880 In.
o Three surrounding motor mount tube
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Motor Mount Tube: Public Missiles Ltd. - PT-2.1 - Airframe tube, Material: Kraft
phenolic
o OD: 2.2800 In. , ID: 2.1500 In. , Len: 19.0000 In.
Boat Tail: Public Missiles - TC-3.9-3.0 - Transition (or tailcone) from 3.9 to 3.0,
Material: Urethane
o Solid transition: Fwd. Dia: 4.0200 In., Len: 1.7500 In., Rear Dia: 3.1300 In.
Font body insert: Len: 0.2500 In., OD: 3.9000 In., Rear body insert: Len:
0.0000 In., OD: 0.0000 In.
Recovery Subsystem
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Main Parachute: Public Missiles - PAR-96R - 96 in. nylon, Material: Rip stop
nylon
Shape: Round Dia: 96.0000 In., Spill hole: 12.0000 In.
Drogue Parachute: Public Missiles - PAR-18R - 18 in. nylon; drogue only,
Material: Rip stop nylon
o Shape: 8 sided Dia: 18.0000 In., Spill hole: 3.5000 In.
Altimeters- MiniAlt/WD, RRC2
Ejection Charges- Eight low current electric matches
o 8 inch tube: .77 grams of black powder
o 24 inch tube: 2.3 grams of black powder
Shock Chord : Kevlar, 30’ for each parachute
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System and Subsystem Requirements
Launch System
The motor will have to safely propel the rocket to an altitude of approximately one mile.
The body tube, nose cone, fins, and launch rail will have to function correctly so that
the rocket has a stable and successful flight. The recovery system will separate the
rocket into three parts (for more information on the recovery system, look at Recovery
Subsystem under the Scientific Payload).
Scientific Payload
The ducted nose cone will have to withstand great stresses during launch. It will have
to successfully direct airflow into the vortex tube. The thermocouple will have to
measure the temperatures of the air exiting the two different vents of the vortex tube,
and the BASIC stamp program will have to store these temperatures.
Motor Selection
Team Rocket plans to use a Cessaroni K500RL. The K500 will allow the rocket to
reach desired altitude and velocity during flight. Simulation results indicate that it will
attain an altitude of approximately 5500 feet. The extra altitude will allow us to take into
consideration extra weight and drag unaccounted for by the simulation software.
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Additionally, it provides enough initial thrust to allow the rocket to attain a stable
velocity (60.3312 ft/s) off a 8’ launch rail.
Manufacturing and Verification Plans:
Team Rocket plans to manufacture its rocket at Clear Lake High School during weekly
meetings. There will be several tests to ensure the proper function of the rocket and its
components. The vortex tube has been tested using an air compressor. Wind tunnel
tests may be conducted on the ducted nose cone to determine its effect on the rocket’s
drag. The altimeters will be tested for accuracy using a vacuum chamber, and tests will
be conducted to ensure that the ejection charges will safely and effectively separate the
rocket. Team rocket has built a scale model of the rocket, but unfortunately, was unable
to launch it due to scheduling conflicts and restrictions placed by JSC on when rockets
can be launched. Team rocket will launch the scale model on the weekend of January
29 and have the results ready for the presentation.
Major Milestone Schedule
November 19..................…PDR Presentation Slides and PDR Report posted on website
December 6-10..................................................Preliminary Design Review Presentation
January 14......................................................................................................Order Parts
January 17............................................................................................Build Scale Model
Week of January 30........................................Ground test altimeters w/ ejection charges
January 24……..…...........CDR Presentation Slides and CDR Report posted on website
January 29............................................................................................Test Scale Model
February 2-8..............................................................Critical Design Review Presentation
February 4-20.......................................................................Actual Rocket Construction
February 25....................................................Ground test ejection charges inside rocket
Week of March .....Conduct an extensive safety check on the rocket and its components
Week of March 6................................................Conduct a full scale test launch of rocket
March 21……........…......FRR Presentation Slides and FRR Report posted on website
March 28-3...........................................................Flight Readiness Review Presentation
April 12…………………..….......…….......…………………….............Travel to Huntsville
April 14-15………………..……......……........……………………......…......…Rocket Fair
April 16…………...……..……….....……………...……………….............….....…Launch
Day
May 9….……………...…Post-Launch Assessment Review (PLAR) posted on Website
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Integrity of Design and Materials
Nose Cone- Team rocket will use a standard PML 4” diameter plastic ogive nose cone.
Fins- Team rocket is using commercially available fins that are specifically designed for
high power rocketry.
Their delta shape is suited for high speed flight. They are
constructed out of G10 fiberglass, which can
withstand high temperatures and
pressures, and unlike plywood, will not delaminate at high speeds.
Body Tube- The entire body of the rocket is constructed out of Kraft Phenolic, which
can withstand the high stress of high power flight.
