aerospace Article Vertical Wind Tunnel for Prediction of Rocket Flight Dynamics Hoani Bryson 1 , Hans Philipp Sültrop 1 , George Buchanan 1 , Christopher Hann 1, *, Malcolm Snowdon 2 , Avinash Rao 2 , Adam Slee 1 , Kieran Fanning 1 , David Wright 1 , Jason McVicar 3 , Brett Clark 1 , Graeme Harris 4 and Xiao Qi Chen 5 1 2 3 4 5 * Department of Electrical and Computer Engineering, University of Canterbury, Private Bag 4800, Christchurch 8140, New Zealand; hoani.bryson@gmail.com (H.B.); philipp.sueltrop@pg.canterbury.ac.nz (H.P.S.); georgebuchanannz@gmail.com (G.B.); a.slee@rocketlab.co.nz (A.S.); kieranfanning@hotmail.co.nz (K.F.); djwnz@hotmail.com (D.W.); clarkbab@gmail.com (B.C.) Rocket Lab Ltd., 3A Airpark Drive, Auckland 2022, New Zealand; malcolm.snowdon@gmail.com (M.S.); avinash.rao43@gmail.com (A.R.) School of Engineering and Information and Communication Technology (ICT), University of Tasmania, Private Bag 65, Hobart 7001, Australia; jason.j.mcvicar@gmail.com Engineering and Architecture Department, Christchurch Polytechnic Institute of Technology (CPIT), P.O. Box 540, Christchurch Mail Centre, Christchurch 8140, New Zealand; Graeme.Harris@cpit.ac.nz Department of Mechanical Engineering, University of Canterbury, Private Bag 4800, Christchurch 8140, New Zealand; xiaoqi.chen@canterbury.ac.nz Correspondence: chris.hann@canterbury.ac.nz; Tel.: +64-3-364-2987 (ext. 7242); Fax: +64-3-364-2264 Academic Editor: Raffaello Mariani Received: 1 February 2016; Accepted: 22 March 2016; Published: 29 March 2016 Abstract: A customized vertical wind tunnel has been built by the University of Canterbury Rocketry group (UC Rocketry). This wind tunnel has been critical for the success of UC Rocketry as it allows the optimization of avionics and control systems before flight. This paper outlines the construction of the wind tunnel and includes an analysis of flow quality including swirl. A minimal modelling methodology for roll dynamics is developed that can extrapolate wind tunnel behavior at low wind speeds to much higher velocities encountered during flight. The models were shown to capture the roll flight dynamics in two rocket launches with mean roll angle errors varying from 0.26˝ to 1.5˝ across the flight data. The identified model parameters showed consistent and predictable variations over both wind tunnel tests and flight, including canard–fin interaction behavior. These results demonstrate that the vertical wind tunnel is an important tool for the modelling and control of sounding rockets. Keywords: rocketry; canard actuation; vertical wind tunnel; flow quality; minimal modelling; roll dynamics; PD control; minimal modelling 1. Introduction A customized vertical wind tunnel has been built by the University of Canterbury (UC) Rocketry Research group [1] to test advanced control systems for application on small sounding rockets at subsonic and supersonic speeds. The common approach to designing and analyzing supersonic rockets is to quantitatively identify aerodynamics in a supersonic wind tunnel. However, these types of wind tunnels have large power requirements and are thus very costly, and usually have much shorter run times around 0.1–0.2 s [2]. Another approach to subsonic and supersonic flow analysis is Computational Fluid Dynamics (CFD). For example, canard–fin interactions have been well studied and modelled with CFD using Aerospace 2016, 3, 10; doi:10.3390/aerospace3020010 www.mdpi.com/journal/aerospace Aerospace 2016, 3, 10 2 of 27 wind tunnel data with relatively good predictions for the smaller angle of attacks [3,4]. However, the available comparisons in the literature are usually for static movements of the canards, so it is not clear how well the CFD models predict transient response in flight. Only very limited comparisons between flight and wind tunnel data have been published and are typically old NASA technical notes (e.g., [5–7]). The results of [6] show a reasonable prediction of pitch flight dynamics in terms of the frequency and phase responses of the pitching velocity per unit canard-fin-deflection frequency, however no roll comparisons are given and CFD analysis is not performed. Hence, although CFD analysis is commonly used for predicting rocket response in a wind tunnel, it has not been fully validated in flight. For the case of hypersonic flow, no vehicle has been flown long enough to obtain the data needed to improve the model accuracy and hypersonic wind tunnels only provide very short durations. Thus, in general, although CFD are useful for gaining trends on the expected flight response, they are not sufficiently accurate to design robust control systems and hence, extensive flight testing is usually required. In addition to CFD, there are a number of empirical approaches to modelling subsonic and supersonic rocket steady state aerodynamics. These methods are primarily based on NASA wind tunnel data and have been developed into engineering-level and intermediate-level aerodynamic prediction codes [7–9]. The models have also been extended to include canard interaction [10,11] but the experimental work is restricted to wind tunnels, so only considers steady state responses to fixed canard angles. Therefore, these methods are primarily for designing responsive canards in missiles and have not been used to understand actual rocket flight, where there are very fast movements and transient effects that often behave very differently to steady state response in a wind tunnel. This paper develops models of rocket roll dynamics that are first identified in the wind tunnel at low speeds and then validated on actual rocket launches at much higher speeds. This type of validation is unique in the literature as most other approaches do not go any further than wind tunnel evaluation [10,11]. The UC rocketry modelling and control methodology is to use a combination of dynamic subsonic wind tunnel testing and sounding rocket launches, to test qualitatively methodologies that have the ability to account for new dynamics in real-time. In other words, the approach is to model the rocket response in the wind tunnel during a control actuation that will be implemented in a flight. In addition, the damping or lift coefficients are not needed to be precisely known before launch, as any uncertainty from the wind tunnel tests, can be accounted for “on-the-fly” during the rocket flight. This UC rocketry control methodology has been successfully validated on several subsonic launches including an unstable rocket. For more details and results see [1]. The vertical wind tunnel has been a critical component to the success of UC Rocketry. In particular, it is important for obtaining quantitative information on the first few seconds of flight and can be used to estimate a full subsonic flight response using minimal modelling and parameter identification [12]. In addition, the vertical test section allows a much simpler and more accurate way of testing roll dynamics since the rocket can be suspended from a string. In a standard horizontal wind tunnel there is extra friction since an additional moving surface, like a bearing is required, so roll response is less realistic. For pitch and yaw dynamics, a gimbal frame [13] is used to allow three˝ of freedom control. This gimbal frame set up is important for debugging the avionics control hardware and software before flight. To test the stability of a fully fueled rocket, two sets of strings are horizontally attached from one edge of the wind tunnel to the center of mass of the rocket, which allows movement in one axis. Hence this vertical wind tunnel has a number of unique features tailored for rocket flight analysis. A typical closed-circuit subsonic horizontal wind tunnel has a motor powered fan which blows air around a looping tube [14]. The settling chamber usually contains a honeycomb flow straightener followed by several wire mesh screens to reduce turbulence [15]. Following the settling chamber, and just prior to the test section, is a contraction in the tube, which increases air speed. The test section is where the test article is placed and data is collected. A diffuser, which is a gradually diverging section of tube, is placed after the test section to decrease the velocity and thus decrease power requirements. Aerospace 2016, 3, 10 3 of 27 Curved vanes guide air around corners [16]. The disadvantage of using a closed-circuit is that more space and materials are required to construct the back loop of the circuit. The curved vanes are complex features and an additional expense in the construction. Heat exchangers are often needed to keep the Aerospace 2016, 3, 10 3 of 27 tunnel at the desired temperature, since the same air is being re-circulated through the circuit many times exchangers and may deviate significantly fromthe thetunnel ambient airdesired temperature [16]. since the same air is are often needed to keep at the temperature, re-circulated through the circuit many times and may deviate significantly from the[17] ambient Abeing key part of the UC Rocketry wind tunnel design is the use of bendy plywood due to its air temperature low cost, light weight[16]. and ease of constructing a circular cross section. Another advantage is that with A key part the UC Rocketry windto tunnel is the use of bendy plywood [17] is, dueifto its shape a circular shape lessof material can be used give design the same cross-sectional area. That the low cost, light weight and ease of constructing a circular cross section. Another advantage is that was changed to a square with side length equal to the circle’s diameter, the volume of space would be with a circular shape less material can be used to give the same cross-sectional area. That is, if the greatershape and was manufacturing simpler, but the maximum displacement of the rocket that can be achieved changed to a square with side length equal to the circle’s diameter, the volume of space in anywould direction, would be the samesimpler, as for the circle. Thus the extra power required in the be greater andstill manufacturing but the maximum displacement of the rocket that can fan to maintain a given flow inwould the square configuration is the effectively wasted. Thepower vertical orientation be achieved in anyvelocity direction, still be the same as for circle. Thus the extra required in the the fan to maintain a given flow velocity in the square configuration is effectivelywind wasted. The and also avoids large floor and building space requirements needed for horizontal tunnels, vertical orientation also avoids the large floor and building space requirements needed was assembled outdoors in a fenced enclosure further simplifying space allocation. A 15 kWfor fan was horizontal wind in tunnels, and was assembled outdoors a fenced enclosure further simplifying already in existence the Department of Electrical and in Computer Engineering at UC, so the wind space allocation. A 15 kW fan was already in existence in the Department of Electrical and Computer tunnel was essentially built around this fan which was at the base and sitting on the ground. Engineering at UC, so the wind tunnel was essentially built around this fan which was at the base This paper details some of the design and construction of the wind tunnel, methods for and sitting on the ground. overcoming swirl induced fan,design and presents a number of wind flightforresults. This paper details from some the of the and construction of the wind tunnel tunnel, and methods A key overcoming finding is that the verticalfrom wind canpresents provide realisticof roll predictions of flight rocketresults. flights well swirl induced thetunnel fan, and a number wind tunnel and beyond the finding wind speeds that can be generated by provide the current fan, and it provides an excellent A key is that the vertical wind tunnel can realistic roll predictions of rocket flights test wellfor beyond the wind speeds that can be generated the currentidentification fan, and it provides an excellent platform modelling rocket behavior and validatingbyparameter methods prior to flight. test platform for modelling rocket behavior and validating parameter identification methods For example, similar canard–fin interaction roll dynamics observed and identified in the prior windtotunnel flight. For example, similar canard–fin interaction roll dynamics observed and identified in the wind were also seen in the subsequent rocket flight. The results show that it is possible to create a low-cost tunnel were also seen in the subsequent rocket flight. The results show that it is possible to create a wind tunnel with excellent flow characteristics, and thus provides a very valuable research tool for low-cost wind tunnel with excellent flow characteristics, and thus provides a very valuable research modelling and control and of sounding rockets. rockets. tool for modelling control of sounding 2. Methodology—Wind Tunnel 2. Methodology—Wind Tunnel This section outlines the design and and manufacture processes of the customized This section outlines the design manufacture processes of the customizedvertical verticalwind windtunnel tunnel by UCasRocketry used by UC used Rocketry shown as in shown Figurein1.Figure 1. Figure 1. Customized tunnelfor for Sounding Rockets. Figure 1. Customizedvertical vertical wind wind tunnel Sounding Rockets. Aerospace 2016, 3, 10 4 of 27 2.1. Concept and Design To simplify the mounting of the rocket and to provide realistic roll response testing, the key design specification was to allow the mounting of the rocket vertically by suspending from the nose cone. Therefore a vertical suck-down wind tunnel was designed. Due to the significant vertical height requirement, the structure was stored outside in a caged enclosure adjacent to the High Voltage Lab, which meant that it needed to be weather resistant. The wind tunnel was designed in individual sections with bolted joints between each section. This approach simplifies fabrication and assembly as the components could be added to or taken from the wind tunnel as required. To create a sufficient quality of flow in the wind tunnel, aluminium honeycomb was used as a flow conditioner. This flow straightener was critical, particularly