ThrustVectorControl

StellarExplorations
DaneLarkinGreatdaneslo@[Link] HarsimranSinghhsingh@[Link]

StatementofDisclaimer

Sincethisprojectisaresultofaclassassignment,ithasbeengradedandacceptedas [Link] [Link] [Link] PolytechnicStateUniversityatSanLuisObispoanditsstaffcannotbeheldliableforanyuseor misuseoftheproject.

Contents
ListofTables.................................................................................................................................................ii [Link] Abstract..v Chapter 1 2 3 4 5 6 7 8 Introduction.1 Background..2 DesignDevelopment....6 3.1Objectives.6 3.2ConceptSelection10 FinalDesign...15 4.1DesignDescription16 4.2EngineeringAnalysis18 4.3CostAnalysis.22 4.4Materal/ComponentSelection23 Manufacturing/Assembly26 ProjectPlanning.28 6.1ProjectManagementPlan.28 6.2DesignVerificationPlan.29 Conclusions&Recommendations..30 FinalProjectUpdate.31 8.1Materials..31 8.2DesignChanges32 8.3Manufacturing....34

 9 Testing36 9.1TestingApparatus36 9.2WiringSetup...37

APPENDIXAConceptSelection..3940 APPENDIXBEngineeringAnalysis..4143 APPENDIXCCostAnalysis.44 APPENDIXDSystemComponents&Assemblies4551 APPENDIXEGanttChart.5255 APPENDIXFOfftheshelfcomponents.5662

ii

ListofTables Table1EngineeringSpecificationsp.8 Table2DecisionMatrix.p.10 Table3ThermalExpansionData.p.20 Table4CostAnalysis.....p.23

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ListofFigures Figure1JetavatorSetup.p.5 Figure2RotatatingSegmentSetup...p.6 Figure3BallandSocketSetupp.6 Figure4InternalManeuveringVanes...p.7 Figure5JetavatorReferencePhotop.12 Figure6ManeuveringVanesReferencePhoto..p.12 Figure7RotatingSegmentsReferencePhoto.p.13 Figure8ManeuveringVanesInstallationp.13 Figure9Ballandsocketsetupsusceptibilitytoerosionp.13 Figure10Furtherdevelopmentofballandsocketconceptp.15 Figure11Isometricviewofsolidmodeldesign..p.17 Figure12Explodedviewofsolidmodeldesign..p.18 Figure13Heattransferinnozzle..p.20 Figure14Thermalexpansionofnozzle.p.21 Figure15Thermalexpansionofcollar..p.23 Figure16Forcesonnozzle....p.24 Figure17GraphiteNozzle..p.25 Figure18InconelFlange.p.26 Figure19RapidPrototypedComponents..p.33 Figure20Prototypedcouplersandbracketsp.34 Figure21DesignFlawsp.34

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Figure22DesignFlawSolutionsp.35 Figure23Machinedsectionofsolidbar.p.36 Figure24Fabricatedfeaturesofcollarp.37 Figure25TestApparatus.p.38 Figure26Pretestsetupp.38 Figure27Testobjectiveverification..p.39 Figure28Wiring...p.39

Abstract
The objective of this project was to design, build and test a thrustvectoring system for a solid booster rocket. The project was sponsored by Stellar Exploration. A two member team of Harsimran Singh and Dane Larkin worked towardtheobjective.

CHAPTER1Introduction
Theprojectdescribedinthisdocumentisathrustvectoringsystemthatwillbeimplementedin [Link] thestatusofthrustvectorcontrol,theprojectrequirementsandobjectives,howthesuccessof the project will be evaluated, and prototype design. In addition the methods used and the timeline the project will follow will be thoroughly outlined. The success of this project is dependentonthecooperationofDaneLarkinandHarsimranSinghandontheparticipationof [Link] are responsible for delivering a viable prototype to Stellar Exploration. Stellar exploration is [Link] ofthisprojectaretodesignandbuildafunctioningthrustvectoringsystemforusebyStellar Explorations.

CHAPTER2Background
Stellar Exploration Incorporated is a small technology company which focuses on low [Link] [Link] allowingoperatorstocontrolthedirectionofthrust,thethrustvectoringsystemwillmakeup [Link] ofbackgroundresearchondifferentthrustvectoringsystemswhichhavebeenusedinthepast. Fixednozzlesystems Fixednozzlesystemsasthenamestatesrefertonozzlesthataresolidmountedinthe [Link]. These were some of the first systems of thrust vector control developed in the Polaris and minute man rockets. The classification of fixed nozzle systems falls into these categories, secondary injection systems where the flow is the nozzle is changed by the addition or rerouting of fluid flow, and mechanical deflection where a mechanical element changes the directionofflow. Liquidinjection Liquidinjectionencompassesanyadditionofafluidthatchangesthecharacteristicsof [Link] [Link],aswellasthefluidthatisinjected,arebothtopicsofmuch debate and research. one of the biggest decisions when considering this method of thrust vectoringistheliquidthatwillbeusedthetwomaindivisionsarewhethertheliquidwillinhibit [Link] ofthenozzlewhilecombustioncontributorswilladdfuelorotheradditivestoincreasethrust on one side of the nozzle. Advantages of this method of thrust vectoring are that it has fast [Link] thissystemarethattheyareheavyandtheamountthevalveopensisnotlinearlyrelatedto therateofchangeofthethrustvector. Gasinjection Gasinjectionisverysimilartoliquidinjectionthedifferencebeingthatinsteadofnew gas being added to the fluid stream combustion gasses are rerouted from behind the nozzle into the diverging section changing the flow through the nozzle itself. The advantages of this methodarethatadditionalfluidsdonotneedtobestoredonboardandsothesystemoverallis lighter in weight. The downside to this method however, is that the hot combustion gasses

haveto beroutedth [Link] onarytestst thevalvesco ouldneverb bemadereliable enought toconsiderf furthertestin ng. Jetvane Thejetvane deflectorischaracteriz zedbyanyf finorplatet thatisdirec ctlyplacedinthe [Link] heplateorf finmovesit willcausetheflowexit tingthenozz zleto deflectfr romthecen nterlineoftherocket.A Advantageso ofthesesys stemsareth hattheforce eson actuators sarelowan ndthusthey ycanbecap pableofquic ckresponse [Link] cetheblade esare directlyintheexhaustthiscause esthedesign nertomake oneofthreechoices,th hepropellan ntcan burnrela ativelycool,thepropella antcanburn nforrelative elyshortper riodoftime,orthevane escan bemade eofexoticheatresistan ntmaterial.T Theotherp problemwith hthismetho odisthata large deflectionofthevan nemustbem madeinord dertocause achangein nthethrust [Link] large deflectionandthein nherentdrag goffluidont thevanesre educethrust t. Jetavator Thejetavator risasimilarconcepttot thejetvane ethedifferen ncebeingth hatinsteado ofthe vanesbe eingintheflowthenozz zletheyare positioned aroundthe perimetero ofthenozzle eand are parallel to the flow. This sy ystem has similar heat r restrictions to the jet v vane. Advant tages thatthedefl ectionofthejetavatori islinearlyre elated includet tothede eflectionoft [Link] downsideso ofthis thethrustv design,b besidestheh heatconside erationsmen ntionedinth hejet vanesec ction,aretha atthesystem mcanbehe eavyandtha atthe jetavator restricts t he exit diam r meter. Nota able applica ations areF16andthePola arisA1. rSetup [Link] Jettab ysteminvolv vesaplateattheendof fthenozzle thatcanberotatedinto oand Thejettabsy t antages tha the thru deflectio is at ust on out of the nozzle disrupting the flow. Initial adva proportio onaltothea areaofthetabthatisex xposedtoth eflowthism makescontrollingthesy ystem relatively [Link] fthissystem misthatwhe enthetabis sinthefluid dstreamthe eflow [Link] estalledflow wcauseslotsoferosion ontheinsid deoftheno [Link] gwas stoppedonthismeth hodbecause eofthematerialerosion nproblems.