Birch plywood can withstand the stresses of high power flight. Team Rocket will use
1/4” thick plywood for the centering rings, bulkheads, and electronics and payload
mounting board. The bulkheads and centering rings are designed and manufactured for
high power flight
All major rocket components (fins, bulkheads, centering rings, electronics mounting
boards, couplers will be glued together using West Systems epoxy. To ensure that the
epoxy provides the strongest connection possible, all guidelines will be followed in the
mixing, application, and curing of epoxy. To properly mount the fins, the team will use a
through the wall method creating 7 contact points per fin between the main body tube
and motor mount with the fin. As for the bulk plates, they will be pressed about ¼”
beyond flush with the couplers and will be filled up to the top of the coupler creating a
¼” wall of epoxy retaining the bulk plate and the eye bolt. The motor will be retained
using a standard Aeropack 54mm motor retainer.
Recovery Subsystem
For our recovery system we plan to use a dual deployment method for reducing the
distance of drift. We will have an 18” drogue shoot that is contained in the lower half of
the rocket that will eject at apogee. Once deployed the rocket will drop to about 700ft
and once at the appropriate altitude it will deploy a main 96” parachute located in the
upper section of the rocket.
Altimeters and Ejection Charges
Team Rocket will use two independent altimeters for redundancy: the PerfectFlite
Minialt/WD and the Missileworks RRC2. Both are capable of single-handedly deploying
the drogue and main chute. The MiniAlt/WD is capable of of firing 10 e-matches. It has
multiple safety features, such as nonvolatile data storage and an audible continuity
check. It can also withstand up to two seconds of power loss. The RRC2 can fire both
a main and drogue chute, and also has an audible continuity check to ensure the proper
connection and function of e-matches. To prevent the over-pressurization of either
chamber, Team Rocket plans to use the RRC2’s deployment delay feature.
The team will use MJG Technology’s JTek electric matches to ignite the black powder
used in the recovery system. Both of the altimeters can supply the necessary 1A
required to fire the JTek match. According to calculations, our drogue chute
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compartment will require .77 grams of black powder and our main chute compartment
will require 2.3 grams of black powder. The black powder will be distributed in eight
compartments, four in each chamber, and four hooked up to each altimeter. The
altimeters will be stored in an electronics bay inside the coupler separating the main and
drogue chutes. They will be mounted on either side of a plank of birch plywood that fits
vertically inside the coupler. Team rocket will use 60’ of 1/4” diameter kevlar shock (30’
for each chute) chord to connect the parachutes, electronics bay, and body tube
sections.
PerfectFlite MiniAlt/WD
MissileWorks RRC2
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GPS Tracking
Team rocket will track the flight of the rocket in real time using an Altus Metrum
Telemetrum GPS device. The Telemetrum will transmit GPS data at 434.550 Mhz.
This device will be mounted inside the payload electronics bay. Our sponsor and one
of our mentors have HAM radio licences.
Parachutes
The team will use a 96” diameter, 12” spill hole parachute for its main chute and a 18”
diameter, 3.5” parachute for its drogue chute. Both are made out of ripstop nylon and
are suitable for high power flight.
Mission Performance Predictions
Criteria- The rocket will have to remain subsonic, attain an altitude of approximately
5280 feet, and remain stable throughout its flight. When interpreting the results of this
simulation, the team must take into account additional weight and drag not considered
by the simulation. The team has added an extra 2lbs of this to try and compensate for
some of this.
Rocksim Simulation Results
Engine selection
[K500-RL-None]
Simulation control parameters
 Flight resolution: 800.000000 samples/second
 Descent resolution: 1.000000 samples/second
 Method: Explicit Euler
 End the simulation when the rocket reaches the ground.
Launch conditions
 Altitude: 0.00000 Ft.
 Relative humidity: 50.000 %
 Temperature: 59.000 Deg. F
 Pressure: 29.9139 In.
Wind speed model: Calm (0-2 MPH)
 Low wind speed: 0.0000 MPH
 High wind speed: 2.0000 MPH
Wind turbulence: Fairly constant speed (0.01)
 Frequency: 0.010000 rad/second
 Wind starts at altitude: 0.00000 Ft.
 Launch guide angle: 0.000 Deg.
 Latitude: 0.000 Degrees
Launch guide data:
 Launch guide length: 96.0000 In.
 Velocity at launch guide departure: 60.3312 ft/s
 The launch guide was cleared at : 0.309 Seconds
 User specified minimum velocity for stable flight: 43.9993 ft/s
 Minimum velocity for stable flight reached at: 53.5534 In.
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Max data values:
 Maximum acceleration:Vertical (y): 1014.415 Ft./s/sHorizontal (x): 0.924
Ft./s/sMagnitude: 1014.415 Ft./s/s
 Maximum velocity:Vertical (y): 646.3443 ft/s, Horizontal (x): 2.9333 ft/s, Magnitude:
646.5629 ft/s
 Maximum range from launch site: 219.40680 Ft.
 Maximum altitude: 5492.91585 Ft.
Recovery system data
 P: Parachute Deployed at : 66.787 Seconds
 Velocity at deployment: 101.0704 ft/s
 Altitude at deployment: 699.90463 Ft.
 Range at deployment: -79.29469 Ft.
 P: Drogue Deployed at : 18.650 Seconds
 Velocity at deployment: 11.5207 ft/s
 Altitude at deployment: 5492.91580 Ft.
 Range at deployment: -219.40680 Ft.
Time data
 Time to burnout: 3.204 Sec.
 Time to apogee: 18.650 Sec.
 Optimal ejection delay: 15.446 Sec.