since winds affect the flow. Another important part of the design was utilizing an existing 1 m diameter, 15 kW fan and speed controller. Thus, the wind tunnel structure was effectively built around the fan. Since the test section was chosen to have a diameter of 0.6 m, wide angle diffusers were necessary to reduce the height of the wind tunnel. Bendy plywood was chosen for the structure as it was easy to form into the required shapes and significantly reduces manufacturing complexity and time, as compared to sheet-metal or fiberglass. The overall rocket wind tunnel design consisted of five main components: the flow conditioner, reducer, test section, diffuser and fan. These components are summarized as follows: ‚ ‚ ‚ ‚ ‚ The flow conditioner was a cylindrical section at the inlet of the tunnel with an internal diameter of 1.4 m and a 9 mm wall thickness. The flow conditioner holds the honeycomb and a mesh screen. The reducer took the flow from the 1.4 m internal diameter flow conditioner to the 0.6 m internal diameter test section. This contraction before the test section can also reduce velocity fluctuations and form a more uniform flow. The reducer walls were fabricated from 6 mm bendy ply so that it would fit into the smaller internal diameter of the test section. The test section was 2 m long, had an internal diameter of 0.6 m and was formed with 6 mm bendy ply. Due to the length and thin walls of the test section a 77 ˆ 38 mm length of pine was run down each side. The door for the test section was then framed using 75 ˆ 38 mm pine and 17 mm plywood. The frame was then removed and the door cut from the test section. At the bottom of the test section, a metal grille recessed into a plywood ring was placed to protect the fan. The diffuser transitioned the flow from the 0.6 m internal diameter test section to the 1 m internal diameter fan housing. The diffuser was also made from 6 mm bendy ply. The fan was 1 m diameter and had up to 15 kW available in power. The blade angle was at 23˝ so was left unchanged. The fan was on wheels, and could be adjusted to meet flush with the diffuser. In addition, the wind tunnel was secured to the wall of the High Voltage (HV) lab by a permanent scaffold and a winch was used to open a lid on the wind tunnel during operation and closed after testing to ensure no rain came into the wind tunnel and fan. 2.2. Construction 2.2.1. General Methods Bendy ply was used for the outer skin of the wind tunnel. Bendy ply is plywood with the two outer lamination grains aligned, and forming most of the thickness of the sheet. A thin central lamination bonded the two outer laminations together with the grain running perpendicular to the outer laminations. This property allows the plywood to be bent down to tight radii without the need for steam/heat, see Figure 2. Aerospace 2016, 3, 10 5 of 27 Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 5 of 27 5 of 27 Aerospace 2016, 3, 10 5 of 27 Figure 2. A sheet of 6 mm bendy ply. Figure of 66 mm mm bendy bendyply. ply. Figure2. 2. A A sheet sheet of The rest of the tunnel structure was constructed from standard 17 mm plywood and 75 × 38 mm Figure 2. A sheet of 6 mm bendy ply. The the tunnelstructure structure was constructed from on standard 17 plywood and 7575reduce ׈ 3838 mm pine.The The 17rest mm plywood was usedwas to form the flanges the ends of each section. To the rest ofof the tunnel constructed from standard 17 mm mm plywood and mm pine. The 17 mm plywood was used to form the flanges on the ends of each section. To reduce thethe amount ofThe material wastage, each flange was made up from four quarter flanges. The parts were pine. The 17 mm plywood was used to form the flanges on the ends of each section. To reduce rest of the tunnel structure was constructed from standard 17 mm plywood and 75 × 38 mm cut amount of material wastage, each flange was made up from quarter flanges. TheTo parts were using a jigsaw. sections of the wind tunnel fabricated byofforming individual outer skin pine. 17The mm plywoodeach was used towas form thewere flanges on four the each section. reduce thecut amount of The material wastage, flange made up from fourends quarter flanges. The parts were cut using a jigsaw. The sections of the wind tunnel were fabricated by forming individual outer skin material wastage, each flange was made up from The parts cut pieces theofflanges, and securing with wood screws, as four shown in flanges. Figure 3a. Once askin complete using amount ato jigsaw. The sections of the wind tunnel were fabricated by quarter forming individual outerwere pieces pieces toathe flanges, and securing with wood screws, as shown in Figureindividual Once outer a complete jigsaw. The sections ofwood the were wind tunnel fabricated by with forming skin had section had been the screws backed off, epoxy resin Westa3a. Systems 403 modifier to theusing flanges, andsecured, securing with screws, as were shown in Figure 3a. Once complete section section had been secured, the screws were backed off, epoxy resin with West Systems 403 modifier pieces to into the flanges, andand securing with wood screws, astightened. shown in Figure 3a. Once a complete was worked the gap, the screws were again The flange joints were then been secured, the screws were backed off, epoxy resin with West Systems 403 modifier was worked wassection worked gap, the andscrews the screws were off, again tightened. flange joints then had into been the secured, were backed epoxy resin withThe West Systems 403 were modifier reinforced with wovenwere fiberglass see Figure 3b. The 75 were × 38 mm pine was used add into the gap, and200 thegscrews again cloth, tightened. The flange joints then reinforced withto 200 g reinforced with 200 woven cloth, see Figure The 75 × The 38 mm pinejoints was were used to add was worked into gthe gap, fiberglass and the screws were again3b. tightened. flange then strength to the openings in the tunnel and provide mounting points for fixtures, see Figure 4. woven fiberglass cloth, Figure 3b. The 75provide ˆ 38 pine used tofixtures, add strength to the4. strength to thewith openings in the tunnel andcloth, mounting points see Figure reinforced 200see g woven fiberglass seemm Figure 3b.was The 75 ×for 38 mm pine was used toopenings add in thestrength tunnel and provide mounting points for fixtures, see Figure 4. to the openings in the tunnel and provide mounting points for fixtures, see Figure 4. (a) (a) (a) (b) (b) (b) Figure 3. (a) A sheet ofof 6 mm 200 ggwoven wovencloth clothreinforcement. reinforcement. Figure 3. (a) A sheet 6 mmbendy bendyply; ply;(b) (b)Flange Flange joint joint with with 200 Figure Figure 3. 3. (a) (a) A A sheet sheet of of 66 mm mm bendy bendy ply; ply; (b) (b) Flange Flange joint joint with with 200 200 g g woven woven cloth cloth reinforcement. reinforcement. Figure 4. 75 × 38 mm pine lengths used for reinforcement and framing. Figure 4. 75 × 38 mm pine lengths used for reinforcement and framing. Figure 38mm mmpine pinelengths lengths used used for for reinforcement reinforcement and and framing. framing. Figure 4. 4. 75 75 ˆ × 38 Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 6 of 6 of 27 27 6 of 27 6 of 27 The internal surface of the tunnel was not perfectly smooth due to the outer skin joints, Theinternal internalsurface surfaceofof the the tunnel tunnel was not not perfectly smooth due totothe outer skin joints, The perfectly smooth due the outer skin joints, The internal surface of manufacturing the tunnel was wasimperfections not perfectly due to the outer skin joints, screw-heads, excess glue and onsmooth the inner plywood face. Therefore, all screw-heads, excess glue and manufacturing imperfections on the inner plywood face. Therefore, allall screw-heads, excess glue and manufacturing imperfections on the inner plywood face. Therefore, screw-heads, excess and faces manufacturing imperfections thealso inner plywoodtoface. all internal surfaces andglue flange were sanded smooth. Iton was necessary fill Therefore, voids on the internal surfaces and flange faces were sanded smooth. It was also necessary to fill voids on the internal surfaces and flange faces were sanded smooth. It was also necessary to fill voids on the inner internal surfaces and flange faces were sanded smooth. It was also necessary to fill voids on the inner side of the skin; both along the seams and behind the screw heads. Poly-filler was applied to inner side of the skin; both along the seams and behind the screw heads. Poly-filler was applied to side of the both along the seams and behind the tunnel screw heads. Poly-filler was was applied to these inner sideskin; ofand the skin; both along the seams andinbehind the screw to these areas sanded back, so that the flow the wouldheads. not bePoly-filler disrupted, as applied shown in these areas and sanded back, so that the flow in the tunnel would not be disrupted, as shown in areas and sanded back, so that the flow in the tunnel would not be disrupted, as shown in Figure these areas Figure 5. and sanded back, so that the flow in the tunnel would not be disrupted, as shown in5. Figure 5. Figure 5. (a) (a) (a) (b) (b) (b) Figure 5. Poly filler (a) before sanding; (b) after sanding. Figure sanding;(b) (b)after aftersanding. sanding. Figure5.5.Poly Polyfiller filler (a) (a) before sanding; Figure 5. Poly filler (a) before sanding; (b) after sanding. 2.2.2. Flow Conditioner and Fan Grille 2.2.2. Flow Conditionerand and FanGrille Grille 2.2.2. Flow Conditioner 2.2.2. Flow Conditioner andFan Fan Grille The flow conditioner was constructed similarly to the rest of the tunnel but required some The flowconditioner conditionerwas wasconstructed constructed similarly similarly to the rest tunnel but some The flow to theledge restof ofthe the tunnel butrequired required some The flow conditioner was constructed similarly the rest of the tunnel some additional features. To support the honey comb, a 9 to mm was built for but it torequired rest upon. In additional features. To support the honey comb, a 9 mm ledge was built for it to rest upon. In additional features. To support the honey comb, a 9 mm ledge was built for it to rest upon. In addition, additionalafeatures. To support the honey comb, a 9 the mmflow ledgeconditioner. was built for to rest upon. addition, galvanized wire mesh was put across Theit square sheet In of addition, awire galvanized wire mesh was put across the flow conditioner. The square sheet ofcut a galvanized mesh was put across the flow conditioner. The square sheet of honeycomb was addition, a galvanized wire mesh was put across the flow conditioner. The square sheet of honeycomb was cut to fit the circular flow conditioner, see Figure 6. wasflow cut to fit the circular flow conditioner, see Figure 6. to honeycomb fit the circular conditioner, see Figure 6. honeycomb was cut to fit the circular flow conditioner, see Figure 6. Figure 6. Honeycombedge edge cut to to match internal diameter ofofflow conditioner. Figure internaldiameter diameterof flowconditioner. conditioner. Figure6.6.Honeycomb Honeycomb edge cut cut to match match internal flow Figure 6. Honeycomb edge cut to match internal diameter of flow conditioner. To prevent damage to the fan due to falling objects, a simple grille was fabricated. A plywood prevent damagetotothe thefan fandue dueto tofalling falling objects, objects, aa simple plywood ToTo prevent damage simple grille grillewas wasfabricated. fabricated.A plywood To prevent to the fan duematching to fallingthe objects, a simple grille was fabricated. AA plywood ring was cut withdamage an internal diameter internal diameter of the test section, and outside ring was cut with an internal diameter matching the internal diameter of the test section, and outside ring was cut with an internal diameter matching the internal diameter of the test section, and outside ring was cut with anthe internal the internal diameter the test diameter matching outer diameter diameter matching of the flanges. A recess was cutofalong thesection, inside and edgeoutside of the diameter matchingthe theouter outerdiameter diameter of of the the flanges. flanges. A recess was cut along the inside edge of of the diameter matching A recess was cut along the inside edge diameter matching thegrille flanges. A recess was cutinalong the flange using a routerthe to outer form adiameter ledge forofthe to rest on, as shown Figure 7. inside edge of thethe flange using a router to form a ledge for the grille to rest on, as shown in Figure 7. flange using a router totoform as shown shownin inFigure Figure7.7. flange using a router forma aledge ledgefor forthe thegrille grille to to rest rest on, on, as Figure 7. Wind tunnel grille to protect fan. Figure 7. Wind tunnel grille to protect fan. Figure 7. Wind tunnel grille to protect fan. Figure 7. Wind tunnel grille to protect fan. Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 7 of 27 7 of 27 3. Methodology—Rocket 3. Methodology—RocketSystems Systemsand andModelling Modelling 3.1. Improvements to Airframe and Avionics Stack Since the launch of Smokey at the end of 2014 [12], there have been a number of improvements improvements can be be seen in Figure 8, which shows the implemented to to the the rocket rocketsystems. systems.These These improvements can seen in Figure 8, which shows three launch configurations of the Smokey and Tasha the three launch configurations of the Smokey and TashaIIIIIIairframes. airframes.The TheSmokey Smokeyand and Tasha Tasha III airframe designs designsare areaerodynamically aerodynamically equivalent. Both designs identical canard, fin,length, tube equivalent. Both designs havehave identical canard, fin, tube length, tube diameter andcone nosegeometry. cone geometry. The main difference between the two airframes tube diameter and nose The main difference between the two airframes waswas the the manufacturing process for attaching the back fins. manufacturing process for attaching the back fins. Figure 8. Improvements (b)(b) Tasha III,III, launch 1; (c) Tasha III, Improvementsto toairframe airframeand andavionics avionicsstack. stack.(a)(a)Smokey; Smokey; Tasha launch 1; (c) Tasha launch 2. 