Movable enozzle Movable noz M zzles control the direction of the e exiting flow by having the nozzle itself w weredeveloped [Link] hesearemo orerecently developedt technologies [Link] onthatthey morerec cently,anda arenowbeco omingmorepopular,is thatitwasd difficulttosu upportthethrust on the nozzle while sealing the gasses and remaining flexible. M n e d g Moveable no ozzle systems are broadlyc categorizedintothetype eofflowins sidethenozz zle. joint Flexiblej The flexible joint system is the sim j m mplest desig of the m gn movable nozz systems. The zle system uses a seal that attaches on the outside of t movable nozzle and the other end u o the e r attaches totherigidstructure.T Thenozzlec cannowbed designedwithouttheco oncernofse ealing thejointsincethefle exiblesealw willholdthenozzlepres [Link] dvantageof fthesesyste emsis thatther rearenosp plitlinesand dthrustlossisnegligible [Link] tagestothis sdesignare ethat thesealw willbeexposedtohight temperature es Rotatable In nitiallyrotata ablenozzles swerecante edinadirect tionandnee ededtobeu usedingrou upsto manage rollpitchan ndyawthesesystemsrequiredlarg gebearings andthemo ovementish highly difficulttocontrol lasallthree enozzlesha avetobein synchroniza ation. Future developme e ents resulted in a segm d mented nozzl that has t le three segme entseachatt tachedbycu utsthataren notperpend diculartothe eaxis oftherocketbym movingthese egmentsrela ativetoeach hotherthea angle oftheexitingflowischanged. [Link] tatingSegm mentSetup Thedesignof fthisnozzle eisjustasth henamesay ysitresemb blesthemot tionofabal lland socket with one inn ball conn w ner necting to the rigid fra me and the e outer ba remainin mobile as the flow transfers from the all ng s e convergingportiono ofthenozzle etothediv vergingnozz leitcrosses s Ball thesplitlinebetweentheinnerb ballandouterball.
Socket

Fig [Link] up

Internalmaneuverin ngvanes Vanesarepla V acedalongt theinsidew wallofthero ocketnozzle [Link] athof the hot thrust gases the vanes are maneuvered by ac t s, ctuators to d direct the th hrust in ord to der bettergu uidearocket [Link] ommonons surfacetoai irmissiles.

[Link] nes

CHAPTER3DesignDevelopment
3.1Objectives
ThisteamseekstodevelopathrustvectoringsystemfortheSwordFishrocketbuiltby Stellar Exploration. The thrust vectoring system will help steer the rocket through the fifteen secondboostphase,[Link],many [Link],sincemostofthesesolutionsmay notsuitStellarExplorationsrequirements,wehaveputtogetheratableofspecificationsusing the Quality Function Deployment (QFD) method to translate customer requirements to [Link](s)whichbestmatchesthesespecificationsarefurther [Link] a house of quality that this team used in the QFD method. This team also provides a specificationstableintheAppendicessection. This team approximated the target values at the bottom of the house of quality, and intendstosubmitthetargetvaluesforreviewandpossiblemodificationbyStellarExploration. Each target value is assigned a relative weight. For example, the target value regarding heat requirements has a relative weight of 14.3%. This figure indicates the importance of heat requirementsrelativetootherdesignspecifications. Thederivationofrelativeweightproceedsasfollows: 1. Theusersqualitativerequirementssuchasinstallation,safety,etcarelisted ineachrowofthehouseofquality. 2. Each customer requirement is assigned an importance weight (i.e. 7.0 for durability). 3. Theimportanceweightsforallcustomerrequirementsareaddedupandthe importance weight for each particular customer requirement is divided by this sum. The resulting figure is then multiplied by one hundred and called the relative weight for the particular customer requirement (i.e. 15.9% for durability). 4. Along each column are listed quantifiable technical requirements such as frequencyresponse,weight,etc. 5. The intersecting cell between each column and row indicates how the respective customer requirement correlates with the respective technical

[Link],[Link] withasolidtriangleifthereisslightcorrelation,withahollowcircleifthere is medium correlation, and with a symbol that resembles theta if there is strong correlation. For instance, heat requirement (quantitative) has light correlationwithsafety,mediumcorrelationwithresponsetoanglechange, strongcorrelationwithdurability,etc. 6. [Link] correlation,oneforlightcorrelation,threeformediumcorrelation,andnine forstrongcorrelation. 7. Take the relative weight for each customer requirement and multiply it by the correlation value in each cell of each respective row (i.e. 15.9*9 for durabilityandheatrequirements). 8. Adduptheresultingvaluesalongeachcolumn,andanimportanceweightis obtained for each technical requirement (i.e. 425 for heat requirements). Thisvalueisplacedatthebottomofthehouseofquality. 9. Sum up the importance weights for all technical requirements, and divide into the importance weight for a particular technical requirement. Multiply the result by one hundred to obtain the relative weight for that technical requirement(i.e.14.3%forheatrequirements). The relative weight indicates the importance of a particular technical requirement for our design. Having a relative weight of 14.3%, heat requirement has a higher relative weight [Link] [Link],thisteamshouldhavethegreatestconcernregardingheat requirement throughout the design, build, and test process. Not satisfactorily meeting heat requirementswillresultinthegreatestadverseimpactonmostcustomerrequirements. Thefollowingtableofengineeringspecificationshighlightsfromlefttoright,thetypeof technical parameter, this teams target numerical value for that parameter, the tolerances it mustmeet,theriskofnotmeetingeachtarget(High(H),Low(L),orMedium(M)),andhowthis

team will meet each parameter (analysis (A), test (T), similarity to existing designs (S), or inspection(I)). Table1 Spec.# Parameter Description Frequency response Weight Temperature Pressure Thrustangle TargetValue (units) 20Hz Adds<4lbs ontosystem Withstand 1300F Withstand 600psi 7degrees fromcentral axis <5.75in diameter1 <30watts Tolerance Risk Compliance

1 2 3 4 5

Min. Max. 20F 50psi Max.

M M L L M

A,T,S A,T A,T,S A,T,S A,T

6 7 8

Size Powerusage Cyclestill failure Slewrate

Max. Max.

L L

A,I A,S

5000cycles Min. L A,T 150 9 0.5seconds 0.001 H A,T,S forhalfcycle second 10 Drag Addsless Max. L A,T than1% 11 Actuation 0.05 Max. M A,T error degrees *ForfurtherreferenceseethebottomofthehouseofqualityinAppendixA.
1

SeeAppendixB

FrequencyResponse:Amountofcyclestheactuatorscanachieveinonesecond. Weight:Onceinstalledontotherocket,[Link] therocketspreinstallationweight. Temperature: The system must withstand the high temperatures that result from fuel combustionandotherfactors.

Pressure:Thesystemmustwithstandallpressuresresultingfromtherocketsthrustandother factors. ThrustAngle:*Seefrequencyresponseabove. Size:Thesystemmustbeabletofitwithina5.75indiameter.*AlsoseeAppendixB. Powerusage:Thesystemmustusenomorethan30wattsofpowerfromtherocketspower supply. Cycles till failure: The system must cycle thrust direction a minimum of 5000 cycles before failure. Slew Rate: Amount of times in one second that the system can cycle direction of thrust between 7 degrees from the rockets central axis. The risk of not being able to meet this [Link] finish steering the rocket to the correct trajectory within 15 seconds of launch. This team is unsurewhetheritcandesignasystemtoachievethisspeedwithinthegivenpowerandsize [Link],thisteamisunsurewhetherallcomponentsofthe systemwillfunctionproperlyatthedesiredslewrateforafulldurationof15seconds. Drag:Onceinstalledontotherocket,thesystemmustaddnomorethan1%oftherockets preinstallationdrag. ActuationError:Theactualthrustanglemustnotdeviatemoreorlessthan0.05degreesfrom theintendedthrustangle.