Landing data
 Successful landing
 Time to landing: 105.890 Sec.
 Range at landing: 26.79310
 Velocity at landing: Vertical: -17.5130 ft/s , Horizontal: 2.5495 ft/s , Magnitude: 17.6976
ft/s
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Illustration of Rocket
Simulated Motor Thrust Curve- K500RL
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Scale Model
Team Rocket’s scale model has been approximately scaled down by a factor of three
(depending on availability of parts). It is 28.8” long and will use an F39-6 motor. The
relative locations of the center of pressure and center of gravity have been kept
consistent. The team was unable to fit the vortex tube inside of the BT-80 body tube,
but a prototype of the ducted nose cone and a copper tube that channels air outside the
rocket have been included.
Illustration of Scale Model
Payload Integration
The payload is currently still being developed in concurrence with the rocket to assure
that any and all issues implementing the payload or integrating it into the rocket can be
minimized and resolved in the least amount of time possible, and so that the
components of the rocket and payload continue to be compatible with each other. The
payload is being constructed in such a way that all mission critical hardware and
equipment used in the experiment is being contained within a dedicated upper section
of the rocket that uses the same size body tube as the rest of the rocket. The
electronics (i.e. the Arudino board, altimeters) will be fastened and secured through the
use of screws to a basswood plank, which will be located in its own area within the
payload section. This design provides easy access to said hardware and equipment,
and therefore simplifies troubleshooting and any revisions, modifications,
reconfigurations, and repairs needed to the payload. The payload’s internal components
will be protected from thermal extremes by a thermally insulating material (or materials)
placed around the exhaust and intake tubes of the vortex tube and from stresses
caused by G-force and shock by being seated in a shock reducing configuration. The
integration of the payload and launch vehicle is relatively simple. The mounting of the
vortex tube inside the rocket is described fully in the Testing and Design of Payload
section. The air intake duct for the vortex tube in the top of the nose cone will be kept
as small as possible to minimize drag and possible instability issues.
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Launch concerns and operation procedures
1. Pack the parachutes and shock cord neatly into the body tube in order to prevent
tangling of the cord and parachute. The shock cord shall be mounted on an eye hook to
prevent it from being removed from the body of the rocket.
2. Integrate the payload with the rocket body, checking to make sure the air tubes are
clear of debris and that the output tube is in its correct place. Check to make sure the
altimeters are active and are “happy” (they beep consistently at timed intervals rather
than altitude data) and ejection charges have continuity, and that the Arduino board is
active and can record the temperature data.
3. Assemble the motor in the reloadable case, without the normal ejection charge.
4. Connect the GPS tracking device to the HAM radio and make sure it is functioning
properly, by checking to see if a receiver can get the signal.
5. Place the motor case in the motor mount, then use the motor retainer to keep the
motor in the motor mount.
6. Lubricate the launch rail.
7. Set the rocket on the launch pad, and make sure it is on the launch rail.
8. Clear the surrounding area of any and all objects and personnel in the range
specified by the RSO.
8. Set up the electric match, and do a continuity check.
9. When the rocket is ready to launch, announce the launch and perform a five-second
countdown.
The launch rail shall be lubricated to minimize friction, then the rocket shall be fixed on
the launchpad and connected to the rail. If there are any problems at any step of launch
preparation, then the rocket shall be disassembled in order to fix the problem, whether it
is a part getting stuck or the rocket being unable to close properly. If there is a problem
when the rocket is on the launchpad, then the current to the igniter shall be cut
immediately, and a wait time of at least sixty seconds will be observed so that the rocket
does not accidentally launch while someone is nearby.
The persons responsible for recovering the rocket shall check the surface of the rocket
for any damage that may prevent the vortex tube from functioning properly. The fins
shall be checked for damage, as shall the nose cone. The inside of the lower body tube
shall be checked for burn damage that may have resulted from the motor’s ignition.
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Safety and Environment (Vehicle and Payload)
Range Safety Officer: Kunal Abichandani
All NAR and TRA safety instructions, SLI guidelines, and the directions of the
RSO will be followed.
Failure Modes: We will use two different altimeters for redundancy, minimizing the risk
of failure of the recovery system. There will also be two parachutes, (the Drogue Chute
and the Main Chute) if the Drogue chute fails to deploy then the rocket would fall
significantly faster until the deployment of the Main chute. If both were to fail then the
rocket could be damaged upon landing.
Personnel Hazards: Improper instructions or care of the rocket may cause future harm
to team members or items around the rocket. Rocket parts that are flawed but are still
used can also cause future harm.
Hazard Mitigation: Precautions at the time of the launch include standing a fair
distance of at least 200 feet, waiting for the rocket to land before going to retrieve it, and
to make sure that all required conditions are safe for the rocket to be launched. Ground
tests will be performed to verify the performance of both the recovery systems and
payload sections for any adverse effects that may occur.
Launch Risks: Ejection charges might fail and cause the rocket to go ballistic, which
could cause injury or property damage.A motor malfunction may cause the rocket to
behave unexpectedly, which could be dangerous. Any type of structure failures such as
fins falling off would cause the rocket to become unstable, possible going ballistic.
Situations
Avoiding the Situations
Rocket may be unstable as it
leaves the launch rail.