2. III, launch Smokey used used Acrylonitrile Acrylonitrilebutadiene butadienestyrene styrene(ABS) (ABS)3D 3Dprinted printedfins fins and canards. The strength Smokey and canards. The strength of of these parts were appropriate for subsonic flight; however, they can be damaged on landing these parts were appropriate for subsonic flight; however, they can be damaged on landing resulting resulting in more spent the repairing the To airframe. To this overcome thisTasha problem, Tasha also used in more time spenttime repairing airframe. overcome problem, III also usedIII3D printed 3D printed but they were towith the airframe Two of3D theprinted Tasha canards III’s 3D fins, but theyfins, were laminated to laminated the airframe fiberglass.with Twofiberglass. of the Tasha III’s printed canards were damaged after its first flight, so on its second flight we used our supersonic were damaged after its first flight, so on its second flight we used our supersonic capable stack, which capable stack, canards. which has fiberglass canards. has fiberglass Cameras were were placed placed in in Tasha III allowing allowing the the recording recording of of flights flights to to provide provide an an insight Cameras Tasha III insight on on how how the on-board avionics were performing. Some holes were cut in the airframe, with one of the the on-board avionics were performing. Some holes were cut in the airframe, with one of the cameras camerasout placed out one side of the airframe by Smokey 10 mm. Smokey did an noton-board use an on-board it placed one side of the airframe by 10 mm. did not use camera,camera, so it hadsono had no camera holes. camera holes. UC Rocketry’s Rocketry’ssupersonic supersoniclaunches launchesrequire require a device to report where the rocket Both UC a device to report where the rocket lands.lands. Both Tasha Tasha III flights included the Spot Tracker to capability test its capability report landing locations. Spot III flights included the Spot Tracker to test its to reporttolanding locations. The SpotThe Tracker Tracker and cameras are the main reason the Tasha III vehicle was heavier than Smokey. The second and cameras are the main reason the Tasha III vehicle was heavier than Smokey. The second Tasha III Tasha III launch wasthan heavier thanTasha the first Tasha IIIbecause launch,the because thewere avionics were exchanged to launch was heavier the first III launch, avionics exchanged to the more the more robust supersonic capable avionics. robust supersonic capable avionics. Each launch of the Smokey Tasha III airframes had different properties. Between each Each launch of the Smokey andand Tasha III airframes had different properties. Between each launch, launch, changes weretomade to the internal avionics which affects theofmass of the vehicle. Changes in changes were made the internal avionics which affects the mass the vehicle. Changes in mass mass affect the torques and airspeeds experienced during flight. Table 1 summarizes the key affect the torques and airspeeds experienced during flight. Table 1 summarizes the key differences differences for each launch. between thebetween vehiclesthe for vehicles each launch. Aerospace 2016, 3, 10 8 of 27 Table 1. Vehicle comparisons between Smokey and Tasha III. Property Aerospace 2016, 3, 10 Mass Length Z-axis Property Inertia Smokey Tasha III Launch 1 Tasha III Launch 2 3.0 kg 1.52 m 3.47 kg 1.51 m 3.99 kg 1.51 m 0.00361 kg·m2 0.00393 kg·m2 Table 1. Vehicle comparisons between Smokey and Tasha III. 0.00311 kg·m2 Smokey Tasha III Launch 1 Tasha III Launch 2 Mass 3.0 kg kg 3D3.47 printed PLA with Fin material 1.52 3D Length m printed ABS 1.51 m 2 fibreglass Z-axis Inertia 0.00311 kg¨ m2 0.00361 kg¨ mlamination Fin material 3D printed ABS 3D printed PLA with fibreglass Canards 3D printed ABS 3D printedlamination ABS Canards 3D printed ABS 3D printed ABS with Avionics Subsonic capable Subsonic Subsonic capable withcapable spot tracker Avionics 8 of 27 Subsonic capable spot tracker kg with 3D printed3.99 PLA 1.51 m fibre glass lamination 0.00393 kg¨ m2 3D printed PLA with fibre glass lamination Fibre glass moulded Fibre glass moulded Supersonic capable with Supersonic capable with spot tracker spot tracker 3.2. Testing Rocket Stability 3.2. Testing Rocket Stability A major advantage of the vertical wind tunnel is that it is a straightforward way to test rocket A major advantage of Rocketry the vertical tunnelthe is that it is a procedure straightforward way stability: to test rocket stability before flight. UC haswind developed following for testing stability before flight. UC Rocketry has developed the following procedure for testing stability: ‚ Assemble the rocket with a dummy mass motor. •‚ Assemble the center rocket of with a dummy mass motor. Measure the mass by balancing the rocket on a beam less than 20 mm wide. Mark the • Measure the center of mass by balancing the rocket on a beam less than 20 mm wide. Mark the center of mass. center of mass. ‚ Fix a pipe clamp, with string tied securely to both ends of the pipe clamp to the rocket, at the • Fix a pipe clamp, with string tied securely to both ends of the pipe clamp to the rocket, at the measured center of mass. measured center of mass. Feed the string from both sides of the clamp through the two 4 mm holes on the sides of the wind ‚ • Feed the string from both sides of the clamp through the two 4 mm holes on the sides of the tunnel. Tie the string around the back of the wind tunnel, and tension the ropes to lift the center wind tunnel. Tie the string around the back of the wind tunnel, and tension the ropes to lift the of mass of the rocket as close as possible to the holes in the side of the wind tunnel. center of mass of the rocket as close as possible to the holes in the side of the wind tunnel. ‚ Attach the nose tip of the rocket to the vertical string. The purpose of this string is to prevent • Attach the nose tip of the rocket to the vertical string. The purpose of this string is to prevent an an unstable rocket from damaging the walls, or prevent the rocket from falling should the clamps unstable rocket from damaging the walls, or prevent the rocket from falling should the clamps slip. The vertical string should be taut only when the nose of the rocket is close to the wind slip. The vertical string should be taut only when the nose of the rocket is close to the wind tunnel walls. tunnel walls. ‚ Startthe thewind windtunnel, tunnel,and andcheck checkthe therocket rocketstraightens straightensat at15, 15,20 20and and30 30m/s. m/s. • Start Figure99gives givesaapicture pictureof ofaastability stabilitytest testset setup. up. Figure (a) (b) Figure 9. Stability set up (a) connection to string; (b) connection to center of mass of rocket. Figure 9. Stability set up (a) connection to string; (b) connection to center of mass of rocket. Since these tests were for roll control only, the exact margin of stability in terms of the number Since was thesenot tests were for roll control thethe exact of stability termsgeneral of the number of calibres, determined. The mainonly, aim of testmargin in Figure 9, was toinprove stabilityof calibres, was not The aim of thedetermination test in Figure of 9, was to prove general stability so so that it would bedetermined. safe to launch. Anmain experimental the center of pressure using this that it would be safe to launch. An experimental determination of the center of pressure using this method will be investigated in future work for pitch and yaw modelling. method will be investigated in future work for pitch and yaw modelling. Aerospace 2016, 3, 10 9 of 27 3.3. Rocket Roll Dynamics Modelling In both launches and all wind tunnel tests in this paper, only roll dynamics were investigated. This section outlines the modelling and parameter identification techniques used to understand and predict the rocket roll dynamics during flight. 3.3.1. Minimal Model The roll model is extended from a previously used model [12] which includes the effect of velocity on the damping and normal forces in the roll axis. Ignoring the yaw term in Equation (6) of [13] and lumping the parameter d into the coefficients of the roll fin angle and damping yields: . Ip p “ 1 2 ” α ı ρ v A βu f in ptq ´ p 2 v (1) where the definition of the parameters is given in the Notation. Expanding out Equation (1), and including the effects of disturbance and defining the roll angle gives the differential equation model: . 1 1 I p p “ ´ ρ v A α p ` ρ v2 A β pu f in ptq ` udist ptqq 2 2 . φ“p (2) (3) where udist ptq udist ptq lumps the effects of fin canard interaction, thrust offsets that may impart a roll and atmospheric effects into a single time-varying parameter. It is shown in the results section that when there are sudden fin movements, it’s critical to allow fast changes in the disturbance at these points to provide a good match to the data. To model these effects, the disturbance is written in the form: N ÿ udist ptq “ Yk Φk (4) k “1 Yk “ ud,k´1 ` pud,k ´ ud,k´1 q pt ´ Tk´1 q pTk ´ Tk´1 q (5) Φk “ Hpt ´ Tk´1 q ´ Hpt ´ Tk q (6) Hptq ” heaviside function, T0 , . . . , TN ” user defined time points (7) ud,0 , . . . , ud,N ” unknown constants identified from data (8) where 3.3.2. Parameter Identification To ensure the optimum possible model is obtained with good numerical parameter identifiability, a grid search is applied to the main parameters excluding the disturbance, which is identified using non-linear regression. This method was applied for both an open-loop model, where u f in ptq is measured directly by encoders on the rocket and a closed-loop model where u f in ptq is defined from a standard proportional derivative controller plus the addition of a pre-defined input. Mathematically these models are defined: Open-loop : Closed-loop : u f in ptq “ u f in, OL ptq ” fin movement measured from encoder u f in ptq “ u f in, CL ptq “ k p pRptq ´ φptqq ` k d pR1 ptq ´ pptqq ` uinput ptq (9) (10) where k p ” proportional gain, k d ” derivative gain Rptq “ pR0 ´ R1 qHpsinp2π f 0 tqq ` R1 (11) (12) Aerospace 2016, 3, 10 10 of 27 The reference function Rptq in Equation (12) is an alternating square wave of frequency f 0 (Hz) between the values of R0 and R1 . This function allows multiple step responses to be analyzed from wind tunnel tests and rocket flights. The function uinput ptq is set to 0 for the wind tunnel tests and the first flight, but is defined as a chirp function with varying amplitudes for the second flight to increase flight dynamics for a rigorous test of the model. The optimization is set up by first fixing the damping α and torque constant β. Two objective functions are defined: OL pUd q “ rφdata pt0 q ´ φOL pt0 q , . . . , φdata ptend q ´ φOL ptend qs Fα,β (13) CL pUd q “ rφdata pt0 q ´ φCL pt0 q , . . . , φdata ptend q ´ φCL ptend qs Fα,β (14) ‰T “ Ud “ ud, 0 , . . . , ud, N (15) φdata ptq ” measured roll angle, t0 , . . . , tend ” data time points (16) φOL ptq ” roll angle solution to Equations p2q – p9q for given α, β and Ud (17) φCL ptq ” roll angle solution to Equations p2q – p8q , p10q – p12q , for given α, β and Ud (18) where A range of values of α and β are then selected: <α “ tαmin ` k∆α, k “ 0, . . . , Nα u , < β “ β min ` k∆β, k “ 0, . . . , Nβ ( (19) For each α and β from the ranges in Equation (19), the open-loop and closed-loop identified disturbance values are defined: ÛOL d “ non-linear least squares solution to Equation p13q (20) ÛCL d “ non-linear least squares solution to Equation p14q (21) The final model parameters that best fit the data are then defined: ” ı OL XOL “ αOL , βOL , ÛOL : FαOL OL , βOL pÛd q “ d ” ı CL X CL “ αCL , βCL , ÛCL : FαCL CL , βCL pÛd q “ d min ˇ ˇ¯ ˇ OL OL ˇ mean ˇFα,β pÛd qˇ (22) min ˇ ˇ¯ ´ ˇ CL CL ˇ mean ˇFα,β pÛd qˇ (23) ´ tαP< α , βP< β u tαP< α , βP< β u Equations (22) and (23) represent a grid search over all the values in Equation (19), where for each pair of α and β a non-linear regression is performed to determine the corresponding disturbance values. This non-linear regression uses the command “lsqnonlin” in Matlab. 4. Results and Discussion 4.1. Wind Tunnel Flow Quality Measurements from a hot wire anemometer placed at various positions from the boundary showed that there are negligible boundary effects greater than 200 mm from the wall, with less than 5% reduction in wind speed at 100 mm from the wall. Since the diameter of the sounding rockets in this research are 80 mm with a 60 mm canard and fin radial distance, the outermost point of the rocket is 160 mm from the wall. Hence, the volume of the test section used in this research, has close to uniform flow. Most importantly, the results from the prediction of rocket flight roll response from wind tunnel derived parameters presented in the sections below, demonstrate that the test section has adequate flow quality for this research. this research are 80 mm with a 60 mm canard and fin radial distance, the outermost point of the rocket is 160 mm from the wall. Hence, the volume of the test section used in this research, has close to uniform flow. Most importantly, the results from the prediction of rocket flight roll response from wind tunnel derived parameters presented in the sections below, demonstrate that the test section has adequate Aerospace 2016, 3,flow 10 quality for this research. 