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3.2Con nceptSelec ction

Th team use a decision matrix to se his ed elect our top design. The four best designs were listed p e acrossthe etopofthem [Link] eincludedthe ejetavator,in nternalmane euveringvane es,ballandso ocket, andcylind derpowered [Link] designwas ch sthengiven a110ratin ([Link] ng olumn(s)3,5, ,7,9) relative to characteristics such as installation ease, durabilit interface ease, etc. Af o i ty, fter the rating for gs eachdesig gnweresummed,theballandsocketd designwasfo oundtohave thehighestt totalratingof83.5 outof100 0(Table1.Column7).Thus,thisteamfoundittobet thebestdesig gn. Table2 Jetavator Vanes Balla andSocket Cylin nders Co olumn2 Column3 Colu umn4 Colum mn5 Colum n6 Column n7 Column8 Column9 Column10 8 Weight Rat W ting Scor re Rating g Score Rating Score Rating Score
6.8 2.3 15.9 11.4 15.9 15.9 15.9 2.3 11.4 2.3

Column1 Criteria
inst tallation eas se Saf fety dura ability inte erface ease hea at requ uirements resp ponse to ang change gle low weight eas of se man nufacture low drag Cos st

8 9 6.5 5 6.5 7 6.5 5 5 6 64.5

54.4 20.7 10 03.35 57 10 03.35 111.3 1 10 03.35 11.5 57 13.8 645 56.45

8.5 9 8 7 4 7.5 8 6 10 6 74

57 7.8 20 0.7 127 7.2 79 9.8 63 3.6 119. .25 127 7.2 13 3.8 1 114 13 3.8 7407 7.4

9 9 8. .5 9 6. .5 8. .5 8 7 1 10 8 83. .5

61.2 2 20.7 7 135.15 5 102.6 6 103.35 5 135.15 5 127.2 2 16.1 1 114 4 18.4 4 8338.5 5

8.5 9 9 9 7.5 8 5 7 9.5 7 79.5

57.8 20.7 143.1 102.6 119.25 127.2 79.5 16.1 108.3 16.1 7957.95

100.1

followingpho otosforrefere ence: *Refertothef

[Link] eringVanes

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[Link] egments
on Installatio

Theballa andsocketconceptwasea asiesttoinsta allontotheS SwordfishRoc cket,thusrec ceivingthehi ighest ratingof9 9fortheinst [Link] avatordesign, ,whichrequirestheinstallation ofmultipl lemaneuvera ablevanesan ndactuationm mechanismsa aroundthero ocketsend(S SeeFig.a),th heball andsocke etdesignonly yrequiresonemovablepa art,andtwoa actuationme [Link] nstallationof vanes inside the nozzle or boattail would also be more challeng ing than inst e b tallation of th ball and s he socket mechanism. It w would require this chine work o the on team to do mac noz zzle or boat ttail in order to make room fo at least three or uation mech hanisms in tight actu spa ace (See Fig d). Althou g. ugh a ier cylinder mechanism is easi to inst tall than th jetavator and he r inte ernalvanesm mechanisms, itstill requires more m moving parts than s [Link] theba ion allandsocketdesign. Safety Sa refore every design received a afety concern are very lo for each design conce ns ow ept, and ther highratingof9inthatcategory. EdgesS SusceptibletoEr rosion Durability y Si incethebolts sandflanges intheballan ndsocketdes signcanupta ake great loa ads, and the overall num e mber of com mponents in the design is relatively low, this designs implementation will proviide a durab n ble mechanism. However, this teams selected des , sign still has a lower rati ing thanthe cylinderdesig gninthedu [Link] asonbeingth hat ing t round it edges. the inlet of the rotati nozzle is susceptible to erosion ar This issue could lead to a notice e eable degrad dation in per rformance. T The

[Link] on

12 [Link] numberofsmallmovingpartsinthejetavatorandinternalvanemechanismincreasestheprobability offailure. Interfacing Anotherselectionparameterishowwelleachtypeofmechanisminterfaceswiththeelectronic [Link],theballandsocketdesignslownumberofmovingpartsand simplicityofactuationgivesitahighratingof9. HeatRequirements Theratinggiventoeachmechanismintheheatrequirementscategoryindicateshowwelleach [Link] thehighestratingduetothefactthatthecylinderswouldmaneuverthenozzlefromoutsideoftheflow [Link],[Link], which would be placed directly in the path of the flow regime (see Fig b), will have the greatest percentage of surface area exposed to exhaust heat. This is why the particular design was given the lowestratingintheheatrequirementscategory. SystemResponse Theresponsetoanglechangecategoryindicateshowfastaparticularmechanismrespondsto [Link] andmotionisgiventhehighestrating. Weight This team gave the ball and socket design the highest rating in the weight category for two [Link],theballand socket design requires redesign of the outward nozzle shape. We expect the redesign to reduce the overallweightoftherocket. Manufacturability Out of the four possible designs we considered, the ball and socket design rated among the highest in ease of manufacturability. The jetavator and internal vane based designs have many small [Link]. The relatively large size and lower number of components in the cylinder and ball and socket based designsmakesthecomponentsmucheasiertomanufacture. Drag Thedesignthatprovidesthelowestamountofdragisonethatresultsintheleastamountof [Link] located around the outer edge of the rockets back end (Fig. a), this particular design results in the

13 amountofsurfaceareaexposedtoairf [Link] nsiderationre esultedinthe elowestratingof5 greatesta forthedragcategory [Link] alvanebased ddesignresulltsinallmech hanismsofth hethrustvect toring systembe eingplacedin nsidetherocketnozzleor rboattail(Fig g.b).Thus,ze eroareaisex xposedtoair rflow, andahigh hestratingof f10isassigne ed. Cost Fo the cost category the ball and soc or e cket design i s assigned th highest ra he ating. The ball and socketde esignwillcost ttheleasttoprototypedu uetothelowe ernumberof fcomponents sandrelative eease ofmanufa acture. FurtherConceptDevelopment Ournext stepsinvolve etheresolutio onofsomed designissues, aswellasfu urthermodific cationstoimprove ourdesign [Link] eamneedsto odecidewhet therornotou urnozzlesho ouldextendoutsideoftheboat e, tail. If it does extend outside, this team pred d dicts lower b back pressure possibly g greater speed and d ion,moreroo omtomaneuv verthenozzle e,butincreas seddrag. accelerati
BoatTail

Ifnozzleextendsoutfurther,its su urfaceismoreex xposedtoairflo ow.

[Link] therDevelop pmentofCo oncept

Iftheent tirelengthof thenozzlein [Link] ortenedandm madetostay yinsidetheb boattail,this team predictsv verylowdrag g,greaterbac ckpressure,a andverylittle espacetoma aneuverthen nozzleforeffe ective operation of the entire system. One adverse possibility of the shorten nozzle b n O f ned being rotated to a d certain an ngle is the flow of gases partially thr rusting agains the walls of the boat st tail before e exiting throughtheback. Anotherissueiswheth hertoround theedgesof fthenozzlein nlettopreventerosionalo ongtheedge esand improve flow perform f mance (See Fig e). In addit g tion, this team is consider m ring coating t outside o the the of nozzles rotating end with a mater that will prevent frictiion and make actuation e r w rial p e easier. Coatin the ng insidewallsofthenoz zzlewithlightheatresista antmaterial isanotherop ptionunderc consideration [Link] teampred dictsthatthe eheatresista antcoatingw willhelpminim mizeperform mancedegrad dationdueto oheat effects.

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LinearactuatoranalysisandselectionisdiscussedfurtheroninthisreportunderAnalysisand Material/ComponentSelection

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CHAPT TER4Fina alDesign n

Fig11

IsometricV Viewofth heFinalSo olidModelDesign

*NOT TE:Actua atorsetup pandpro ototyper requirementshave echange ed. SeeC Chapter8 8forfurtherdetai ils

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Fig12

Explod dedandLabeledView woftheFi inalDesign nSolidMo odel

4.1Des signDescription
ItemNo. .1Socket:T Thesocketh holdsthecon nvergingand dthroatsectionsofthe nozzle(Item mNo. 3;alsore eferredtoas stheball).Thisballandsocketsetu pallowsthe enozzletoro otateindiffe erent direction nswiththeh helpofactua [Link] emwillbem madeofgrap phite. Item No.2Flange: Flanges serve a two tier purpose. T F They hold t together the ballandso e ocket setupagainstthepr ressureprod ducedbyho otgasflowt throughthe nozzle,and dserveplatf forms ntingtheact tuators(Item mNo.4). formoun

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These items will be made of Inconel 718. It was decided that in addition to the required ductility,[Link], Inconelisassumedtobeagoodchoicefortheserequirements. Item No.3Ball (interchangeably called nozzle from this point on): This component is a convergingdiverging nozzle which accelerates hot gas flow from subsonic to supersonic. The outside of the converging section is shaped like a sphere to allow rotation via the balland socketsetupforthesakeofvectoringthrustindifferentdirections. This item will be made of graphite. Graphite was chosen for its resistance to oxidation and suitable thermal properties. These thermal properties included low conduction and thermal expansion coefficients. The balls outside diameter was made small enough to make up for thermalexpansionduetohightemperaturesduringoperation. Item No.4Actuator Assembly: Actuators push and pull against the diverging section of the nozzle,causingrotationallalongtheconvergingsphericalsection. [Link] [Link] actuator would be working against both the weight of the nozzle and the pressure built up insidethenozzle. Item No.5Actuator Mount: Holds the actuator in place and connects the actuators to the divergingsectionofthenozzle. ItemNo.6Collar:Mountsontothe divergingsectionofthenozzleand servesasamountfor theactuatormounts.ThisitemwillbemadeofInconel718. Amajordesignconsiderationwasmakingthiscollarthickenoughsothatitdidntpopoutofits slotoncethermalexpansiontookeffect.