Team Rocket will use the longest launch rail possible,
and use a motor with a high initial thrust to gain as
much velocity as possible during the initial moments of
the launch. The team will use simulation software to
ensure that the rocket is stable.
Malfunctions in the recovery
subsystem may prevent the
successful deployment of one
or both chutes.
The team will use two altimeters for redundancy.
These altimeters will be completely independent of
each other, and the proper functioning of either one of
them will be enough to deploy the parachutes. Ground
tests will be conducted to ensure the success of this
system.
Motor Malfunction.
Follow all instruction from the RSO, as well as all NAR
and TRA rocketry safety codes. Assemble motor
carefully.
Temperature data may not be
recorded properly by the
thermocouples or Arduino
board.
Ground test the vortex tube with an Arduino board and
thermocouples. Use fast response thermocouples.
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When receiving the parts for
the team’s rocket, there may
be problems with the delivery,
such as receiving the wrong
parts, receiving broken parts,
or delays.
Team Rocket will order parts as soon as possible to
allow for lost time caused by these potential problems.
A team member may be
absent from a meeting or
launch when their expertise is
needed, which could hinder
the progress of the project.
Team rocket will train its members as necessary to
ensure that any given task can be handled by more
than one team member. All team members will be
trained in critical procedures (such as launch
procedures) and these procedures will be written down
and stored in the appropriate place for easy access.
The SLI grant may not cover
all of Team Rocket’s costs.
The team will use fundraising to cover the extra costs.
Each team member may have to contribute money to
cover expenses not covered by fundraising or grant
money.
Winter break and other school
holidays will cut time for Team
Rocket to meet at the school.
Team Rocket has alternative meeting areas such as
the Harris County Freeman Memorial Library and team
member’s homes.
Possible burn bans which
may affect the team’s
launching schedule.
The team will plan ahead to allow for possible delays
caused by burn bans, and may have to pursue a more
aggressive launch schedule with the remaining time or
locate another launch spot while any burn bans are in
effect.
Nosecone may overheat
because of the exposure to
extreme temperatures created
as air enters the nose cone
and exits the vortex tube
Team rocket will include insulation around the copper
tubes and vortex tube, and will also buy a nosecone
suitable for high power rocketry.
Since the motor is high power
the risks increase significantly
with the black powder
Fire extinguishers would be posted at every 100 feet,
and the Team would take precautions listed in the NAR
and TRA safety, the Team would also ensure that the
motor and the black powder are in separate
departments.
Since the rocket’s length is
quite large, the landing might
break the rocket because the
rocket will be going too fast.
To ensure the possibility of this would diminish, Team
Rocket would have a dual deploy system-one at
apogee and one at 700 feet, and this would slow down
the rocket
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The shock cord and
parachute for the recovery
system might not ensure the
rocket’s safety.
Vortex tube malfunctions or
becomes disloged
Team Rocket will follow the suggestion of making the
recovery cord two-three times the rocket length and the
parachute around 105.1 inches by using this formula:
Diameter in inches = sqrt( rocket_weight_in_pounds *
0.454 ) * 39.6
Make sure vortex generator is securely fastened
to copper tube.
Make sure vortex generator is securely attached
to inside of body tube.
Be careful attaching any payload part to rocket.
Mitigation of Risks
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Always make sure that only the person who is using the tool is in the area when
the tool is in use, and that observers stand several feet away. Stay in a wellventilated area to prevent buildup of fumes.
Wear a dust mask to prevent the inhalation of harmful dust particles when
working with wood. Always wear a respirator when sanding fiberglass. Wear
long-sleeved clothing or gloves to help prevent irritation of the skin.
Do not touch the soldering iron, and make sure to wear thermal gloves when
using the iron. Since the soldering iron is extremely hot, do not set it down
anywhere but its stand. Wash hands after using soldering iron, since solder
contains lead, which is poisonous.
Cut away from self and do not hold object in hand when cutting. Make small, sure
incisions, not large quick ones.
When using power tools, always wear safety goggles. Keep hand several inches
away from area being drilled or sawed. Always put power tools’ switches in the
“lock” position when not in use to prevent their accidental start.
Mix epoxy with toothpicks or a similarly shaped tool.
Never hold wiring by the ends. Use pliers to help direct wiring and prevent
puncture wounds. Never touch wiring when circuit is on and wait several minutes
after power has been cut to ensure cool down of wires.
Do not light cigarettes near black powder and other flammable or explosive
materials. Keep explosives away from electrical equipment to prevent ignition
and make sure the area is well ventilated to prevent an explosion.
Do not use sandpaper on or near bare skin to prevent irritation. Wear a dust
mask to help prevent the inhalation of sawdust and other harmful particles.
Always have a range safety officer inspect the rocket before it is launched to
ensure that it is stable and won’t pose any safety risks.
Before launching a rocket, always perform a countdown and make sure everyone
in the launch area is aware of the upcoming launch.
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Follow all NAR guidelines regarding the establishment of a perimeter around the
launch pad inside which there is no person or object to prevent damage or injury
in the event of a misfire.