11 of 27 4.1.1. Turbulence Intensity 4.1.1. Turbulence Intensity To demonstrate the quality of the flow over time, in the wind tunnel, a Kestrel 4500 wind To[18] demonstrate of the theedge flowatover time, inofthe tunnel, 4500 wind sensor was placedthe 200quality mm from the bottom the wind door in Figurea1.Kestrel This position was sensorthroughout [18] was placed 200 mm from the sensor edge atmeasures the bottom of the Figure 1.a This fixed the experiment. This every 2 door s andin outputs windposition speed was fixed throughout experiment. sensor measures every 2 s andwith outputs a wind speed measurement rounded the to the nearest 0.1 This m/s. A finer resolution wind sensor a higher frequency measurement rounded to the nearestsince 0.1 m/s. finer resolution sensor a higher frequency was not required for this analysis, windAspeeds less thanwind 0.1 m/s havewith a negligible effect on was not required In foraddition, this analysis, since wind speeds than 0.1 m/s have a negligible effect rocket dynamics. turbulence properties areless independent of the time scale so this teston is rocket dynamics. In addition, turbulence properties are wind independent of the time scaleper so this test adequate to characterize the turbulence intensity in the tunnel. The revolutions minute is adequate to characterize the turbulence intensity in the wind tunnel. (RPM) reference on the fan was set to a sequence of values defined by: The revolutions per minute (RPM) reference on the fan was set to a sequence of values defined by: RPM ref = 570,870,1100,1400,1650,1700 (24) [ ] RPMre f “ r570, 870, 1100, 1400, 1650, 1700s (24) Taking into account the controller time constant, the times when the fan reaches steady state Taking are: into account the controller time constant, the times when the fan reaches steady state are: TRPM = [100, 230,390,550, 718,858] (s) TRPM “ r100, 230, 390, 550, 718, 858s psq (25) (25) The measured wind speed is shown in Figure 10. At each steady state there are only very small The measured wind speed is shown in Figure 10. At each steady state there are only very small oscillations, showing that the flow is close to laminar. Figure 11a shows a plot of the RPM versus oscillations, showing that the flow is close to laminar. Figure 11a shows a plot of the RPM versus wind wind speed and Figure 11b plots the turbulence intensity Γ versus wind speed which is defined: speed and Figure 11b plots the turbulence intensity Γ versus wind speed which is defined: σ2 2(v) Γ(v) = σ pvq , σ ≡ standard deviation, v ≡ wind speed Γpvq “mean(v) , σ ” standard deviation, v ” wind speed mean pvq (26) (26) 2 wind speed (m/s) -1 wind speed (m s ) There is a correlation of 2R = 0.9999 for RPM versus wind speed, thus the fan controller is There is a correlation of R = 0.9999 for RPM versus wind speed, thus the fan controller is creating creating a very linear response. The turbulence intensity is very low and less than 0.04% over all a very linear response. The turbulence intensity is very low and less than 0.04% over all wind wind speeds tested. speeds tested. Figure 10. Kestrel) versus timetime for different revolutions per minute (RPM) Figure 10. Measured Measuredwind windspeed speed(from (from Kestrel) versus for different revolutions per minute values values in the fan. (RPM) in the fan. 12 of 27 12 of 27 12 of 27 mean wind speed (m/s) mean wind speed (m/s) turbulence intensity (m/s)(m/s) turbulence intensity Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 wind speed (m/s) wind(b) speed (m/s) (b) (a) (a) Figure 11. (a) RPM versus wind speed; (b) Turbulence intensity versus wind speed. Figure 11. (a) RPM versus wind speed; (b) Turbulence intensity versus wind speed. Figure 11. (a) RPM versus wind speed; (b) Turbulence intensity versus wind speed. 4.1.2. Swirl 4.1.2. Swirl 4.1.2.ItSwirl was noticed that in every airframe tested in the wind tunnel, there was a roll rate with the It was noticed that in every airframe tested in the wind tunnel, there was a roll rate with the canards set to 0. However, was not initially known what percentage was ofwas this aroll caused by It was that in itit every airframe tested in what the wind tunnel, there rollrate, rate with canards setnoticed to 0. However, was not initially known percentage was of this roll rate, caused bythe fin offsets the However, airframe orwas swirl the wind tunnel. Topercentage characterize theofswirl, several sets of canards setinto notin known what was thisseveral roll rate, fin offsets in 0. the airframe it or swirl ininitially the wind tunnel. To characterize the swirl, setscaused of aluminium fins were machined to provide a baseline where there was no fin offset. The fins were byaluminium fin offsetsfins in the airframe or swirl in thea wind tunnel. characterize swirl, several sets of were machined to provide baseline whereTo there was no finthe offset. The fins were made from two thin sheets of aluminium formed in a cross. These fins were attached to a steel pipe aluminium were to provide aformed baseline was fin offset. Thetofins were made made fromfins two thinmachined sheets of aluminium in where a cross.there These finsno were attached a steel pipe and by in tunnelin asashown shown inFigure Figure 12. Tests showed the roll rate from two thin sheets of aluminium formed cross. in These fins were attached to that a the steel pipe andsuspended suspended bystring string in the the wind wind tunnel as 12. Tests showed that roll rateand observed was highly dependent on the total diameter of the fins. For a diameter less than 100 mm, suspended by string independent the wind tunnel shown in Figure 12.fins. Tests showed that the rate observed was highly on theas total diameter of the For a diameter lessroll than 100observed mm, there was greater 300 mm mm thefins. rollrate rate verylow. low. This result suggests that there wasno noroll rollrate rateand and greater than 300 the roll very This result thatwas was highly dependent on the totalthan diameter of the Forwas awas diameter less than 100suggests mm, there the swirl is mainly isolated to a concentric ring between 100 and 300 mm from the centre of the wind the swirl is mainly isolated to a concentric ring between 100 and 300 mm from the centre of the wind no roll rate and greater than 300 mm the roll rate was very low. This result suggests that the swirl is tunnel. The was detailed analysis had diameter of 200 which maximized tunnel.isolated Thefin finset setathat that waschosen chosen detailed analysis had aadiameter 200 mm which maximized mainly to concentric ringfor between 100 and 300 mm from theof centre ofmm the wind tunnel. The roll rate. the roll rate. finthe set that was chosen for detailed analysis had a diameter of 200 mm which maximized the roll rate. Figure 12. Aluminium fin set up. Figure 12. Aluminium fin set up. The first test was to take a video of the 200 mm aluminium fin rocket for 5 min at the maximum The first test take aa video of mm aluminium fin for min at maximum wind speed 30was m/s to and visually count the 200 number revolutions work out average rate. The first of test was to take video of the the 200 mm of aluminium fintorocket rocket for 55the min at the theroll maximum wind speed of 30 m/s and visually count the number of revolutions to work out the average roll rate. The result was 87.0 deg/s which demonstrates there was certainly a relatively significant swirl in the wind speed of 30 m/s and visually count the number of revolutions to work out the average roll rate. The result was 87.0 deg/s which demonstrates there was certainly a relatively significant swirl in wind tunnel. To overcome this swirl, an egg crate was placed up to a height of 20 cm in a hexagon The result was 87.0 deg/s which demonstrates there was certainly a relatively significant swirl in the the shape on theTo grill at the bottom of thean wind just placed above the shown This wind tunnel. overcome this egg crate up to height of 20 cm in in 13. hexagon wind tunnel. To overcome this swirl, swirl, an eggtunnel, crate was was placed up fan, to aa as height of in 20Figure cm aa hexagon egg crate effectively provided additional flow straightener reducing it was near shape on the the grillatatthe the bottoman thewind wind tunnel, just above the as swirl shown in Figure 13.the This shape on grill bottom ofofthe tunnel, just above the fan,fan, asthe shown inasFigure 13. This egg fan which caused the swirl. Another video was then taken of the aluminium fin rocket and the egg crate effectively provided an additional flow straightener reducing the swirl as it was near the crate effectively provided an additional flow straightener reducing the swirl as it was near the fan average roll rate observed was 25.7 deg/s which is a 340% reduction in the swirl. There were also fan which caused the swirl. Another video was then of the aluminium fin the rocket and roll the which caused the swirl. Another video was then taken of taken the aluminium fin rocket and average severalroll periods where therewas was25.7 no roll rate.which is a 340% reduction in the swirl. There were also average rate observed deg/s rate observed was 25.7 deg/s which is a 340% reduction in the swirl. There were also several periods severalthere periods where waswhere no rollthere rate.was no roll rate. Aerospace 2016, 3, 10 Aerospace 2016, 3, 3, 1010 Aerospace 2016, 13 of 27 1327 of 27 13 of 13 of 27 Aerospace 2016, 3, 10 Figure13. 13.Egg Egg crate crate used used as Figure Egg crate used as aaa flow flowstraightener straightener reduce swirl. Figure 13. as flow straightenertoto toreduce reduceswirl. swirl. Figure 13. Egg crate used as a flow straightener to reduce swirl. To fully characterize the impact of the flow straightener with various wind speeds on the Tasha ToTo fully characterize the impact the flow straightener with various wind speeds Tasha To fully characterize the impact ofof flow straightener with various wind speeds onon thethe Tasha III fully characterize the impact ofthe the flow straightener with various wind III rocket, an uncontrolled airframe with the same dimensions as Figure 8b wasspeeds placedon in the the Tasha wind III rocket, an uncontrolled airframe with the same dimensions as Figure 8b was placed in the wind rocket, an uncontrolled airframe with with the same dimensions as Figure 8b was in theinwind tunnel. III rocket, anairframe uncontrolled airframe same Figure 8b placed was placed the wind tunnel. This was primarily usedthe to test thedimensions parachute as before implementing the controlled tunnel. This airframe was primarily used to test the parachute parachute beforeimplementing implementing the controlled This airframe was primarily used to test the parachute before implementing the controlled launch, so tunnel. This airframe was primarily used to test the before the controlled launch, so had slightly different back fins as a result of natural manufacturing variations, launch, so had slightly different back fins as a result of natural manufacturing variations, had slightly back fins as a result of natural variations, butfor was essentially launch, sodifferent had slightly different backspecific fins as a manufacturing result of natural manufacturing variations, but was essentially the same rocket. The rocket in Figure 8b was not available this test as but was essentially the same rocket. The specific rocket in Figure 8b was not available for this test but was essentially the same rocket. The specific rocket in Figure 8b was not available for this test as as the same rocket. The specific rocket in Figure 8b was not available for this test as the back fins were the back fins were damaged on landing due to swinging into rocky ground with a large gust of thewind, back fins were damaged on landing due to swinging into rocky ground with a large gust the back fins were damaged on landing due swinging into rocky ground with a large gust of of damaged on landing due to swinging into rocky ground with a large gust of wind, just as it landed. just as it landed. wind, just as it landed. wind, just as it landed. The canards logging was wasenabled. enabled.Figure Figure 14a plots rate The canardswere wereset settoto00and androll roll rate rate data data logging 14a plots thethe rollroll rate The canards wereset settoto0with 0with andand roll rate rate data datathe logging was Figure 14a plots the roll rate The canards were and roll logging wasenabled. enabled. Figure 14a plots the rate response for two without the flowstraightener. straightener. The RPM inputs used in each response for twoexperiments experiments and without flow The RPM inputs used inroll each response for two experiments with and without flow straightener. The RPM inputs used in each response for two experiments with and without the flow straightener. The RPM inputs used in each experiment are plotted in Figure 14b. Figure 14a shows that the flow straightener has significantly experiment are plotted in Figure 14b. 14a shows that the flow straightener has significantly experiment are plotted inFigure Figure 14b. Figure 14a shows that flow has significantly experiment are plotted inthe 14b. 14a shows that the the flow straightener has significantly reduced the roll rateofofthe rocket. TheFigure mean absolute absolute steady state roll rate two experiments reduced the roll rate rocket. The mean steady state rollstraightener ratefor forthe the two experiments reduced the roll rate of the rocket. The mean absolute steady state roll rate for the two experiments reduced the roll rate the ofthe the rocket. The mean absolute steady statein rate15. for the two experiments were plotted against corresponding mean steady steady state velocity Figure were plotted against corresponding state velocity inroll Figure 15. were plotted againstthe thecorresponding corresponding mean mean steady steady state were plotted against state velocity velocityininFigure Figure15. 15. (a) (a) (b) (b) Figure 14. Tasha III results with and without flow straightener (a) RPM inputs;(b) (b) roll rate response. (a) with Figure 14.14. Tasha (a)RPM RPMinputs; inputs;(b) (b)roll rollrate rate response. Figure TashaIIIIIIresults results withand andwithout without flow flow straightener straightener (a) response. ss ss mean |p -1 | (deg/s) ss | (deg/s) mean mean |p|p mean|p | (deg ) -1s -1 ) ss s|ss mean|p | (deg/s) (deg ss mean|p | (deg s ) Figure 14. Tasha III results with and without flow straightener (a) RPM inputs; (b) roll rate response. mean wind speed (m/s) mean wind speed (m/s) Figure 15. Mean steady state roll rate with and without flow straightener. wind speed (m/s) Figure roll rate with andwithout withoutflow flowstraightener. straightener. Figure15. 