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4.2Eng gineeringA Analysis

HeatTransferAnalys sis Thehightemperatur resintheno ozzlewarran ntaheattra nsferanalys sisofkeyare easintheno ozzle. Theseinc cludethebe eginningof theconverg gingsection wherether reisathinw wallbetweenthe 4000deg greecombus stiongassesandtheelec ctronicsthat twillpower andcontrol ltherocket. SystemS Sketch
GasFlow G HeatConduct H tion

[Link] ferinnozzle e Objective e Tocomputethetemperature(s)insidethenozzlewallsa andattheno ozzlesurface es. Assumptions Theheat ttransferwa assimplifiedasonedime ensionalcon nductionthroughawall. . Method/ /Approach 1. St tartoutby lookingupw whattypical lconvection ncoefficientsforforcedconvectionflow [Link] esevaluesra angefrom25250depe endingonho owturbulent ttheflowis. . 2. Useavalueo U of200w/mK Kbecauseth heelectronic csneedtola astthrought theextento ofthe burn time. Analysis is do for a du A one uration of f fifteen secon and usin a .2inch thick nds ng pyrolyticcarb bon.

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Results Analysis results gave a relatively constant temperatur through the wall rig around 3400 e re ght degrees. This tempe erature analysis really gave a start g ting point to be able t start choosing to s. materials

ThermalExpansionA Analysisont theNozzle Due to temperature of up to 3400 degr t es o rees Fahren nheit, this t team expect the nozz to ts zle undergothermalexp [Link] econtactstr ressesbetwe eenthenozz zleandflang gesuponthe ermal expansio onofthenoz zzlemaygen neratemore efrictiontha anthesolen noidactuatorsusedtorotate thenozzl lecanactuallyovercome e. SystemS Sketch
Directionof fNozzleExpan nsion Nozzlefits here

Socket [Link] hermalexpa ansionofno ozzle Objective e The purp pose of this analysis is to find the point of m s e maximum e expansion al long the ou utside surface of the nozzle. Doing so will allow this team t o take ther o o rmal expansion into acc count duringdi imensionspe ecification. Assumptions 1. The thermal expansion at each cross section o the nozzle will be ap a of pproximately the y sa ame as the thermal expansion for a hollow c cylinder with the same inner and o h outer diametersasthegivencr rosssection. Approach h/Method 1. The nozzle converges on the inside and has a spherical o n e a outside surf face. Due to the o va aryinginner randouter diameters,t thermalexp pansionanal lysishadto beconductedat more than one point along the no m o ozzle length to see whe the greatest amount of ere ex xpansionwo ouldoccur.

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2. Thermal expansion analysis was conducted at the thinnest cross section of the nozzle (theentrance)aswellasthethickestcrosssection(thethroat). Results *SeeAppendixEformoredetailedAnalysis
Table3

CrossSection Atnozzleentrance Atthroat Conclusions/Recommendations

RadialExpansionduetothermalexpansion 0.00434inches 0.008112inches

We recommend a 0.008112 inch tolerance between the nozzle and the flanges. Mounting O ringsonthenozzleissuggestedinordertomakeupforthelossinrotationalstabilityresulting [Link]. ThermalExpansionAnalysisonInconelCollar AcalculationofthethermalexpansionfortheInconelcollarmountedonthedivergingsection ofthenozzlewasrequired.Thecollarisabout0.15inchesthick,andwehadtoconfirmthatit would not expand enough to overcome the depth of its mounting slot. The mounting slot is 0.06inchesdeep.

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SystemS Sketch
Collarplace esonmountings slot(0.06 inchesinde epth)viathisraisededge, whichis0.0 06inchesinheig ght.

Directionofcollarexpansion

Fig15.T Thermalexpansionofco ollar Objective e Theobjectiveofthis sanalysisist tocompute theradiale expansionof fthecollar, andconfirm mthat itisnotg greaterthanthedeptho ofthecollarsmountingslot. Assumptions 1. Approximatecollartobeahollowcylinder. A Method/ /Approach 1. Apply a basic thermal expansion eq A c quation to t collar us the sing advanced mechani of ics materialsprin m nciples. Results RadialEx xpansiononCollar:5.303 38*10^3inc ches Depthof fSlot:0.06in nches Conclusio ons/Recomm mendations Thetherm malexpansionoftheco [Link] tisgoodtou useasis.

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ForceAn nalysis Actuator rselectionre equiresanan nalysisoftheforcerequ uiredtorotatethenozzle. SystemS Sketch

Actuatio onForces

SealMoun nts(Pointofa actionfor frictionfor rces) Colla arMount(Po ointsofaction n for actuation forc a ces)

Fig [Link] onnozzle Assumptions Inthisan nalysisitwas srealizedthattheseals mountedov vertheball shapedsect tionofthen nozzle wouldbe ethemainfr rictioncomp ponenttopr rovideresista ancetomot tion. Method/ /Approach Themaximumpressuredifferenceacrossth henozzlewa asusedtoap pproximate thenormal force thatwou uldbeonthe eseals. Results Theresultsofthisan nalysistoldu usthattheforcerequire edtobreakt thefrictionw wouldbear round 40lbs.

4.3CostAnalysis
Theprice eofInconel component tsvariesdep pendingon thegradeo ofInconelth hesponsorw wants [Link] iceisforInc conel600([Link] [Link]#8),w whilethehig ghestprice isfor

23

Inconel 718 (i.e. bar price. Cell #8). Incone 718 is ma 7 r el ainly used in aerospace and gas n e nozzle applicatio ons,butInco onel600ma aysufficeduetothevery ysmalloper ratingtime. Inconelf fastenershavealeadtim meof12w weekstoman nufacture.T Thecostofthefinished parts canbese eenintheta ablebelow(F [Link]#8).
Table4

Material M

Co omponent(s)

Quantity

Price $256 64 eners:$34$4 8 44 Faste each Bar: $1450$ $2400 each eners: Hex Head Faste Quot teRequested $90e each12

Graphite1 Nozzle2 1,6 Diameter,1 3 12 Solid Lon ng, Gra aphiteRod Inconel5 Fastene ers,Flanges, ,6 8re eadymade 7 6 fast teners, Collar Dia meter; 6 long soli dbar;HexH Head m r, 4mm diameter 12 mm mlongfasten ners 9 10 Grafoil ORingSeals 4 11

CarbonF Felt13 Insulati ion14 N/A 15 N/A16 A Aluminum m17 LinearA Actuators 18 8 19 $80e each 20
Total:~$1910$2870 21

terial/Com mponentSe election 4.4Mat

NozzleW Wechosetom maketheno ozzleoutofg [Link] etalssuchas saluminumandsteelwe ere notselec ctedforthisapplicationduetotheir rthermaland doxidation propertie es.
Fig17 G GraphiteNoz zzle

24

Regardin ngoxidationproperties,thesolidfue elusedtopo owertheroc cketishighly [Link] metalsoxidizeeasily y,fuelflowt throughana aluminumo orstealnozzlewillhave ahighlyadv verse impact on the syste o ems perfor rmance. However, grap phite does not oxidize easily, and the d oxidative enatureofthefuelwillh haveaneglig gibleimpact tduringthe17secondsofoperation n. Inadditio on,graphite ehasacoeff ficientofexp pansionof2 2.2in/in Fc comparedto o12.3in/in Ffor aluminum and a min m nimum of 5.5 in/in F fo steel. A llower therm expansio for the n or mal on nozzle requires a smaller to olerance between the nozzle and f n flange. This poses less risk to rotat tional stabilityd duringopera ation. Flanges Our team chose to have flange and fasteners of the system ma out of m es ade Inconel.A AlthoughInc conel718ismostsuitab bleforgasno ozzleapplica ations,we maygow withalower rgradeofIn nconelduet tothesmall operationt timeof17 [Link] oritssuperioryieldand drupturestr rengthsat extremetemperatur res. Fig1 [Link] Flange However r,oneimpor rtantthingto onoteistha atwewillon nlyuseIncon nelinourpr rototypedes signif StellarEx xplorationsp pecifiesthat ttheprototy ypeneedsto obetested underextre emetemperature condition ns. Fasteners Thisteam mchoseInco onel20X3slottedflatheadsocket [Link] crews tobeappropriate,a astheywouldnegateth heriskofint terferenceb betweenfas stenerheads sand othercom mponentsofthesystem m.