To brief all the members of Team Rocket, we will create a poster in Ms. Woods room
that states all of the materials and their safety regulations and what not to do. Each time
Team Rocket starts its meetings, The Safety Regulator would tell Team Rocket what
supplies and tools we are going to use and how to avoid the issues, and how to work
with those tools, going back to the poster, if any information is unclear. The team will
then be familiar with and will abide by all federal and local regulations concerning high
power rocketry, including but not limited to: range safety checks, FAA regulations. The
Range Safety Officer has the final say whether the rocket may be launched, and has the
right to delay and/or cancel launches due to safety violations.
The team will have a binder containing all of the required MSDS sheets at all meetings
and launches. The binder will be placed in a conspicuous location for easy access in
case of an emergency, with the knowledge of Team Rocket. Additionally, all MSDS
sheets and safety codes and procedures will be included in all plans and documents,
both official and unofficial.
Environmental Concerns:
-Rocket engine could explode and cause a fire on dry grass.
-A rocket with a motor improperly assembled could cause an explosion, starting a fire, and
injuring people around the launch site.
-Missing rockets that are lost after launch or fly too far could land and start fires.
-Any rocket debris that happens to fall off during flight could land in local rivers or streams.
-Rocket motors disposed of improperly could harm local plants and animals.
-Missing rockets that are lost after launch or fly too far could land and harm plants and animals.
TRA High Power Rocket Safety Code
1. Only a person who is a certified flyer shall operate or fly a high power rocket.
2. Must comply with United States Code 1348, "Airspace Control and Facilities",
Federal Aviation Act of 1958 and other applicable federal, state, and local laws,
rules, regulations, statutes, and ordinances.
3. A person shall fly a high power rocket only if it has been inspected and approved
for flight by a Safety Monitor for compliance with the applicable provisions of this
code.
4. Motors
a. Use only certified commercially made rocket motors.
b. Do not dismantle, reload, or alter a disposable or expendable high power
rocket motor, not alter the components of a reloadable high power rocket
motor or use the contents of a reloadable rocket motor reloading kit for a
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purpose other than that specified by the manufacture in the rocket motor
or reloading kit instructions.
A high power rocket shall be constructed to withstand the operating stresses and
retain structural integrity under conditions expected or known to be encountered in
flight.
A high power rocket vehicle intended to be propelled by one or more high power
solid propellant rocket motor(s) shall be constructed using lightweight materials such as
paper, wood, plastic, fiberglass, or, when necessary, ductile metal so that the rocket
conforms to the other requirements of this code.
A person intending to operate a high power rocket shall determine its stability
before flight, providing documentation of the location of the center of pressure and
center of gravity of the high power rocket to the Safety Monitor, if requested.
Weight and Power Limits.
. Ensure that the rocket weighs less than the rocket motor manufacturer's
recommended maximum liftoff weight for the rocket motor(s) used for the flight.
During pre-flight inspection, The Safety Monitor may request documentary proof
of compliance.
a. Do not install a rocket motor or combination of rocket motors that will
produce more than 40,960 Newton-seconds of total impulse (4.448
newtons equals 1.0 pound).
Recovery.
. Fly a high power rocket only if it contains a recovery system that will return all
parts of it safely to the ground so that it may be flown again.
a. Install only flame resistant recovery wadding if wadding is required by the
design of the rocket.
b. Do not attempt to catch a high power rocket as it approaches the ground.
c. Do not attempt to retrieve a high power rocket from a place that is
hazardous to people.
Payloads
. Do not install or incorporate in a high power rocket a payload that is intended to
be flammable, explosive, or cause harm.
a. Do not fly a vertebrate animal in a high power rocker.
Launching Devices
. Launch from a stable device that provides rigid guidance until the rocket has
reached a speed adequate to ensure a safe flight path.
a. Incorporate a jet deflector device if necessary to prevent the rocket motor
exhaust from impinging directly on flammable materials.
b. A launching device shall not be capable of launching a rocket at an angle
more than 20 degrees from vertical.
c. Place the end of the launch rod or rail above eye level or cap it to prevent
accidental eye injury. Store the launch rod or rail so it is capped, cased, or
left in a condition where it cannot cause injury.
Ignition Systems
. Use an ignition system that is remotely controlled, electrically operated, and
contains a launching switch that will return to "off" when released.
19
a. The ignition system shall contain a removable safety interlock device in
series with the launch switch.
b. The launch system and igniter combination shall be designed, installed,
and operated so the liftoff of the rocket shall occur within three (3)
seconds of actuation of the launch system. If the rocket is propelled by a
cluster of rocket motors designed to be ignited simultaneously, install an
ignition scheme that has either been previously tested or has a
demonstrated capability of igniting all rocket motors intended for launch
ignition within one second following ignition system activation.
c. Install an ignition device in a high power rocket motor only at the launch
site and at the last practical moment before the rocket is placed on the
launcher.
Launch Site.
. Launch a high power rocket only in an outdoor area where tall trees, power lines,
and buildings will not present a hazard to the safe flight operation of a high power
rocket in the opinion of the Safety Monitor.
a. Do not locate a launcher closer to the edge of the flying field (launch site)
than one-half the radius of the minimum launch site dimension.
b. The flying field (launch site) shall be at least as large as the stated in
Table 1.