15.Mean Meansteady steady state statemean with and Figure 15. Mean steady state roll rate with and without flow straightener. Aerospace 2016, 3, 10 14 of 27 As2016, a final Aerospace 3, 10analysis of these experiments, the effective steady state fin offset is computed14using of 27 known values of the damping α and torque constant β of the airframe as discussed in the next section. Specifically, at steady state, the roll rate p&, so assuming that u fin , ss = 0 , the disturbance in As a final analysis of these experiments, the effective steady state fin offset is computed using Equation (2) can be solved to yield: known values of the damping α and torque constant β of the airframe as discussed in the next section. . Specifically, at steady state, the roll rate p, so assumingαthat p u f in,ss “ 0, the disturbance in Equation (2) u fin offset = ss (27) can be solved to yield: βαp vssss u f in o f f set “ (27) βvss where “ss” refers to the steady state value for each steady state wind speed vss which is computed where “ss” refers to the steady state value for each steady state wind speed vss which is computed from the average of the velocity during the steady state period of interest. This analysis allows a from the average of the velocity during the steady state period of interest. This analysis allows characterization of the swirl in terms of the effective canard angle. Note that the canards and extra a characterization of the swirl in terms of the effective canard angle. Note that the canards and extra fin area in Tasha III, as well as a larger diameter airframe would cause significantly more damping in fin area in Tasha III, as well as a larger diameter airframe would cause significantly more damping Tasha III than in the aluminium fin rocket of Figure 12. Therefore, it’s reasonable to assume that the in Tasha III than in the aluminium fin rocket of Figure 12. Therefore, it’s reasonable to assume that very small amount of swirl remaining after the addition of the flow straightener would have a the very small amount of swirl remaining after the addition of the flow straightener would have negligible effect on the Tasha III rocket. The aluminium fin rocket also has a very low moment of a negligible effect on the Tasha III rocket. The aluminium fin rocket also has a very low moment of inertia, so the threshold of torque required to overcome the damping in the fins, would be much inertia, so the threshold of torque required to overcome the damping in the fins, would be much lower lower in this rocket and thus much more sensitive to swirl than Tasha III. in this rocket and thus much more sensitive to swirl than Tasha III. A plot of u versus vss for both experiments, is given in Figure 16. This figure shows that A plot of u f infinooffset f f set versus vss or both experiments, is given in Figure 16. This figure shows that in in the of flow no flow straightener, the swirl a greater the lower velocities. the casecase of no straightener, the swirl has ahas greater effecteffect at theatlower velocities. This This resultresult was was expected since the vertical component in the windwould tunnelnot would not be sufficiently high to expected since the vertical component in the wind tunnel be sufficiently high to overcome overcome the horizontal induced from However, the swirl. with However, withstraightener the flow straightener the horizontal componentcomponent induced from the swirl. the flow there was therelittle wasdifference very littlein difference in the finall offset over allwhich velocities, which provides further very the fin offset over velocities, provides further evidence thatevidence there is that there swirl is negligible swirlSubtracting in this case.the Subtracting curves in Figure 16 provides a measure negligible in this case. two curvesthe in two Figure 16 provides a measure of the swirl in −1, there is an average of theof swirl in termscanard of the offset. effective canard Afteris20 of in about 2° of terms the effective After 20 m¨offset. s´1 , there anm·s average of about 2˝ of swirl the wind swirl inThis the value wind will tunnel. will need be subtracted from future tests to better tunnel. needThis to bevalue subtracted fromtofuture tests to get a better estimate of get the atrue fin estimate the prediction. true fin offset for flight prediction. offset for of flight wind speed (m/s) Figure Figure 16. 16. The The equivalent equivalent fin fin offset offset versus versus velocity velocity representing representingswirl swirlin inthe thewind windtunnel. tunnel. 4.2. 4.2. Tasha TashaIII—Launch III—Launch11 Tasha Tasha III III from from Figure Figure 8b 8b was was launched launched from from Kaitorete Kaitorete Spit Spit on on 22 22July July2015. 2015. The The aim aim of of this this launch was primarily to test the new avionics stack and fibreglass rear fins. In the previous flight launch test the new avionics stack and fibreglass rear fins. In the previous flight of of Smokey [12], finswere were3D 3Dprinted. printed.The Thereason reasonfor forthe the fibreglass fibreglass was was to provide further Smokey [12], thethefins further strengthening strengthening suitable suitable for for supersonic supersonic flights flights in in future future research. research. In In addition, addition, to to gain gain some some useful useful data data from the launch, a PD controller was implemented during flight in both the thrust and coast periods. from the launch, a PD controller was implemented Since Since the the vehicle vehicle was was finished finished only only days days before before the the launch, launch, there there was was not not sufficient sufficient time time to to do do aa full full Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 15 of 27 15 of 27 wind tunnel test, analysis of data and rigorous testing of gains. The only wind tunnel test performed was the stability test of Section 3.2. wind tunnel test, analysis of data and rigorous testing of gains. The only wind tunnel test performed For the flight, the gains chosen were k p = 1, kd = 0.1 , which were known to give a reasonable was the stability test of Section 3.2. response from previous wind tunnelwere testing with the were gimbal frameto[12]. reference For the flight, the gains chosen k p “of1,Smokey k d “ 0.1, which known giveThe a reasonable was chosen to previous be a series of responses starting at 0° forwith a pre-determined amount afterreference clearingwas the response from wind tunnel testing of Smokey the gimbal frame [12]. The launch to guide, by an alternation between and 15° every second. As clearing a precaution, since chosen be a followed series of responses starting at 0˝ for a−15° pre-determined amount after the launch this was the first with thebetween avionics, a ˝maximum limitsecond. of 6° was in since each this canard. guide, followed by flight an alternation ´15 and 15˝ every As a enforced precaution, was ˝ Unfortunately, there a significant fin limit offsetof in the airframe which was greater than the the first flight with thewas avionics, a maximum 6 was enforced in each canard. Unfortunately, canards compensate for with maximum so onlythan about s of oscillatory data was there wascould a significant fin offset in thethis airframe whichlimit, was greater the1canards could compensate obtained. However, this data set was sufficient to identify parameters and thus analyse the rocket for with this maximum limit, so only about 1 s of oscillatory data was obtained. However, this data set roll response. was sufficient to identify parameters and thus analyse the rocket roll response. The apogee apogeefor forthis thisflight flightwas was522 522 time apogee s and the maximum velocity The m,m, thethe time to to apogee waswas 10.210.2 s and the maximum velocity was −1 −1 ´ 1 ´ 1 was . The wind speed was very low day, varying between 1 and 2 m·s 97 m¨97s m·s . The wind speed was very low onon thethe day, varying between 1 and 2 m¨ s on on the the ground. ground. The flight flight was was successful successful and and the the rocket rocket safely safely recovered recovered apart apart from from aa couple couple of of broken broken canards canards that that The were easily replaced. Figure 17 shows video stills from the ignition, take-off, onboard footage and were easily replaced. Figure 17 shows video stills from the ignition, take-off, onboard footage and parachute recovery. recovery. parachute Figure recovery. Figure 17. Tasha Tasha III launch 1 stills (a) ignition; (b) take-off; (c) onboard video; (d) recovery. Since there there was Since was only only one one step step response response from from 0° 0˝ to to −15°, ´15˝the , thecontrol controlreference referenceisismodeled modeledbybya asingle singleHeaviside Heavisidefunction functionand andthe theproportional proportionalderivative derivative(PD) (PD)control controlcommand commandisisdefined: defined: u = max{min{uˆ , u }, u }H (t − T ) cmd cmd max min u , umin u Hpt ´ TPD ucmd “ max tmin tûcmd , umax PD q umax “u uˆcmd = k p ( R(t ) − φ(t )) + kd ( R1′(t ) − p(t )) ûcmd “ k p pRptq ´ φptqq ` k d pR ptq ´ pptqq (29) (29) R(t )“=RR00´−pR ( R00´−RR11qHpt ) H (t´−TTPD −1q 1) Rptq PD ´ (30) (30) 6 π 6π ´6 π ´15π , u , u“ = −6, π ,R0 R “ 0, R1R“= −15π, , kkp “= 1, 1, min 180 0 = 0, 1 p 180= 180min 180 180 180 max (28) (28) “ 0.1, 0.1, TTPD= “ 0.42 kkdd = 0.42 PD (31) (31) The Heaviside function in Equation (28) provides a delay of TPD after the launch detect to ensure TPD after The Heaviside in Equation (28) provides a delayFor of launch the launch detect to the rocket is well clearfunction of the launch guide before starting control. detection to occur, the on ensureaccelerometer the rocket is on well of the launch guide starting control.2 For to board theclear rocket’s vertical axis needsbefore to detect a consistent g orlaunch higher detection acceleration occur,0.2the on board accelerometer onsensor the rocket’s vertical needs to detect a consistent 2 g or over s. This requirement prevents errors or motoraxis misfires from triggering launch control. highertheacceleration over 0.2thes. rocket’s This requirement sensor errors or motor misfires from Once launch is detected, vertical axisprevents acceleration is transformed to the earth reference triggering launch control. Once to thedetermine launch isthe detected, rocket’s axisguide. acceleration is frame and then double integrated rocket’s the height abovevertical the launch Using the transformed to the earth reference and then double integrated to determine the rocket’s height two conditions of launch detectionframe and launch guide clearance enables safe conditions for actuating above the launch guide. Using the two conditions of launch detection and launch guide clearance the rocket’s canards. enables for actuating thekey rocket’s canards. Thesafe rollconditions rate data including all the points of the launch are given in Figure 18, where t “ 0 The rollto rate including allThe the control key points the launch Figurewas 18, 2where t =the 0 corresponds 1.5data s before launch. wasof started whenare thegiven rocketinheight m above 4corresponds m launch guide. However, due to the specified 0.2 s delay in the launch detect, the actual altitude to 1.5 s before launch. The control was started when the rocket height was 2 m above when control started was 7 m which was 0.63 s after lift-off. Aerospace 2016, 3, 10 16 of 27 Aerospace 2016, 3, 10 16 of 27 the 4 m launch guide. However, due to the specified 0.2 s delay in the launch detect, the actual the 4 m2016, launch guide.started However, to thewas specified 0.2 s lift-off. delay in the launch detect, the 16 actual altitude when control was 7due m which 0.63 s after Aerospace 3, 10 of 27 altitude when control started was 7 m which was 0.63 s after lift-off. 200 200 control starts control starts true launch true time 100 launch time 0 100 end of thrust end of thrust parachute deployment parachute deployment 0 -100 -100 launch detect launch -200 detect -200 -300 -3000 2 4 0 2 4 6 8 10 12 8 10 12 time 6 (s) time (s) Figure 18. Roll rate response for Tasha III launch 1 including key points in the launch. Figure III launch launch 11 including including key key points points in in the the launch. launch. Figure 18. 18. Roll Roll rate rate response response for for Tasha Tasha III The commanded and encoder measured canard roll angle are defined as the average of all The commanded encoder measured canard inputs which is and standard in the literaturecanard [19]: roll angle are defined as the average of all The commanded and encoder measured canard roll angle are defined as the average of all canard canard inputs which is standard in the literature [19]: inputs which is standard in the literature [19]:+ cmd + cmd + cmd cmd ucmd = cmd1 + cmd2 + cmd3 + cmd4 (32) 4 cmd 3 ` cmd 4 ucmd = cmd11 ` cmd22 ` (32) 3 4 ucmd “ (32) 4 enc1 + enc2 +4 enc3 + enc4 uenc = enc + enc + enc + enc (33) 4 enc33 ` enc44 enc11 ` enc22 ` uuenc = (33) (33) enc “ 44 The data is analyzed from just before control starts up to a couple of seconds before the The data isisanalyzed from justjust before control startsstarts up to aup couple seconds thebefore parachute The data analyzed before to a of couple of before seconds the parachute deployment. Thefrom roll rate and fincontrol angle u enc which is computed from Equation (33) deployment. The roll rate and fin angle u which is computed from Equation (33) using the encoder enc fin angle u parachute deployment. The roll rate and is computed from Equation (33) enc which using theenc encoder outputs enc1 , …, enc for eachin canard, in Figure where time is 4 plotted outputs are Figureare 19,plotted where the time is19, reset to 0.the Note that 1 , . . . , enc4 for each canard, enc , … , enc using the encoder outputs for each canard, are plotted in Figure 19, where the time is for some the thrust period all thrust of the4 coast period all of thethe canards are set at maximum reset to 0.ofNote that for someand of1the period and all coast period alltheir the canards arevalues set at ˝ ˝ reset to Note some of the roll thrust period allisofaThe the period all canards are at their values of 6°,negative. yet staysisand negative. reason is there isthe a fin offset which is of 6 ,maximum yet0.the rollthat ratefor stays Therate reason there fin coast offset which is larger than the 6 set that their maximum values of 6°, yet the roll rate stays negative. The reason is there is a fin offset which is larger than the that the canards the canards can6°compensate for. can compensate for. larger than the 6° that the canards can compensate for. (deg/s) roll roll raterate (deg/s) measured canard angle (deg) measured canard angle (deg) 6 (a) (a) 6 4 4 2 2 0 0 -2 -2 -4 -4 -6 -60 2 4 6 