25

Actuatorselection [Link] were thought more suitable because of their ability to produce very quick movements. The problemwithsolenoidsisthatfortheforcedesiredthelightestonesarearoundthirtypounds. Thisweightwouldnotbereasonabletoaddtotherocket. Duetothestatedreasons,[Link] provide the desired force were very large. After a long search, two actuators that would be [Link].Theseactuatorsare3incheslong and can produce a peak thrust of 14.6lbs. However, they sell this actuator for one thousand [Link] in a range of options with different gearing and lengths of stroke. The 10mm (.394in) stroke option with a 210 to 1 gear ratio that with a 12 volt battery will produce a peak force of 45N(10.1lbf)at2.5mm/s(.0984in/s).Fouroftheseactuatorswillberequiredineachdirection [Link] [Link] [Link] thatthesystemwilluse12.48wattsmaximum. Grafoil Grafoil seals were selected due to their good combination of rigidity and flexibility under the [Link] addition,thismaterialcanwithstandupto6000degreesFahrenheit. CarbonFelt [Link],it [Link],itcanbeusedinlowenoughamountsforitto nothaveabigeffectonthesystemsweightspecifications.

26

CHAPTER5Manufacturing/Assembly
Manufacturing/Assembly
NozzleParts [Link] campushavemachineswhicharecapableoffollowingtheshapeprofileofournozzledesign. Afterobtainingtheoverallshapeofthenozzle,slotsforOringsandcollarwillbemadeona lathemachine. Flanges [Link],inaddition, boringandthreadingisrequiredforwheretheboltswillbeplaced. FurtherFabricationandAssemblyInstructions The boat tail will need to be modified from its current design to provide more space for the [Link] iscurrentlyacontinuationofthenozzlemustbelathedsothatthenewnozzlewillhaveroom [Link] [Link] cutsandthenarotarycuttingbladetofinishthebottompartofthetrapezoidshapedcuts. Thecollarthatisplacedaroundthenozzletoprovideattachmentpointsfortheactuatorswill be manufactured by taking a ring of the metal (either steel or inconel) being used for the flangesandlathingthecircularportionthentheringwillbecutandtabswillbeweldedtothe [Link] betodrillholesforthescrewsthatwillholdtheactuatorbrackets.*Forfurtherdetail,seethe ManufacturingsectioninChapter8.

27

Assembly of the entire system starts with inspection of the parts all dimensions should be checked so that problems will not be encountered later. After all the dimensions have been [Link] brackets can be attached using hex head screws coming from the inside of the collar and holdingthebracketsonwithonewasherandanutatthisstagetheycanjustbetightenedby [Link] downoverthesmallendoftheball/nozzleandfittedintothelocatingslotaboltcanbeslipped through the hole in the tabs and finger tightened. Take the grafoil seals and cut two lengths [Link] [Link] [Link]. Take the two flanges and the remaining actuator brackets and attach them to their [Link] socket around the ball aligned with the bolt holes. Care should be taken to place the grafoil sealsintotheslotsintheflangeswithoutdamagingthem.The20x3inboltscanbeplacedin the holes in the flange and through the socket. Washers and nuts can be tightened onto the [Link] brackets place the actuator in the brackets using the M4 bolts provided. These bolts can be tightenednextyoucantightentheboltsholdingtheactuatorbracketsdownandmoveonto [Link] [Link] the chamber where the batteries and controller will be kept. Care should be taken with the [Link] thissectionwithlongstripsoverlappingthepreviousendwitheachsuccessivepassuntilthere isjustenoughroomtoplacethebatteriesandotherelectricalcomponentsdirectlyupagainst [Link] insertedintothefuselageandassemblyiscomplete. This rocket nozzle is designed to be used once so no maintenance schedule or repair is recommended.

28

CHAPTER6ProjectPlanning
6.1ProjectManagementPlan
[Link] thisfinaldesignreportcompletedbyFebruary1,2011(GanttChart,Row34).However,wehave beendelayedbyafewdays,andthisreportisnowcompleteonFebruary5,2011. The first milestone was the Project Requirements Document (Gantt Chart, Row 14). This document showed a translation of all customer requirements to engineering specifications. Requirementssuchasdurability(QFD,Row3)weretranslatedtorequirementssuchasability towithstandaspecifiedhightemperature. MilestonesincludingthePreliminaryDesignPresentation(GanttChart,Row20),creationofthe solid model (Gantt Chart, Row 25), Conceptual Design Report (Gantt Chart, Row 28), and ConceptualDesign Review (GanttChart, Row 29) served to present the basicworkings of the system. The Conceptual Design Report included everything from the Project Requirements Document,afinalizeddesignconcept,aprojectmanagementplan,[Link] ReviewconsistedofapresentationoftheConceptualDesignReportsmainpartstotheproject sponsor. The current report is a more detailed version of the Conceptual Design Report. The content takes into account detailed analysis used to finalize system dimensions. It also expands on additionalsubsystemssuchastheactuators. For the final design phase of the project, Harsimran Singh handled the thermal expansion analysis and contact stress analysis. This is in addition to taking charge in acquisition of materialssuchasgraphite,Inconelbars,[Link] [Link] additiontotakingchargeinacquisitionofmaterials/componentssuchaslinearactuators,graph foilOringsandcarbonfeltinsulation.

29

Fromthispointon,thisteamwillbeconcernedwithmanufacturingandtestingthesystem.A leadtimeof12.5weeksforacquisitionofallmaterials(GanttChart,Rows36&37),and810 weekstobuildandfullytestthesystem(GanttChart,Rows3739)[Link],thisis [Link] somecomponents,[Link] [Link] anddesignverificationplansisprovidedbelow.

6.2DesignVerification/TestingPlan
Planstovalidatetheconceptwillbeginbymeasuringgeneralattributesoftheassemblysuchas overallweightsizeandclearancebetweenmovingpartsandrangeofmotionofthenozzle. Aftergeneralattributeshavebeenmeasuredtheassemblywillbefittedintoatestfixturethat [Link] [Link] up,[Link] functiongeneratorsupsothattheywouldbeabletocyclethenozzlethroughthetwodegrees [Link] [Link] requirementsthatweresetoutatthebeginningoftheproject. Inaddition,[Link] thatthesystemreactsasdesiredtooperationaltemperaturesandpressures.

30

CHAPTER7ConclusionsandRecommendations
The outside diameter of the nozzles converging and throat sections is designed a specific amount smaller than the inside diameter on each flange cross section to take thermal expansion during operation into account. The Orings mounted on top of the nozzle are specificallydimensioned to make up for the difference indiameter. These Orings reestablish therotationalstabilityofthenozzle,whichwouldotherwisebecompromisedbythenozzlenot being flush with the flanges. Any careless changing of these dimensions will have an adverse impactonsystemperformance. This team has left it up to the sponsor to decide which grade of Inconel should be used. Although industry generally uses 718 grade for aerospace and gas nozzle applications, we recommend the use of a lower grade such as Inconel 600 or 625. Systems in industry are expected to operate for much longer durations than the 17 second operating time of our [Link],Inconel718isamuchmoreexpensivegrade.TheuseofInconel600willbe [Link] Inconel718forfutureapplications,theuseofalowergradewouldbemorepracticalatleast forthecurrenttestingpurposes. Unless overall system dimensions are increased, we recommend continued use of flat head fastenerstonegatethepossibilityofinterferencebetweenthefastenerheadsandotherparts ofthesystem. TheInconelcollarmountedonthedivergingsectionofthenozzleispredictedtoexpand0.0032 [Link] adepthof0.0032inches.

31

Chapte er8Final lProjectU Updates

Theprec cedingwritte enmaterials sandthema aterialsinth heAppendic cesregarda prototypew which will unde ergo full tes sting. That is to say, th prototyp will unde he pe ergo both hot gas tests and s actuation [Link] wever,forth hepurposes ofthissenio orprojectSt tellarExplor rationdecidedto limitthe projectrequirementstoaprototyp pethatwill onlyneedtoundergoa actuationtes sting. Thus, the prototype has not been built using materiials such as graphite a e b u s and Inconel. The currentm modelusess standardste eelnutsandbolts,astee elcollarcon nnectingthe eactuatorstothe nozzle,andrapidpro ototypingma aterials. Writtena andvisualm materialpres sentedfrom mhereonun ntiltheAppe endicessect tionconcern nsthe currentp prototypemodel.