Launcher Location
. Locate the launcher more than 1,500 feet from any occupied building.
a. Ensure that the ground for a radius of 10 feet around the launcher is clear
of brown grass, dry weeds, or other easy-to-burn materials that could be
ignited during launch by the exhaust of the rocket motor.
Safe Distances
. No person shall be closer to the launch of a high power rocket than the person actually
launching the rocket and those authorized by the Safety Monitor.
a. All spectators shall remain within an area determined by the Safety
Monitor and behind the Safety Monitor and the person launching the
rocket.
b. A person shall not be closer to the launch of a high power rocket than the
applicable minimum safe distance set forth in Table 2.
Launch Operations.
. Do not ignite and launch a high power rocket horizontally, at a target, or so the rocket's
flight path goes into clouds or beyond the boundaries of the flying field (launch site).
a. Do not launch a high power rocket if the surface wind at the launcher is
more than twenty (20) miles per hour.
b. Do not operate a high power rocket in a manner that is hazardous to
aircraft.
Launch Control.
. Launch a high power rocket only with the immediate knowledge, permission, and
attention of the Safety Monitor.
a. All persons in the launching, spectator, and parking areas during a
countdown and launch shall be standing and facing the launcher if
requested to do so by the Safety Monitor.
20
b. Precede the launch with a five (5) second countdown audible throughout
the launching, spectator, and parking areas. This countdown shall be
given by the person launching the rocket, the Safety Monitor, or other
flying site operating personnel.
c. Do not approach a high power rocket that has misfired until the safety
inter-lock has been removed or the battery has been disconnected from
the ignition system, one minute has passed, and the Safety Monitor has
given permission for only a single person to approach the misfired rocket
to inspect it.
TABLE 1: LAUNCH SITE DIMENSIONS
Installed Total
Impulse
(N-sec)
Equivalent Motor
Type
Minimum Site
Distance
(feet)
Equivalent
Distance
(miles)
160.01 - 320.00
H
1,500
.28
320.01 - 640.00
I
2,500
.50
640.01 - 1280.00
J
5,280
1.00
1280.01 - 2560.00
K
5,280
1.00
2560.01 - 5120.00
L
10,560
2.00
5120.01 - 10240.00
M
15,480
3.00
10240.01 20480.00
N
21,120
4.00
20480.01 40960.00
O
26,400
5.00
TABLE 2: SAFE DISTANCE
Installed Total
Impulse
(N-sec)
Equivalent Motor
Type
Minimum Safe
Distance
(feet)
Complex
Minimum Safe
Distance (feet)
21
160.01 - 320.00
H
50
100
320.01 - 640.00
I
100
200
640.01 - 1280.00
J
100
200
1280.01 - 2560.00
K
200
300
2560.01 - 5120.00
L
300
500
5120.01 10240.00
M
500
1,000
10240.01 20480.00
N
1,000
1,500
20480.01 40960.00
O
1,500
2,000
NAR High Power Rocket Safety Code
Certification. I will only fly high power rockets or possess high power rocket motors that
are within the scope of my user certification and required licensing.
1. Materials. I will use only lightweight materials such as paper, wood, rubber,
plastic, fiberglass, or when necessary ductile metal, for the construction of my
rocket.
2. Motors. I will use only certified, commercially made rocket motors, and will not
tamper with these motors or use them for any purposes except those
recommended by the manufacturer. I will not allow smoking, open flames, nor
heat sources within 25 feet of these motors.
3. Ignition System. I will launch my rockets with an electrical launch system, and
with electrical motor igniters that are installed in the motor only after my rocket is
at the launch pad or in a designated prepping area. My launch system will have a
safety interlock that is in series with the launch switch that is not installed until my
rocket is ready for launch, and will use a launch switch that returns to the "off"
position when released. If my rocket has onboard ignition systems for motors or
recovery devices, these will have safety interlocks that interrupt the current path
until the rocket is at the launch pad.
4. Misfires. If my rocket does not launch when I press the button of my electrical
launch system, I will remove the launcher's safety interlock or disconnect its
battery, and will wait 60 seconds after the last launch attempt before allowing
anyone to approach the rocket.
22
5. Launch Safety. I will use a 5-second countdown before launch. I will ensure that
no person is closer to the launch pad than allowed by the accompanying
Minimum Distance Table, and that a means is available to warn participants and
spectators in the event of a problem. I will check the stability of my rocket before
flight and will not fly it if it cannot be determined to be stable.
6. Launcher. I will launch my rocket from a stable device that provides rigid
guidance until the rocket has attained a speed that ensures a stable flight, and
that is pointed to within 20 degrees of vertical. If the wind speed exceeds 5 miles
per hour I will use a launcher length that permits the rocket to attain a safe
velocity before separation from the launcher. I will use a blast deflector to prevent
the motor's exhaust from hitting the ground. I will ensure that dry grass is cleared
around each launch pad in accordance with the accompanying Minimum
Distance table, and will increase this distance by a factor of 1.5 if the rocket
motor being launched uses titanium sponge in the propellant.
7. Size. My rocket will not contain any combination of motors that total more than
40,960 N-sec (9208 pound-seconds) of total impulse. My rocket will not weigh
more at liftoff than one-third of the certified average thrust of the high power
rocket motor(s) intended to be ignited at launch.