8 0 2 time4 (s) (b) time (s) 6 8 (b) Figure 19. Data for analysis (a) Roll rate response; (b) Measured canard angle from encoders. Figure 19. Data for analysis (a) Roll rate response; (b) Measured canard angle from encoders. Figure 19. Data for analysis (a) Roll rate response; (b) Measured canard angle from encoders. To identify the torque constant β, damping α and disturbance udist (t ) from the roll model of To identify the torque constant β, damping α and disturbanceuudist(ptq the roll model of ) from To identify the torque constant β, damping α and disturbance from the roll model of dist tas Equations (2)–(8), the first step is to specify the range in the β and α values given Equations (2)–(8), the first step is to specify the range in the β and α values as givenin inEquation Equation(19). (19). Equations (2)–(8), the first step is to specify the range in the β and α values as given in Equation (19). These These ranges ranges are are defined: defined: These ranges are defined: <α “ t1, 2, . . . , 60u , < β “ t5, 5.5, 6.5, 7, . . . , 15u (34) Aerospace 2016, 3, 10 17 of 27 ℜα = {1, 2,…, 60} , ℜβ = {5,5.5, 6.5, 7,…,15} (34) The next step is to define the time values for the disturbance changes in Equation (7). These Aerospace 2016, 3, 10 17 of 27 values are equally spaced in both the thrust period and the coast period of the data which are denoted in Figure 19a. Let Nthrust be the number of time points in the thrust period and Ncoast the The next step is to define the time values for the disturbance changes in Equation (7). These values number of time points in coast period. The values in Equation (7) are defined: are equally spaced in both the thrust period and the coast period of the data which are denoted in T points in the thrust period and Ncoast the number of time Figure 19a. Let Nthrust be the number of time Ti = i thrust , i = 1,…, Nthrust (35) points in coast period. The values in Equation N (7) are defined: thrust Tthrust (Tend, −i “ Tthrust 1, . .).,, Njthrust i “ i+ j TNthrust + j = TTthrust = 1, …, N coast Nthrust N coast (35) (36) pT ´ Tthrust q TNthrust ` j in “ the Tthrust ` j end “ 1, . .is . , set Ncoast (36) Since there are no dynamics canards during coast,, jN to the minimum possible coast N coast value Since whichthere obtains a reasonable match in the coast period. found empirically that higher are no dynamics in the canards during coast,ItNwas coast is set to the minimum possible values than 2 do not help identifiability due to the lack of dynamics during period, and value value which obtains a reasonable match in the coast period. It was foundthis empirically thata higher ofvalues 1 gavethan a consistently large error. Therefore setdynamics to 2 for all the analysis on this launch. 2 do not help identifiability due to N the lackisof during this period, and a valueThe of 1 coast value alsoerror. minimized andNcoast it was found that alsolaunch. a goodThe choice. gave aofconsistently Therefore is set to 2 for all the analysis on this value N thrust waslarge Nthrust = 2 was of N was also minimized and it was found that N = 2 was also a good choice. Higher values thrust Higher values gave a progressively better match to thrust the data in the thrust period as would be gave a progressively better match to the data in the thrust period as would butgave were expected, but were much slower computationally. Specifically, the values frombeNexpected, thrust = 2, …,6 much slower computationally. Specifically, the values from Nthrust = 2,¨ ¨ ¨ ,6 gave virtually identical virtually identical results with an improvement in the match to the roll angle˝ by less than 0.1°. More results with an improvement in the match to the roll angle by less than 0.1 . More importantly, the importantly, the identified damping remained unchanged and the torque constant only varied by a identified damping remained unchanged and the torque constant only varied by a maximum of 0.05. maximum of 0.05. The results for Nthrust = 2 and N coast = 2 are defined: The results for Nthrust = 2 and Ncoast = 2 are defined: αbest ,OL = 8.5, βbest ,OL = 10.0 αbest,OL “ 8.5, β best,OL “ 10.0 (37) (37) μ|µp|,OL ≡ mean absolute error in roll rate = 9.82 deg/s ” mean absolute error in roll rate “ 9.82 deg{s (38) (38) μµ|φ||,φOL|,OL≡ ”mean rate =“1.51 meanabsolute absoluteerror error in in roll roll angle 1.51 deg/s deg{s (39) (39) | p|,OL Themodel modelresponse responseisisplotted plottedagainst againstthe themeasured measuredvalues valuesfor forboth boththe theroll rollrate rateand androll rollangle angle The in Figure 20. A zoomed in plot of Figure 20a is given in Figure 21a and the identified time-varying in Figure 20. A zoomed in plot of Figure 20a is given in Figure 21a and the identified time-varying disturbanceisisplotted plottedininFigure Figure21b. 21b. disturbance 200 0 model data roll rate (deg/s) -200 -400 -600 -800 -1000 -1200 -1400 0 2 4 6 time (s) (a) (b) Figure Figure20. 20.Model Modelresponse responseversus versusdata data(a) (a)Roll Rollangle angleresponse; response;(b) (b)Roll Rollrate rateresponse. response. 8 Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 18 of 27 18 of 27 0 10 model data 0 Second PD controlled response (reference -15 deg) First PD controlled response (reference 0 deg) -10 -20 -2 fin offset dominates response -4 -6 -30 -40 canard-fin interaction dominates response 0 0.5 1 1.5 -8 0 2 4 time (s) time (s) (a) (b) 6 8 Figure 21.21. (a)(a) Zoomed inin roll angle response versus data; (b) Identified Figure Zoomed roll angle response versus data; (b) Identifieddisturbance. disturbance. Figure 21a shows that although there is some error in the first controlled response, the overall Figure 21a shows that although there is some error in the first controlled response, the overall trends are captured accurately. For example the data drops 27.2°˝from the local maximum at t = 0.49 s trends are captured accurately. For example the data drops 27.2 from the local maximum at t = 0.49 s to the local minimum at t = 1.02 s where the model predicts a drop of 26.15° ˝which corresponds to to the local minimum at t = 1.02 s where the model predicts a drop of 26.15 which corresponds to less than 4% error. The model also captures all the coast period, in both the roll angle and roll rate, as less than 4% error. The model also captures all the coast period, in both the roll angle and roll rate, as shown in Figure 20. The disturbance is quite low initially in the first 0.5 s of the data. This behavior is shown in Figure 20. The disturbance is quite low initially in the first 0.5 s of the data. This behavior is caused due to low velocity and therefore the canard–fin disturbance dominates the dynamics, as the caused due to low velocity and therefore the canard–fin disturbance dominates the dynamics, as the fin offset takes some time to take effect. After about 1 s the disturbance rapidly converges to a near fin offset takes some time to take effect. After about 1 s the disturbance rapidly converges to a near constant value around −7° which remains for the rest of the flight with only a minor increase at the constant value around ´7˝ which remains for the rest of the flight with only a minor increase at the end. The results of Figures 20 and 21 and Equations (38) and (39) show that quite a simple model end. The results of Figures 20 and 21 and Equations (38) and (39) show that quite a simple model with with a relatively smooth disturbance function, is very effective in capturing the rocket roll response. a relatively smooth disturbance function, is very effective in capturing the rocket roll response. Note that the second PD controlled roll response in Figure 21a has a very large steady state Note that the second PD controlled roll response in Figure 21a has a very large steady state error, error, since the reference was −15°. The reason for this error is that the fin offset is having a major since the reference was ´15˝ . The reason for this error is that the fin offset is having a major effect due effect due to the increased velocity and the maximum and minimum canard constraints do not to the increased velocity and the maximum and minimum canard constraints do not provide enough provide enough actuation to overcome this fin offset. However, the goal of this launch was not actuation to overcome this fin offset. However, the goal of this launch was not control, but to test the control, but to test the logistics of the new launch vehicle and avionics and provide an initial logistics of the new launch vehicle and avionics and provide an initial proof-of-concept of the model proof-of-concept of the model and methods. and methods. The final validation of the model and methods for this launch is to match the closed-loop model The final validation of the model and methods for this launch is to match the closed-loop model of Equations (28)–(31) to the data. The results are: of Equations (28)–(31) to the data. The results are: αbest ,CL = 7.5, βbest ,CL = 10.0 (40) αbest,CL “ 7.5, β best,CL “ 10.0 (40) μ| p|,OL ≡ mean absolute error in roll rate = 9.76 deg/s µ| p|,CL ” mean absolute error in roll rate “ 9.76 deg{s μ|φµ|,OL ≡ mean absolute error in roll rate = 1.50 deg ” mean absolute error in roll angle “ 1.50deg |φ|,CL (41) (41) (42)(42) These Theseresults resultsare arevery veryclose closetotothe theopen-loop open-loopresponse responsewith withaamean meanerror errordifference differenceofof0.06 0.06deg/s deg/s ˝ ininthe roll rate and 0.01° in the roll angle. However, there are some small differences in the the roll rate and 0.01 in the roll angle. However, there are some small differences in thethrust thrust period periodininthe theroll rollangle angleasasshown shownininFigure Figure22a, 22a,but butthe theoverall overallbehavior behaviorofofthe thetwo tworesponses responsesare are very similar. In addition, apart from a small period in the thrust, the identified closed and open-loop very similar. In addition, apart from a small period in the thrust, the identified closed and open-loop disturbances disturbancesare arevirtually virtuallyidentical identicalasasshown shownininFigure Figure22b. 22b. Hence, in summary, there is no noticeable change in the output responses and identified parameters when using the closed-loop model over of the open-loop model, although the closed-loop model typically takes about 50% longer to simulate. The advantage of the open-loop model computationally is that the roll rate is decoupled from the roll angle which is simpler to handle numerically. Aerospace 2016, 3, 10 19 of 27 Aerospace 2016, 3, 10 19 of 27 10 closed-loop model measured (deg) 0 dist -10 u -20 Aerospace -302016, 3, 10 19 of 27 10 -40 0 0.5 1 closed-loop model 1.5 time (s) 0 measured (b) (deg) (a) -10 Figure 22. (a) Roll angle closed loop response versus data; (b) Identified disturbance comparison. dist Figure 22. (a) Roll angle closed loop response versus data; (b) Identified disturbance comparison. u -20 4.3. Tasha III—Launch 2 Hence, in summary, there is no noticeable change in the output responses and identified A-30 new vehicle was manufactured for the second launch including fibreglassing the rear fins and parameters when using the closed-loop model over of the open-loop model, although the closed-loop 3D printing two new canards to replace the ones that were broken during the Tasha III launch 1, see model typically abouta number 50% longer to simulate. The advantage of the open-loop model Figure 8c. For takes this vehicle, of controlled step responses were performed in the wind tunnel -40 0 0.5 1 1.5 computationally theHence, roll rate from thetoroll angle which is simpler to shortly before is thethat launch. there is is adecoupled good amount of data identify torque, damping and time (s) handle numerically. disturbances and to analyze the capability of the wind tunnel tests to predict flight response. (a) (b) Figure 22. (a)2Roll closed loop response versus data; (b) Identified disturbance comparison. 4.3. Tasha 4.3.1. III—Launch Wind Tunnel Stepangle Responses Thevehicle rocket wasmanufactured string, andlaunch 8 stepincluding responsesfibreglassing were performed withfins a and A new was for athe second the rear 4.3. Tasha III—Launch 2suspended from −1. The highest wind speed of 30 m·s−1 was not used in magnitude 45°, canards at a windtospeed of 22 m·s 3D printing twoofnew replace the ones that were broken during the Tasha III launch 1, see A new vehicle manufactured for the second launch the rear fins and and this case, it vehicle, was was found that thisofairframe also step had a fin including offset,were so fibreglassing it performed was spinning rapidly Figure 8c. For as this a number controlled responses in launch the wind tunnel 3D printing two new canards to replace the ones that were broken during the Tasha III 1, see starting to swing backwards and forwards, risking damaging the canards. The gains and frequency shortly before the launch. Hence, there is a good amount of data to identify torque, damping Figure 8c. For and this vehicle, a number of controlled were performed in the wind tunnel and were reduced the parameters in Equations (11)step andresponses (12) are defined: disturbances and to analyze the capability of the wind tunnel tests predicttorque, flight response. shortly before the launch. Hence, there is a good amount of data totoidentify damping and 45π disturbances and to analyze the capability of the response. (43) k p = 0.5, kd = 0.05, f 0 wind = 0.1,tunnel R0 =tests to,predict R1 = flight 0 4.3.1. Wind Tunnel Step Responses 180 4.3.1. Wind Tunnel Step Responses The rocket suspended from a string, 8 step responses The rollwas angle and roll rate responses areand plotted in Figure 23. were performed with a magnitude rocket was fromhighest a string, andspeed 8 step werenot performed withcase, a as of 45˝ , at aThe wind speed of suspended 22 m¨ s´1 . The wind of responses 30 m¨ s´1 was used in this 50 −1. The highest wind speed of 30 m·s−1 was not used in magnitude of 45°, at a wind speed of 22 m·s it was found that this airframe also had a fin offset, so it was spinning rapidly and starting to swing 40 as it was found that this airframe also had a fin offset, so it was spinning rapidly and this case, backwards and forwards, risking damaging the canards. 