8.1Mat terials
Thenozz zle,flangesa andsocketarerapidpro ototypemod delsmadeen ntirelyoutofathermop plastic called Ac crylonitrile butadiene st b tyrene (ABS). All actuat mounting brackets a coupler are tor and rs alsorapid dprototypemodels,but taremadeo ofresinbase edrapidprototypemate erialinstead.

Sock ket

Nozzle

Flange

Fig 19 Rapid Pr 9. rototyped C Componen nts

32 Resin R

Actua coupler and moun ting bracket ator rs ts

Fig 20
andthreadedstockarestandardsteelp partsboughtf fromahardw warestore. Allboltsa

8.2Des signChang ges

The origi inal design called for th actuator mounts pro c he ovided by th supplier t be installed at he to the collar and flange However, mounting actuators c es. g close to the flanges, an mounting one e nd g actuatorpermountp posedriskso ofovercons strainingthe esystem.
Toom manyactuator r moun ntscouldcaus se constr raining A Actuatorsnext ttoflangesm may preventneces ssaryamountof otation ro

[Link] signFlaws

33

In order to resolve these issues, the number of m r e mounting p points was first decreased from 16 to 8 by cou upling two actuators at each poin The couplers (see y a nt. yellow bloc in cks h ssembly, th hus allowin mountin points to be ng ng o Fig 22) increased the length of the as f ck e T nted any s sort of interference du uring moved further bac from the flanges. This preven nozzle rotation. The couplers are fixed to the rest o the asse r of embly with o the shel rod off lf ends.

Twoact tuatorscouple edusing threade stock ed

AlteredMo ountingPoint (Movedbac ckfromflanges) OriginalMountingPo oints

[Link] signFlawSo olutions

34

8.3Manufacturing
Aspreviouslystated,mostpartsoftheprototypesuchasball,socket,flangesandmountswere rapid prototyped. The only machined component is the collar. The collar was manufactured [Link]:

1. Machine a section of round solid steel bar at an angle.

Angle

[Link] 2. [Link] [Link]. 3. Drillholeswhereactuatormountsmustbeplaced 4. [Link] 5. Weldtabsontoedgesofthediscontinuity.
radius

MachinedBarSection

35 Thick kness Welde edTabs Holesfo ractuatormounts o

Placecut there RaisedEd dge

[Link] tedfeatures sofcollar

36

Chapte er9Testi ing

9.1Test tingAppar ratus
Thenozz zlesrotation ntoanangle eof+/7deg greeswasth heonlytesto objectivewh hichrequired fulfillmen [Link] apparatusw wassetupas sfollows: 1. ConstructanIsoscelestrianglewitha atotalvertex xangleof14 4degrees

7degrees 7

ratus [Link] thenozzlew withvertexfa acingdown. 2. Placethetriangleinsidet 3. Alignaweigh A htedstringal longtriangle esvertex.

Triang gle(HandDra awn)

Wei ightedString

Fig2 [Link]

37

4. [Link] A fweightedst tringalignsw withatriang gleside,obje ectivehasbe een met. m

Alignmenta at7degrees

[Link] tobjectivev verification

9.2W WiringSet tup

Motio oncontrolfo ortestingisdonewithswitcheshoo okeduptoabreadboard d.

Sw witch

Fig28.W Wiring

38

Eachactuationpointonanaxisofrotationhasapolarityoppositetothepointattheotherend [Link],asonepairofactuatorsextendsthepairontheotherendoftheaxis [Link].

 APPENDIX A

39

Column1 Criteria
installation ease Safety durability interface ease heat requirements response to angle change low weight ease of manufacture low drag Cost

Jetavator Vanes BallandSocket Cylinders Column2 Column3 Column4 Column5 Column6 Column7 Column8 Column9 Column10 Weight Rating Score Rating Score Rating Score Rating Score
6.8 2.3 15.9 11.4 15.9 15.9 15.9 2.3 11.4 2.3

8 9 6.5 5 6.5 7 6.5 5 5 6 64.5

54.4 20.7 103.35 57 103.35 111.3 103.35 11.5 57 13.8 6456.45

8.5 9 8 7 4 7.5 8 6 10 6 74

57.8 20.7 127.2 79.8 63.6 119.25 127.2 13.8 114 13.8 7407.4

9 9 8.5 9 6.5 8.5 8 7 10 8 83.5

61.2 20.7 135.15 102.6 103.35 135.15 127.2 16.1 114 18.4 8338.5

8.5 9 9 9 7.5 8 5 7 9.5 7 79.5

57.8 20.7 143.1 102.6 119.25 127.2 79.5 16.1 108.3 16.1 7957.95

100.1

40
Title: Author: Date: Notes:

Legend

Strong Relationship Moderate Relationship Weak Relationship Strong Positive Correlation Positive Correlation Negative Correlation Strong Negative Correlation Objective Is To Minimize Objective Is To Maximize Objective Is To Hit Target

9 3 1

Column # Direction of Improvement: Minimize (), Maximize (), or Target (x) Quality Characteristics (a.k.a. "Functional Requirements" or "Hows") Weight / Importance

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25 Competitive Analysis (0=Worst, 5=Best)

Our Company

liquid injection

Max Relationship Value in Row

number of cycles till failure

thrust vanes

Competitor 3

frequency response

heat requirements

Relative Weight

drag measured

actuation error

angle of thrust

liquid injection

Our Company

rotatable

flexible joint

Competitor 3

thrust vanes

Demanded Quality (a.k.a. "Customer Requirements" or "Whats") installation ease safety durabillity interface ease heat requirements response to angle chage low weight ease of manufacture low drag cost

flexible joint

slew rate

pressure

rotatable

Row #

weight

power

size

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

3 3 9 9 9 9 9 9 9 9

15.6 2.2 15.6 11.1 15.6 20.0 8.9 2.2 6.7 2.2

7.0 1.0 7.0 5.0 7.0 9.0 4.0 1.0 3.0 1.0

2 3 4 3 2 2 2 2 5 3

4 5 4 5 2 2 5 2 5 2

2 5 3 3 3 4 2 2 2 2

2 4 4 3 4 5 5 3 5 3

3 4 5 5 4 5 5 4 5 5

withstand 1300 for 15 sec

adds less than 1% to drag 5 9 60.0 2.0

Target or Limit Value

Difficulty (0=Easy to Accomplish, 10=Extremely Difficult) Max Relationship Value in Column Weight / Importance Relative Weight

9 9 315.6 10.4

4 9 200.0 6.6

5 9 408.9 13.5

4 9 288.9 9.6

7 9 395.6 13.1

3 9 233.3 7.7

2 9 208.9 6.9

5 9 204.4 6.8

5 9 280.0 9.3

428.9 14.2
Powered by QFD Online ([Link]

less than .05 degree 5 9

7 degree resultant vector

less than 30watts

4lb over existing

5k cycles before failure

.5 sec half cycle

less than5.75 d

600 psi

20 hz

41 APPENDIX B

Actuators

Actuators

42

Heat Transfer Analysis

Thermal Expansion of Collar

43

Thermal Expansion of Nozzle

44 APPENDIX C

Material/Component Graphite

Vendor [Link]

Price $256for one graphite rod

Contact
Address:[Link], Inc. 1348 Busch Parkway Buffalo Grove, IL 60089 US Phone: 800-305-1664 (Toll Free US only) 847-279-1925 Fax: 847-279-1926

E-mail: support@[Link]

Fasteners

FastenerSolutions,Inc.

InconelRods

CaliforniaMetaland Supply,Inc.