8. Flight Safety. I will not launch my rocket at targets, into clouds, near airplanes,
nor on trajectories that take it directly over the heads of spectators or beyond the
boundaries of the launch site, and will not put any flammable or explosive
payload in my rocket. I will not launch my rockets if wind speeds exceed 20 miles
per hour. I will comply with Federal Aviation Administration airspace regulations
when flying, and will ensure that my rocket will not exceed any applicable altitude
limit in effect at that launch site.
9. Launch Site. I will launch my rocket outdoors, in an open area where trees,
power lines, buildings, and persons not involved in the launch do not present a
hazard, and that is at least as large on its smallest dimension as one-half of the
maximum altitude to which rockets are allowed to be flown at that site or 1500
feet, whichever is greater.
10. Launcher Location. My launcher will be at least one half the minimum launch
site dimension, or 1500 feet (whichever is greater) from any inhabited building, or
from any public highway on which traffic flow exceeds 10 vehicles per hour, not
including traffic flow related to the launch. It will also be no closer than the
appropriate Minimum Personnel Distance from the accompanying table from any
boundary of the launch site.
11. Recovery System. I will use a recovery system such as a parachute in my
rocket so that all parts of my rocket return safely and undamaged and can be
flown again, and I will use only flame-resistant or fireproof recovery system
wadding in my rocket.
12. Recovery Safety. I will not attempt to recover my rocket from power lines, tall
trees, or other dangerous places, fly it under conditions where it is likely to
recover in spectator areas or outside the launch site, nor attempt to catch it as it
approaches the ground.
23
MINIMUM
DISTANCE
TABLE
Installed Total
Impulse
(NewtonSeconds)
Equivalent
High Power
Motor Type
Minimum
Diameter of
Cleared Area
(ft.)
Minimum
Personnel
Distance (ft.)
Minimum
Personnel
Distance
(Complex
Rocket) (ft.)
0 -- 320.00
H or smaller
50
100
200
320.01 -640.00
I
50
100
200
640.01 -1,280.00
J
50
100
200
1,280.01 -2,560.00
K
75
200
300
2,560.01 -5,120.00
L
100
300
500
5,120.01 -10,240.00
M
125
500
1000
10,240.01 -20,480.00
N
125
1000
1500
20,480.01 -40,960.00
O
125
1500
2000
Testing and Design of Payload Experiment
Our scientific payload consists of an experiment involving the measurement of
temperature differentials generated by an on-board vortex tube. A vortex tube takes in
pressurized air and turns it into a rapidly rotating vortex that separates warm air from
cool air. The tube has specially configured air ducts that direct warm air out one end of
the tube and cold air out of the other end. Our proposed science experiment will attempt
to use the velocity of the air relative to the rocket to generate the necessary air
24
pressure. Our nose cone will have an air duct to compress the air and feed it into the
vortex tube. Air exiting the vortex tube will be vented through holes in the body tube.
Thermocouples will be used to measure the temperature of the air exiting these vents at
regular time intervals, and these measurements will be recorded using an Arduino
Board. After the launch, the data will be analyzed to determine the velocities at which
the vortex tube was effective, i.e. when significant temperature differences between air
exiting from opposite sides of the vortex tube were recorded. The scientific payload will
be placed in body tube right behind the ducted nosecone. Two bulkheads will be used
in the rocket to hold the vortex tube in place. The vortex tube will held by friction while
the bulkheads themselves will be held to the inside of the rocket by epoxy. Outlets will
be made to allow the vortex tube’s output to vent out of the rocket. The system will be
continuously taking data and recording the values necessary to determine whether or
not the vortex tube is functioning properly. Team Rocket expects to obtain accurate
thermocouples with little margin of error. Team Rocket will be using thermocouples that
will record temperatures at a rate of 1 recording every 0.15 seconds. Since the ascent is
20 seconds long Team Rocket expects to get at least 130 temperature recordings.
Components
Ducted Nose Cone: Our nose cone will be modified by drilling a 1/4” diameter hole in
its tip, and epoxying a 1/4” diameter copper tube to the inside of this hole.
Copper Tubing: A 1/4” diameter copper tube will be attached to the inside of the nose
cone and will channel the air into a vertically placed vortex tube. Tubes will be placed at
each output on the vortex tube, and will be used to vent air out of the side of the body
tube. The copper tubes will have to be strong enough to withstand high g-forces placed
upon them during launch as well as high pressure air flowing through them.
Vortex Tube: The team will use an Exair model 3202 vortex tube. It is 4.13” long and
requires 2 SCFM of air at 20 PSIG to function.
Thermocouples: Unsheathed fine gauge microtemp thermocouples manufactured by
Omega Engineering will be used. These thermocouples have response times between
.02 and .004 seconds, so they will be suitable for our purposes.
Arduino Board: The Arduino board will be used to record the temperatures during flight
along with the corresponding times for those temperatures. The Arduino board will also
have to be compatible with the software in order to collect the data. The Arduino board
will also have several battery back-ups for safety. A socket will be on board that can be
connected to a computer for download.