50 The gains and frequency were reduced and starting 30 to swing backwards and forwards, risking damaging the canards. The gains and frequency the parameters in Equations (11) and (12) are defined: were reduced and the parameters in Equations (11) and (12) are defined: 20 0 45π 45 π k p k“ = 0.5, k “ 0.05, f “ 0.1, 0 d = 180 ,, 0.5, kd = 0.05, f 0 = 0.1, RR00 “ p 10 180 0 RR11=“0 0 (43) -50 -10 angle and roll rate responses are plotted in The roll Figure23. 23. The roll angle and roll rate responses are plotted in Figure -20 50 -30 400 20 40 60 80 time (s) 30 -100 0 50 20 60 80 time (s) (a) 20 40 (b) Figure 23. Wind tunnel 45 degree step responses (a) Roll angle; (b) Roll rate. 0 10 0 Figure 23 shows there are significantly different overshoots and rise times for each step -50 response as well as a major difference in dynamics depending on the direction of rotation, which is -10 likely caused by the fin offset in the airframe. To account for these variations, the model of Equations -20 (2)–(12) is identified for each individual step response. Since the oscillations reduce quite quickly -30 0 20 40 time (s) (a) 60 80 -100 0 20 40 60 80 time (s) (b) Figure 23. Wind tunnel 45 degree step responses (a) Roll angle; (b) Roll rate. Figure 23. Wind tunnel 45 degree step responses (a) Roll angle; (b) Roll rate. Figure 23 shows there are significantly different overshoots and rise times for each step response as well as a major difference in dynamics depending on the direction of rotation, which is likely caused by the fin offset in the airframe. To account for these variations, the model of Equations (2)–(12) is identified for each individual step response. Since the oscillations reduce quite quickly (43) Aerospace 2016, 3, 10 20 of 27 Figure 23 shows there are significantly different overshoots and rise times for each step response as well as a major difference in dynamics depending on the direction of rotation, which is likely caused Aerospace 2016, 3, 10 20 of 27 by the fin offset in the airframe. To account for these variations, the model of Equations (2)–(12) is identified for each step half response. oscillations reduce quite quickly after the first after the first peak,individual only the first of theSince data the in each step response is used for the parameter peak, only the first half of the data in each step response is used for the parameter identification. The identification. The remaining half is essentially disturbances in the wind tunnel, and there are very remaining is essentially disturbances in the wind tunnel, and there are very few dynamics few canardhalf dynamics so it does not contribute to identifiability. The time points incanard the disturbance so it does not contribute to identifiability. The time points in the disturbance model of Equations model of Equations (4)–(8) were chosen to be simply the beginning and end points with (4)–(8) N =1 were chosen(4). to be simply the beginning with N =is1 reset in Equation (4).time, Sincethe 5 stime is analyzed in Equation Since 5 s is analyzed in and eachend datapoints set, and time to 0 each points in each data set, and time is reset to 0 each time, the time points are defined: are defined: T00 “ = 0, T 0, T T1 = “ 55 (44) (44) For For the the grid grid search search and and non-linear non-linear regression regression algorithm, algorithm, the the ranges ranges of of the the parameters parameters are are taken taken from Equation (34). The results identified parameters and mean model response errors for from Equation (34). The results identified parameters and mean model response errors for the the open-loop of Equation Equation (9) (9) are aregiven givenin inTable Table2.2.An Anexample exampleset setofofmodel model responses plotted open-loop model model of responses is is plotted in in Figure which is the sixth response in Figure 23. Both the angle roll angle roll match rate match Figure 24,24, which is the sixth stepstep response in Figure 23. Both the roll and and roll rate very very closely the measured even awith very simple for disturbance the closely to thetomeasured data, data, even with veryasimple linear linear model,model, for disturbance across across the whole whole data set considered. data set considered. 50 model measured 40 30 20 10 0 -10 -20 0 1 2 3 4 5 time(s) (a) (b) Figure 24. Open-loop model response versus measured data (a) Roll angle; (b) Roll rate. Figure 24. Open-loop model response versus measured data (a) Roll angle; (b) Roll rate. Table 2. Summary of the identified model parameters for each of the 8 wind tunnel step responses. Table 2. Summary of the identified model parameters for each of the 8 wind tunnel step responses. Step Response Step Response 1 12 2 3 3 44 55 66 77 8 8 Mean Mean α α 13 1315 15 22 22 1515 2525 2323 1515 27 27 19.4 19.4 β β 10.5 10.5 6.5 6.5 10.5 10.5 6.0 6.0 12.5 12.5 10.5 10.5 10.5 10.5 10.0 10.0 9.6 9.6 [ud 0 , ud 1 ] rud0 , ud1 s [−5.59,−7.71] [´5.59,´7.71] [−5.82,−6.10] [´5.82,´6.10] [−6.04,−6.35] [´6.04,´6.35] [−4.18,−7.16] [´4.18,´7.16] [−5.90,−6.51] [´5.90,´6.51] [´5.12,´6.25] [−5.12,−6.25] [´6.11,7.41] [−6.11,7.41] [´5.47,´5.44] [−5.47,−5.44] [´5.47,6.62] [−5.47,6.62] [μ”| p|,OL , μ|φ|,OL ] ı µ ,µ |p|,OL |φ|,OL [1.64,6.23] [1.64,6.23] [0.70,2.38] [0.70,2.38] [1.13,4.40] [1.13,4.40] [0.42,2.08] [0.42,2.08] [0.82,2.92] [0.82,2.92] [0.26,1.66] [0.26,1.66] [1.43,5.84] [1.43,5.84] [0.60,2.66] [0.60,2.66] [0.88,3.52] [0.88,3.52] Table showsthere there a significant variation of parameters the step responses. The Table 22shows is is a significant variation of parameters acrossacross the step responses. The average ˝ andwas average model over 3.52 angle and roll model error overerror all tests wasall 0.88tests 3.520.88° deg/sand for the rolldeg/s anglefor andthe roll roll rate respectively. The rate size ˝ respectively. The size of the45step was 45°, so the average model errorsfrom in Table vary from of the step response was , soresponse the average model errors in Table 2 vary 0.6%2 to 3.6% of 0.6% to 3.6% change in roll angle. and Hence, the model andeffective methodsat are very effective at the change in of rollthe angle. Hence, the model methods are very capturing rocket roll capturing rocket roll response in the vertical wind tunnel. The disturbances in column 4 of Table 2 show a trend for a lower disturbance in the first period, which was similar to the flight in Figure 22b, showing that the canard-fin interaction effects can minimize the effect of fin offset in the airframe. The average fin offset across all tests was −6.1°, so taking into account the swirl this value corresponds to −4.1°. The wide range of values of the damping, torque constant and fin offsets in Aerospace 2016, 3, 10 21 of 27 response in the vertical wind tunnel. The disturbances in column 4 of Table 2 show a trend for a lower disturbance in the first period, which was similar to the flight in Figure 22b, showing that the canard-fin interaction effects can minimize the effect of fin offset in the airframe. The average fin offset across all ˝ ,10 Aerospace 2016, 3, 21 of 27 of tests was ´6.1 so taking into account the swirl this value corresponds to ´4.1˝ . The wide range values of the damping, torque constant and fin offsets in Table 2 give the range of uncertainty in the Table 2 give the range of uncertainty in the launch, and will be compared with the flight data in the launch, and will be compared with the flight data in the next section. next section. 4.3.2. Flight Data 4.3.2. Flight Data Tasha III from Figure 8c was launched from Kaitorete Spit on 4 December 2015. The aims of this Tasha III from Figure 8c was launched from Kaitorete Spit on 4 December 2015. The aims of this launch included testing the rocket under a greater amount of actuations and to overcome the fin offset launch included testing the rocket under a greater amount of actuations and to overcome the fin problem that occurred in the July launch as detailed in Section 4.2. Importantly, the launch provided offset problem that occurred in the July launch as detailed in Section 4.2. Importantly, the launch a characterization of the ability of the wind tunnel to predict flight dynamics far outside the wind provided a characterization of the ability of the wind tunnel to predict flight dynamics far outside speeds that can be generated by the fan. Since wind for the tunnel datadata was only the wind speeds that can be generated by the fan.the Since the speed wind speed forwind the wind tunnel was 1 , this launch provided a rigorous test of how well the model could be extrapolated to higher 22 only m¨ s´22 m·s−1, this launch provided a rigorous test of how well the model could be extrapolated to ´1 which wind speeds. apogee this flight was 422was m, and maximum velocity was 81was m¨ s81 higher windThe speeds. Thefor apogee for this flight 422 the m, and the maximum velocity m·s−1 were much lower than the July launch, due to the increased weight from the more robust, supersonic which were much lower than the July launch, due to the increased weight from the more robust, capable avionics stack.avionics The wind speed reasonably on the day an day average speed supersonic capable stack. Thewas wind speed waslow reasonably lowwith on the withground an average −1. Figure of ground 3 m¨ s´1speed . Figure shows several stills of the rocket moving up and leaving the launch of 325m·s 25 shows several stills of the rocket moving up and leaving guide. the launch guide. Thewas overall launchalthough was a success although the damaged back fins were damaged ontolanding, The overall launch a success the back fins were on landing, due a sudden due a sudden gust of wind that pushed the rocket onto stony ground. gust ofto wind that pushed the rocket onto stony ground. Figure Sequenceofofstills stillsshowing showing Tasha Tasha III III rocket rocket moving guide. Figure 25.25.Sequence movingup upand andleaving leavinglaunch launch guide. The controller for this launch was a single step response from 0° to −20°, which occurred 2 s The controller for this launch was a single step response from 0˝ to ´20˝ , which occurred 2 s after after the controller was switched on. The canard limits were increased to ±9° in this launch to the controller was switched on. The canard limits were increased to ˘9˝ in this launch to overcome overcome the fin offset from the first launch. In addition, some open-loop oscillatory inputs were theincluded fin offsetinfrom the first launch. In addition, some open-loop oscillatory inputs were included in the the PD control signal of Equation (10). This input signal was implemented 0.4 s after the PDcontrol controlstarted signaland of Equation (10). 5This input wasresponse. implemented 0.4 s after control chirp started was stopped s after thesignal −20° step The input was athe modified ˝ and was defined: stopped 5 s after the ´20 step response. The input was a modified chirp signal defined: signal (t ) “ = (pA A00 +`Δ∆Aptqqsin A(t )) sin (ppω (ω00(ptq t ) +`Δω (t ))t ) uuinput ∆ωptqqtq input ptq = AA00 “ 4π 4π tt (t )“= 2πp2 2π(2´− q,), ∆Aptq, ΔA(t ), Δω (t ) ≡”random ,, ωω00ptq ∆ωptq randomvariation variation on on signal signal 180 10 180 (45)(45) (46)(46) AA plot ofof the applied 26. plot the appliedinput inputsignal signalisisgiven given in in Figure Figure 26. The roll rate data including all the key points of the launch given in Figure 27, where The roll rate data including all the key points of the launch areare given in Figure 27, where t = 0t = 0 corresponds to 1.5 s before take-off. For this launch, two accelerometers were used to improve corresponds to 1.5 s before take-off. For this launch, two accelerometers were used to improve the therobustness robustnessininthe thelaunch launchdetect detectand andthe thedelay delaythreshold threshold was reduced addition, was reduced to to 0.10.1 s. s.In In addition, thethe accelerometer threshold increased to 2.5 g. Similarly to the Tasha III launch 1, the control was started accelerometer threshold increased to 2.5 g. Similarly to the Tasha III launch 1, the control was started when thethe rocket height when rocket heightwas was2 2mmabove abovethe the44m mlaunch launch guide. guide. Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 Aerospace 2016, 3, 10 22 of 27 22 of 27 22 of 27 6 6 4 4 2 2 0 0 -2 -2 -4 -4 -6 -6 -8 -8 0 2 4 6 8 0 2 time4 (s) time (s) 6 8 (deg/s) roll roll raterate (deg/s) Figure 26. Input signal applied to PD Controller ( t = 0 corresponds to start of controller). Figure 26. Input signal applied to PD Controller (t = 0 corresponds to start of controller). Figure 26. Input signal applied to PD Controller ( t = 0 corresponds to start of controller). Figure 27. Roll rate response for Tasha III launch 2 including key points in the launch. Figure 27.27.Roll includingkey keypoints pointsininthe thelaunch. launch. Figure Rollrate rateresponse responsefor forTasha TashaIII III launch launch 2 including For this launch, the data is split into the two PD controlled responses with the set point of 0° followed bylaunch, −20° which was 2ississplit later. A sharp roll rate can be seen for this second set point this launch, thedata data splitinto into thechange two PD PDincontrolled controlled responses with the set ofof 0°0˝ ForFor this the the two responses with the setpoint point at aboutby 4by s´20 in Figure 27.was The2first period ofsharp analysis isinstarted at 2.4 in Figure 27 which is 0.4 afterset followed −20° which AA sharp change roll can seen this second setspoint ˝ which followed was 2s slater. later. change in rate roll ratesbe can befor seen for this second the control starts and27. corresponds to theofimplementation of at the2.4 input signal 27 from Figure 26.s after This at about 4 s in Figure The first period analysis is started s in Figure which is 0.4 point at about 4 s in Figure 27. The first period of analysis is started at 2.4 s in Figure 27 which is starting point wasand chosen since there oscillatory dynamics in thefrom canards which will the control starts corresponds to are thesignificant implementation of the input signal Figure 26. This 0.4 s after the control starts and corresponds to the implementation of the input signal from Figure 26. ensure of the model The second period of starts at 4 will s in startinggood pointidentifiability was chosen since there are parameters. significant oscillatory dynamics in analysis the canards which This starting point was chosen since there are significant oscillatory dynamics in the canards which Figure 27, which is when the set point changes from 0° to −20°. ensure good identifiability of the model parameters. The second period of analysis starts at 4 s in will ensure good identifiability of the model parameters. The second period of analysis starts at 4 s in Figure which when athe set point changes 0° to −20°. For27,the first is period, similar approach tofrom the Tasha III launch 1 model is applied, where N1 Figure 27, which is when the set point changes from 0˝ to ´20˝ . For the first period, a similar approach to the Tasha IIIuntil launch 1 model issignificantly applied, where N1 equally pointsa similar are chosen, and toNthe increased For thespaced first period, approach III launch 1 there modelisis no applied, where Nfurther 1 isTasha 1 equally N equally spaced points are chosen, and is increased until there is no significantly further spaced points are chosen, and N is increased until there is no significantly further improvement 1 Forthe improvement in the fit to the1 data. The values of N1 investigated were from 1 to 6 points. in fit to the data. The values N were of from to 6 points. For N1from = 1,¨ 1¨ ¨ to ,4, 6the best model 1 investigated N11angle investigated were points. For improvement fit of to the data. The average values N1 = 1,…, 4 , in thethebest model fits had roll errors of 2.36, 2.15, 0.57 and 0.26° fits had average roll angle errors of 2.36, 2.15, 0.57 and 0.26˝ respectively. There was no significant N1 = 1,…, 4 There , the best no model fits had average roll of 2.36, 2.15, 0.57 and 0.26° N1 virtually = 5errors respectively. improvement for angle and 6identical and the parameters improvement for N1 =was 5 and significant 6 and the parameters remained for N1 = 3,¨ remained ¨ ¨ ,6. Hence N = 5 respectively. There was no significant improvement for and 6 and the parameters remained 1 a value of N1 = 4 is chosen for the final model. The results are defined: Aerospace 2016, 3, 10 23 of 27 virtually identical Aerospace 2016, 3, 10 for N1 = 3,…, 6 . Hence a value of N1 = 4 is chosen for the final model. 23 ofThe 27 results are defined: αbest ,OL = 23.0, βbest ,OL = 9.0 μ| p|,OL ≡ mean absolute error in roll rate = 4.10 deg/s (47) (47) (48) (48) μµ|φ|φ|,OL ≡ mean absolute error in roll angle = 0.26 deg/s |,OL ” mean absolute error in roll angle “ 0.26 deg{s (49) (49) αbest,OL “ 23.0, β best,OL “ 9.0 µ| p|,OL ” mean absolute error in roll rate “ 4.10 deg{s The The model model response response for for the the roll roll angle angle and and roll roll rate rate are are shown shown in in Figure Figure 28 28 and and the the offset offset angle angle is is plotted plotted in inFigure Figure29. 29. 6 model measured 4 2 0 -2 -4 -6 -8 0 0.5 1 1.5 time (s) (a) (b) Figure 28. 28. Modelled Modelled roll roll angle angle (a) (a) and and roll roll rate rate (b) (b) versus versus the the measured measured data datafor forfirst firstanalysis analysisperiod. period. Figure -1 -2 -3 -4 -5 -6 -7 -8 0 0.5 1 1.5 time (s) Figure29. 29.Identified Identifiedtime-varying time-varyingoffset offsetangle angle uuoffset for first analysis period. Figure offset for first analysis period. The toto thethe average wind tunnel predicted values of 19.4 andand 9.6 The results resultsofofEquation Equation(47) (47)are areclose close average wind tunnel predicted values of 19.4 in 2, with of 15.7% 4.4%, The offset angles in angles Figure 29 all within 9.6Table in Table 2, errors with errors of and 15.7% andrespectively. 4.4%, respectively. The offset in are Figure 29 arethe all range of values of the wind tunnel tests as well. There is also a similar trend of lower offset angles for within the range of values of the wind tunnel tests as well. There is also a similar trend of lower the smaller finfor movements was the case inas the wind Thewind meantunnel. offset angle of Figure 29angle was offset angles the smallerasfin movements was the tunnel. case in the The mean offset ˝ ˝ ˝ 4.9 which29 is was 0.8 4.9° greater thanisthe 4.1 the predicted wind tunnel.inThis of Figure which 0.8°average greaterofthan averageinofthe 4.1° predicted thevalue wind corresponds tunnel. This to an error of 16.3% but well within the expected variation of Table 2. value corresponds to an error of 16.3% but well within the expected variation of Table 2. A similar procedure was applied to the second period of data corresponding to a reference angle of ´20˝ . In this case, a value of N2 = 2 was sufficient for the modelling and the identified parameters are defined: αbest,OL “ 23.0, β best,OL “ 9.0 (50) A similar procedure was applied A similar procedure was applied angle of −20°. In this case, a value of angle of −20°. In this case, a value of parameters are defined: parameters are defined: to the second period of data to the second period of data N 2 = 2 was sufficient for the N 2 = 2 was sufficient for the corresponding to a reference corresponding to a reference modelling and the identified modelling and the identified αbest ,OL = 48.0, βbest ,OL = 8.0 αbest ,OL = 48.0, βbest ,OL = 8.0 μ OL ≡”mean absolute error in roll rate“=8.32 8.32 deg/s meanabsolute absoluteerror error in in roll |,OL≡ mean μµ|| pp||,|,pOL roll rate rate = 8.32deg{s deg/s μµ OL mean roll angle angle“=0.99 0.99deg{s deg/s meanabsolute absoluteerror error in in roll |,OL≡” μ||φφ||,|,φOL ≡ mean absolute error in roll angle = 0.99 deg/s Aerospace 2016, 3, 10 24 of 27 (50) (50) (51) (51) (51) (52) (52) (52) The 3030 and the offset angle is The model model responses responsesfor forthe theroll rollangle angleand androll rollrate rateare areshown shownininFigure Figure and the offset angle Theinmodel responses for the roll angle and roll rate are shown in Figure 30 and the offset angle plotted Figure 31. is plotted in Figure 31. is plotted in Figure 31. 5 5 0 0 -5 -5 -10 -10 -15 -15 -20 -20 -25 -25 -30 -30 0 0 model model measured measured 1 1 2 3 2 time (s) 3 4 4 5 5 time (s) (a) (a) (b) (b) Figure 30. Modelled roll angle (a) and roll rate (b) versus the measured data for second analysis period. Figure30. 30.Modelled Modelledroll rollangle angle(a) (a)and androll roll rate rate (b) (b) versus versus the the measured measured data Figure data for for second secondanalysis analysisperiod. period. -8.5 -8.5 -9 -9 -9.5 -9.5 -10 -10 0 0 1 1 2 2 time (s) time (s) 3 3 4 4 5 5 Figure 31. Identified time-varying offset angle uoffset for second analysis period. Figure31. 31.Identified dentifiedtime-varying time-varyingoffset offsetangle angle u uoffset Figure forsecond secondanalysis analysisperiod. period. offset for The modeled torque constant in Equation (50) is reasonably close to the wind tunnel predicted The modeled torque constant in Equation (50) is reasonably close to the wind tunnel predicted value of 9.6 with an error of 16.7%, however the damping is significantly larger than all the damping value of 9.6 with an error of 16.7%, however the damping is significantly larger than all the damping values of Table 2. This extra damping is likely due to the rocket pitching over with an increasing values of damping is likely duedue to the rocket pitching over over with with an increasing angle of Table Table2.2.This Thisextra extra damping is likely to the rocket pitching an increasing angle of attack as well as the higher velocity. On the other hand, the average identified offset of of attack as wellas aswell the higher On the other hand, thehand, average offset of Figure angle of attack as the velocity. higher velocity. On the other the identified average identified offset 31 of Figure ˝31 is −4.7°, which is even closer to the wind tunnel average of 4.1°. Hence, although the ˝ . Hence, is ´4.7 , which is even closer to the wind tunnel average of 4.1 although the damping is Figure 31 is −4.7°, which is even closer to the wind tunnel average of 4.1°. Hence, although the damping is less accurate in the post-thrust period, the torque constant and the offset angles are both less accurate in the post-thrust period, the period, torque constant and the offset are both accurately damping is less accurate in the post-thrust the torque constant andangles the offset angles are both accurately predicted for all stages of the flight, which are more important for control design. A predicted all stagesfor of the more which important control design.for A similar accuratelyfor predicted all flight, stageswhich of theare flight, are for more important controlanalysis design.has A been performed for the closed-loop responses, but since the results were very similar to the open-loop analysis above, these results are not shown. Note that the torque constant values of β = 8 and β = 9 in this second Tasha III launch are reasonably close to value of β = 10 identified in the first Tasha III launch. However, both of the values of damping in the second launch are considerably larger than the damping from the first launch. Aerospace 2016, 3, 10 25 of 27 This result is probably because there were a lot less dynamics in the first launch so the damping was less identifiable. 5. Conclusions A vertical wind tunnel has been designed and built at the University of Canterbury. This wind tunnel has been specifically customized for sounding rocket research and has a unique feature of allowing the rocket to be suspended by string for accurate prediction of roll dynamics. It is also very useful for testing stability before flight. The flow of the wind tunnel was analyzed in detail and turbulence intensity was estimated to be less than 0.04%. However, there was a reasonable amount of swirl equivalent to 2˝ of canard fin. This swirl was dramatically reduced to a negligible amount by using an egg crate at the bottom of the wind tunnel near the fan to straighten the flow. Two new airframes were developed in this research with a supersonic capable avionics stack in the second vehicle. Both rockets had reinforced fiberglass to give strength to the fins, but it was found that they had significant fin offset, with post-thrust average values of about 7˝ for the first vehicle and 5˝ for the second. Wind tunnel tests on the second vehicle revealed a high roll rate, which suggested a combination of swirl and fin offset. After the second flight, tests with and without the flow straightener using a similar airframe, showed that swirl could be modeled by the equivalent canard offset. This value was then used to compare the wind tunnel tests of the second vehicle to the flight data. A minimal modelling approach for roll dynamics was developed using a velocity dependent model and a piecewise-linear time-varying canard offset function. Open and closed loop models were considered with PD control, with encoders used to measure the canard movements. A combination of a grid search and non-linear regression provided a rigorous way of identifying the parameters. The models identified gave an excellent match to the flight data in both launches, with quite a smooth varying canard offset profile. It was found that with high dynamic movement in the canards the identified fin offset was lower, showing that canard–fin interaction dominates during these periods. This phenomenon occurred in both the wind tunnel tests and flight. A significant outcome of this paper was proving that wind tunnel tests give accurate predictions of the torque constant and fin offset and importantly, the resulting minimal roll models predict flight behavior closely. The damping is typically underestimated in the wind tunnel so a greater uncertainty should be included in this parameter for future control design. In summary, the vertical wind tunnel at the University of Canterbury is a unique facility and a key part of the success of UC Rocketry. A combination of wind tunnel tests and rocket launches have allowed a thorough understanding of rocket flight and control. Acknowledgments: Funded by the Rutherford Discovery Fellowship, Royal Society New Zealand; Callaghan Innovation PhD Fellowships; and Rocket Lab Ltd. Author Contributions: Hoani Bryson, Hans Philipp Sültrop, George Buchanan, Christopher Hann, Malcolm Snowdon, Avinash Rao, Adam Slee, Kieran Fanning, David Wright: developed the hardware, did the experiments, analyzed the data, developed models and wrote the paper. Jason McVicar, Brett Clark, Graeme Harris and Xiao Qi Chen: helped to construct the wind tunnel including setting up the fan and controller, provided expertise and advice on the flow quality and instrumentation and sensors for the wind tunnel tests, and contributed to writing the paper. Conflicts of Interest: The authors declare no conflict of interest. Notation Ip ρ α β u f in Inertia in roll axis (kg/m2 ) Air density (kg/m3 ) Damping constant (m2 ) Torque constant (m) Roll fin angle (rad) Aerospace 2016, 3, 10 A p v k p , kd Rptq ud,0 , . . . , ud,N φdata φOL , φCL <α , < β Γ σ ucmd uenc cmd1 , . . . , cmd2 enc1 , . . . , enc2 umin , umax µ| p|,OL , µ| p|,CL µ|φ|,OL , µ|φ|,CL uinput 26 of 27 Cross sectional area (m2 ) Roll rate (rad/s) velocity (m/s) Proportional and derivative gains Reference angle (rad) Time-varying disturbance offset angle parameters (rad) Measured roll angle (rad) Open and closed loop numerical solutions to roll equations (rad) Ranges for α, β in the grid search for parameter identification Turbulence intensity (m/s) Standard deviation of wind speed (m/s) Commanded canard angle (rad) Measured canard angle by encoder (rad) Individual canard commands (rad) Individually measured encoders (rad) Minimum and maximum canard limits for actuation (rad) Mean absolute roll rate for open loop and closed loop controllers Mean absolute roll angle for open loop and closed loop controllers Open loop input signal into PD controller Abbreviations PD NASA UC CFD RPM OL CL Proportional-derivative The National Aeronautics and Space Administration University of Canterbury Computational Fluid Dynamics Revolutions per minute Open loop Closed loop References 1. 2. 3. 4. 5. 6. 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