LinearActuators

FirgelliTechnologies

$34$44 Name: Matt Bridges foreach Office:866 463 2910 ext. 242F fastener Cell: 225-200-7909 Quote Fax: 225-927-9292 Requested [Link] onSmaller Dimension Fasteners Phone:8007076061 $1450 $2400for Fax:8007073439 eachbar [Link] $80each Phone:2063479684
Fax:2063479684 sales@[Link],[Link]

GrafFoil CarbonFelt

[Link] ChemShine

$90each N/A

Phone:7143611435 Tel:00865925530176 Fax:00865925531751 MSN:guoxingyw@[Link] Email:info@[Link]

45 APPENDIX D

.60 5.10 1.52 1.18 R.15 3.96

SECTION A-A 35

R1.75 .19 .60 .88 A A .17 67

.15 .06 18

.05

Stellar Thrust Control

DRAWN BY: DANE LARKIN TOLERANCE: .001 NEXT ASSY: DWG #: 001 UNITS: INCHES SCALE: 1/4 DATE: 2/5/11
3

INIT:

CKD BY: SIMRAN SINGH MATERIAL: CARBON TITLE: BALL GROUP:

2 1

INIT:

46
5.75

3.50 2.92

50 R2.88 1.13 .19 .50 .30 2.38 .10 A .19 .75 .10 .19 SECTION A-A DRAWN BY:DANE LARKIN TOLERANCE: .001 NEXT ASSY: DWG #: 004
5 4

45

6X

.25

25 A .50 1.35 R2.35

R1.76 .09

.40

3.50

25 INIT: UNITS:INCHES SCALE:2:1 DATE: 2/5/11

3

.17 INIT:

Stellar Thrust Control

CKD BY:SIMRAN SINGH MATERIAL: CARBON TITLE: SOCKET GROUP:

2 1

47
SECTION B-B

.25 3.75 2.25 .80 .95 1.70 5.75 6.00 2.50 .40

4.76 B B 15

Stellar thrust control

DRAWN BY: DANE LARKIN TOLERANCE: .001 NEXT ASSY: DWG #: 002 UNITS:INCHES SCALE:1:4 DATE: 2/5/11
3

INIT:

CKD BY: SIMRAN SINGH MATERIAL: ALUMINUM TITLE: MODIFIED BOAT TAIL GROUP:
2 1

INIT:

48

.07 A .12

.50

.25 R.20 .17

.10

18

.25

.06 .14

1.74

A SECTION A-A

Stellar Thrust Control

DRAWN BY: DANE LARKIN TOLERANCE: .001 NEXT ASSY: DWG #:003 UNITS: INCHES SCALE: 2:1 DATE:2/5/11
3

INIT:

CKD BY: SIMRAN SINGH MATERIAL: STEEL OR INCONEL TITLE: COLLAR GROUP:
2 1

INIT:

49

.20 2.00

25

R.13X4

.28 .09 R1.95 .19

50 .53

13

2.60

R2.88 .14 R1.76

R1.95

R2.35

.10 DRAWN BY: DANE LARKIN TOLERANCE: .001 NEXT ASSY: DWG #: 005
5 4

Stellar Thrust Control

INIT: UNITS: INCHES SCALE: 2:1 DATE:2/5/11

3

CKD BY: SIMRAN SINGH MATERIAL: ALUMINUM OR INCONEL TITLE: FLANGE GROUP:
2 1

INIT:

50

Stellar Thrust Control

DRAWN BY:DANE LARKIN TOLERANCE: .001 NEXT ASSY: DWG #: 006 UNITS:INCHES SCALE: 1:2 DATE: 2/5/11
3

INIT:

CKD BY: SIMRAN SINGH MATERIAL: TITLE: FULL ASSEMBLY GROUP:

2 1

INIT:

51
6 3

4 5

ITEM NO. 1 2 3 4 5 6
DRAWN BY:DANE LARKIN TOLERANCE: .001 NEXT ASSY: DWG #: 007
5 4

PART NUMBER socket flange ball actuatorAssem actuator mount collar

Stellar Thrust Control

INIT: UNITS: INCHES SCALE: 1:4 DATE: 2/5/11

3

CKD BY: SIMRAN SINGH MATERIAL: TITLE: EXPLODED ASSEMBLY GROUP:

2 1

INIT:

QTY.

1 2 1 8 16 1

ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Task Name selecting projects project presentations project preference form sponsor communication team introduction to sponsor visit the sponsor team contract projects requirement Doc background research QFD development specification Development method of approach management plan project Requirements Doc Correct Requirements Doc Idea Generation brain storming PEW diagram conceptual model preliminary design presentation Conceptual Design Enhance design requirements doc priliminary calculations initial drawings solid model proto type preliminary plans for constructioon and te conceptual design report conceptual design review Design finalization reanalyze certain design aspects make changes to concept student presentations Design Report Doc manufacturing Task Split

Duration

Start

52 APPENDIX E Finish
12 19 26

Oct '10 3

10

17

24

Nov '10 31 7

14

21

Dec '10 28 5

3 days? Tue 9/21/10 Fri 9/24/10 3 days? Tue 9/21/10 Thu 9/23/10 0 days Fri 9/24/10 Fri 9/24/10 6 days Wed 9/29/10 Thu 10/7/10 0 days Wed 9/29/10 Wed 9/29/10 0 days Wed 10/6/10 Wed 10/6/10 0 days Thu 10/7/10 Thu 10/7/10 17 days? Mon 9/27/10 Tue 10/19/10 17 days? Mon 9/27/10 Tue 10/19/10 1 day? Thu 10/14/10 Thu 10/14/10 2 days? Thu 10/14/10 Sat 10/16/10 1 day? Mon 10/18/10 Mon 10/18/10 2 days? Mon 10/18/10 Tue 10/19/10 0 days Tue 10/19/10 Tue 10/19/10 31 days Mon 10/25/10 Mon 12/6/10 13 days? Thu 10/21/10 Tue 11/9/10 9 days? Thu 10/21/10 Tue 11/2/10 1 day? Fri 11/5/10 Fri 11/5/10 1 day Fri 11/5/10 Sat 11/6/10 0 days Tue 11/9/10 Tue 11/9/10 19 days? Wed 11/10/10 Mon 12/6/10 19 days? Wed 11/10/10 Mon 12/6/10 7 days Wed 11/10/10 Thu 11/18/10 10 days Fri 11/12/10 Thu 11/25/10 0 days Thu 11/25/10 Thu 11/25/10 1 day? Fri 11/26/10 Fri 11/26/10 2 days? Tue 11/23/10 Wed 11/24/10 0 days Fri 12/3/10 Fri 12/3/10 0 days Mon 12/6/10 Mon 12/6/10 18 days? Thu 1/6/11 Tue 2/1/11 5 days Thu 1/6/11 Wed 1/12/11 1 day? Thu 1/13/11 Thu 1/13/11 0 days Tue 1/18/11 Tue 1/18/11 0 days Tue 2/1/11 Tue 2/1/11 42 days? Mon 2/7/11 Tue 4/5/11 External Milestone Inactive Task Inactive Milestone Inactive Summary Manual Task Duration-only Page 1

9/24 9/29 10/6 10/7

10/19

11/9

11/25

12/3 12

Manual Summary Rollup Manual Summary Start-only Finish-only Progress Deadline

Project: senior [Link] Date: Fri 2/4/11

Milestone Summary Project Summary External Tasks

53
ID 36 37 38 39 40 Task Name contact sponsor about materials machineing and assembly testing fixing anything that is broken final project design report Duration 5 days? 21 days? 11 days? 6 days? 0 days Start Mon 2/7/11 Fri 2/11/11 Mon 3/14/11 Tue 3/29/11 Fri 6/3/11 Finish 12 Fri 2/11/11 Sat 3/12/11 Mon 3/28/11 Tue 4/5/11 Fri 6/3/11 19 26 Oct '10 3 10 17 24 Nov '10 31 7 14 21 Dec '10 28 5

Task Split Project: senior [Link] Date: Fri 2/4/11 Milestone Summary Project Summary External Tasks

External Milestone Inactive Task Inactive Milestone Inactive Summary Manual Task Duration-only Page 2

Manual Summary Rollup Manual Summary Start-only Finish-only Progress Deadline

54
'10 5 12 19 26 Jan '11 2 9 16 23 Feb '11 30 6 13 20 Mar '11 27 6 13 20 27 Apr '11 3 10 17 24 May '11 1 8 15 22 Jun '11 29 5

12/3 12/6

1/18 2/1

Task Split Project: senior [Link] Date: Fri 2/4/11 Milestone Summary Project Summary External Tasks

External Milestone Inactive Task Inactive Milestone Inactive Summary Manual Task Duration-only Page 3

Manual Summary Rollup Manual Summary Start-only Finish-only Progress Deadline

55
'10 5 12 19 26 Jan '11 2 9 16 23 Feb '11 30 6 13 20 Mar '11 27 6 13 20 27 Apr '11 3 10 17 24 May '11 1 8 15 22 Jun '11 29 5

6/3

Task Split Project: senior [Link] Date: Fri 2/4/11 Milestone Summary Project Summary External Tasks

External Milestone Inactive Task Inactive Milestone Inactive Summary Manual Task Duration-only Page 4