Perfectflite MiniAlt/WD: This altimeter will log the altitude of the rocket as a function of
time throughout the rocket’s flight. This information will be used to determine the
velocity of the rocket at any given moment
Illustration of Payload
25
Verification of payload
For the scale model we have made a small cut in the nose cone that will be the opening
to one of the ends of the copper tube. The other end of the copper tube will be
connected to the vortex tube. The copper tube is bent perpendicular to the rocket at the
end so the hole will fit on the vortex tube. Since the vortex tube cannot fit in a BT-80,
we have put mass where the vortex tube and Arduino board would be for the scale test.
The vortex tube has been tested and has been found to be functioning. When 30 psi air
was pumped into the tube, an exit temperature of 2 degrees Fahreinheit was recorded.
The Arduino board has yet to be programmed.
Payload Concept Features and Definition
To Team Rocket’s knowledge, the experiment, which involves testing a vortex tube
inside a model rocket, has not been attempted before. A vortex tube has several
possible rocketry-related applications. It has no moving parts and uses no power, so
components which may overheat during launch can be cooled without any energy being
spent on the cooling mechanism. This will make it a very efficient air cooler. The
difference in the output temperatures could also be used to provide electricity by
powering a thermoelectric generator. A thermoelectric generator uses differences in
temperatures to generate electricity. There are many challenges associated with this
project. The nose cone and air vents on the side of the rocket will potentially effect the
flight of the rocket by creating drag and could have consequences that would endanger
the success of the experiment. To mitigate these risks, Team Rocket will have to
determine how the experiment will effect the overall flight of the rocket. Team Rocket
must also design a system that records the temperature of the air output by the vortex
tube and record the times during ascent at which the air temperature is recorded. The
Arduino board must be able to respond quickly and it must rapidly record the
information from the thermocouples.
Science Value
Team Rocket plans to test whether the rocket can accelerate to such a speed that
would allow the vortex tube to function. To generate a vortex and successfully vent two
airstreams of different temperatures, the vortex tube requires input air with a pressure of
at least 20 PSIG. The team believes that the force of the air going through a ducted
nosecone will be able to provide enough pressure for the vortex tube to work. Team
Rocket will be testing the functionality of the vortex tube by using thermocouples.
These thermocouples will measure the temperature of the air at both of the vortex
tube’s vents. This will tell the team recorders how effectively the tube is functioning; the
larger the temperature difference, the better the performance. If there is data indicating
significant temperature differences between the two vortex tube’s outputs during the
rocket’s flight, the team will consider the experiment a success. The team has ground
tested the vortex tube with an air compressor and it has been determined that it is
functioning properly. During the flight the team will also calculate the speed of the
rocket by using a Perfectflite Minialt/WD (this altimeter measures altitude as a function
of time). Using the results of the ground test and the calculated speed of the rocket, the
team can calculate the approximate inlet pressure at specific speeds. The team will try
26
to determine the relationship between the velocity of the rocket, measured
temperatures, and the inferred pressure inside the ducted nose cone. Team Rocket will
also check these values against the calculated values.
Experiment Process Procedures:
1. During the rocket’s flight the Arduino boards will actively take data from the
thermocouples and altimeters as it relates to the time of the flight.
2. This data will be stored in the Arduino memory.
3. Once the rocket is recovered, the data will be downloaded from the Arduino boards
and then analyzed in the manner specified above.
V) Activity Plan
Project Budget
Travel Budget
Rocket Parts:
Airfare (15 people)
$7430
Body Tube
$300.00
Nose Cone/ Tail Cone
$100.00
Fins
$35.00
Altimeters
$220.00
Meals:
Payload Equipment (Electronics
and Vortex Generator)
$300.00
Cost per Day (12 people,
$20 per person)
$240
Tools (donated)
$0
Total Meal Cost (5 days)
$1200
Parachutes
$150.00
Motor
$200.00
Outreach Project
$50.00
Shipping for Rocket Parts
$200.00
Epoxy
$50.00
Sandpaper
$40.00
Other Expenses:
Hotel Stay:
Total Hotel Cost (5
nights) +tax
$2030
27
Miscellaneous Expenses
Total
$150.00
$1,865
Total
$10,900
Since Team Rocket’s Budget wont be able to cover the cost of flight, each member will
have to pay for their own ticket, and will have to distribute their own money for the
Budget. The Airline (US Airways) would like Team Rocket to pay a $25 deposit by
February 2nd, and a $100 extra by February 28. The Hotel has already held 5 rooms for
Team Rocket, which is another main part of where the budget goes. The budget
consists of the NASA grant, corporate sponsorship, and Team Rocket’s pocket money.
The corporate sponsors pay for Team Rocket on the account that they would get
rewards for the different amount of money that is donated. There are five different
rewards, which will decide if Team Rocket will include the companies name on the
rocket, T-shirt, website and/or banner. Additionally, Team Rocket plans to conduct a
fundraising event at Clear Lake High School, such as a Talent show or a pageant. The
team may conduct door to door fundraising drives or fund raise with the use of selling
candy.
Timeline: Over the Winter Break Team Rocket met one or two times because it was
difficult to compensate for everyone schedules, therefore the building schedule has
been moved toward January. This is the only change in the Timeline.
VI) Conclusion
Team Rocket is staying committed and working hard to finish this project. The team is
making progress and is working to make this experiment as successful as can be.
Although the team was unable to have a scale rocket test by the deadline, Team
Rocket is working hard to complete it as soon as possible.