Manual Summary Rollup Manual Summary Start-only Finish-only Progress Deadline

56 APPENDIX F

57

Graphite Store: Product Data Sheet GR001CC

58

Page 1 of 1

Print

Close

Grade: GR001CC
Manufacturer: Method of Manufacturing: Description: Graphtek LLC Isostatically Pressed High strength, wear resistant graphite

PROPERTY Density Shore Hardness Flexural Strength Oxidizing Atmosphere Neutral Atmosphere Porosity Electrical Resistivity Thermal Conductivity Ash Content CTE

US VALUE 0.065 76 7250 801 5000 12 0.00055 49 100 2.6

psi F F % ohm/inch BTU/([Link] ppm in/in F x 10 -6
2

METRIC VALUE 1.81 50 427 2760

gr/cm 3

lb/in

mpa C C

ohm/cm F/ft)

85 4.6

W/(m 2 . K/m)

Microns/m C

Print

Close

[Link]

2/5/2011

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Miniature Linear Motion Series L12

Firgelli Technologies unique line of Miniature Linear Actuators enables a new generation of motion-enabled product designs, with capabilities that have never before been combined in a device of this size. These small linear actuators are a superior alternative to designing with awkward gears, motors, servos and linkages. Firgellis L series of micro linear actuators combine the best features of our existing micro actuator families into a highly flexible, configurable and compact platform with an optional sophisticated on-board microcontroller. The first member of the L series, the L12, is an axial design with a powerful drivetrain and a rectangular cross section for increased rigidity. But by far the most attractive feature of this actuator is the broad spectrum of available configurations.

L12 Specifications
Gearing Option Peak Power Point 1 Peak Efficiency Point Max Speed (no load) Backdrive Force 2 Stroke Option Weight 50 12 N @ 11 mm/s 6 N @ 16 mm/s 23 mm/s 43 N 10 mm 28 g Positional Accuracy 0.1 mm Max Side Force (fully extended) 50 N Mechanical Backlash Feedback Potentiometer Duty Cycle Lifetime Operating Temperature Storage Temperature Ingress Protection Rating Audible Noise Stall Current 100 210 23 N @ 6 mm/s 45 N @ 2.5 mm/s 12 N @ 8 mm/s 18 N @ 4 mm/s 12 mm/s 5 mm/s 80 N 150 N 30 mm 50 mm 100 mm 34 g 40 g 56 g 0.2 mm 0.2 mm 0.3 mm 40 N 30 N 15 N 0.1 mm 2.75 k/mm 30%, 1% linearity 20 % 1000 hours at rated duty cycle 10C to +50C 30C to +70C IP54 55 dB at 45 cm 450 mA at 5 V & 6 V, 200 mA at 12 V

Benefits
Compact miniature size Simple control using industry standard interfaces Low voltage Equal push / pull force Easy mounting

1 1 N (Newton) = 0.225 lbf (pound-force) 2 a powered-off actuator will statically hold a force up to the Backdrive Force

Applications
Robotics Consumer appliances Toys Automotive Industrial automation
cm AWG leadwires with . mm pitch female header connector

Dimensions (mm)

Firgelli Technologies Inc.

4585 Seawood Tce. Victoria, BC V8N 3W1 Canada 1 (206) 347-9684 phone 1 (888) 225-9198 toll-free 1 (206) 347-9684 fax sales@[Link] [Link]

Copyright 2008 Firgelli Technologies Inc. Patent Pending. 23 July 2008

60 L12 Specifications
Load Curves

Current Curves

Gearing Option
Current (mA)

6 V Models
Gearing Option

Speed (mm/s)

V Models
Gearing Option

Force (N)

Force (N)

Model Selection
The L12 has five configurable features. L12 configurations are identified according to the following scheme:

Basis of Operation
The L12 actuator is designed to move push or pull loads along its full stroke length. The speed of travel is determined by the gearing of the actuator and the load or force the actuator is working against at a given point in time (see Load Curves chart on this datasheet). When power is removed, the actuator stops moving and holds its position, unless the applied load exceeds the backdrive force, in which case the actuator will backdrive. Stalling the actuator under power for short periods of time (several seconds) will not damage the actuator. Do not reverse the supply voltage polarity to actuators containing an integrated controller (I controller option). Each L12 actuator ships with two mounting clamps, two mounting brackets and two rod end options: a clevis end and a threaded end with nut (see drawing on page 4). When changing rod ends, extend the actuator completely and hold the round shaft while unscrewing the rod end. Standard lead wires are 28 AWG, 30 cm long with 2.56 mm (0.1") pitch female header connector (HiTec and Futaba compatible). Actuators are a sealed unit (IP54 rating, resistant to dust and water ingress but not fully waterproof).

L12-SS-GG-VV-C-L
feature options 10, 30, 50, 100 Any stroke length between 10 and 100 mm is available on custom orders, in 2 mm increments.

SS: Stroke Length (in mm)

GG: Gear reduction ratio (refer to force/speed plots) VV: Voltage

50, 100, 210 Other gearing options may be possible on custom orders. 06 6 V (5 V power for Controller options B and P) 12 12 V

C: Controller

B Basic 2-wire open-loop interface, no position feedback, control, or limit switching. Positive voltage extends, negative retracts. S 2-wire open-loop interface (like B option) with limit switching at stroke endpoints.

P Simple analog position feedback signal, no on-board controller. I Integrated controller with Industrial and RC servo interfaces (see L12 Controller Options section). Not available with 10mm stroke length configurations.

Ordering information
Sample quantities may be ordered with a credit card directly from [Link]. Please contact Firgelli at sales@[Link] for volume pricing or custom configurations. Note that not all configuration combinations are stocked as standard products. Please refer to [Link]/orders for current inventory.

R RC Linear Servo. Not available with 10mm stroke or 12 volts.

L: Mechanical or electrical interface customizations

Custom option codes will be issued by Firgelli for custom builds when applicable.

Miniature Linear Motion Series L12 Firgelli Technologies Inc. for more info call 1 (888) 225-9198 or visit [Link]

61 L12 Controller options

Option BBasic 2-wire interface
WIRINg: 1 (red) Motor V+ (5 V or 12 V) 2 (black) Motor ground The B actuators offer no control or feedback mechanisms. While voltage is applied to the motor V+ and ground leads, the actuator extends. If the polarity of this voltage is reversed, the actuator retracts. The 5 V actuator is rated for 5 V but can operate at 6 V.

Option IIntegrated controller with industrial and RC servo interfaces

WIRINg: 1 (green) Current input signal (used for 420 mA interface mode) 2 (blue) Voltage input signal (used for the 05V interface mode and PWM interface modes) 3 (purple) Position Feedback signal (03.3 V, linearly proportional to actuator position) 4 (white) RC input signal (used for RCservo compatible interface mode) 5 (red) Motor V+ (+6 Vdc for 6 V models, +12 Vdc for 12 V models) 6 (black) ground The I actuator models feature an onboard software-based digital microcontroller. The microcontroller is not userprogrammable The six lead wires are split into two connectors. Leads 4, 5 and 6 terminate at a universal RC servo three-pin connector (Hi-Tec and Futaba compatible). Leads 1, 2 and 3 terminate at a separate, similarly sized connector. When the actuator is powered up, it will repeatedly scan leads 1, 2, 4 for an input signal that is valid under any of the four supported interface modes. When a valid signal is detected, the actuator will selfconfigure to the corresponding interface mode, and all other interface modes and input leads are disabled until the actuator is next powered on. 05 V Interface Mode: This mode allows the actuator to be controlled with just a battery, and a potentiometer to signal the desired position to the actuator a simple interface for prototypes or home automation projects. The desired actuator position (setpoint) is input to the actuator on lead 2 as a voltage between ground and 5 V. The setpoint voltage must be held on lead 2 until the desired actuator stroke position is reached. Lead 2 is a high impedance input. 420 mA Interface Mode: This mode is compatible with PLC devices typically used in industrial control applications. The desired actuator position (setpoint) is input to the actuator on lead 1 as a current between 4 mA and 20 mA. The setpoint current must be held on lead 1 until the desired actuator stroke position is reached.

RC Servo Interface Mode: This is a standard hobby-type remote-control digital servo interface (CMOS logic), compatible with servos and receivers from manufacturers like Futaba and Hi-Tec. The desired actuator position is input to the actuator on lead 4 as a positive 5 Volt pulse width signal. A 1.0 ms pulse commands the controller to fully retract the actuator, and a 2.0 ms pulse signals full extension. If the motion of the actuator, or of other servos in your system, seems erratic, place a 14 resistor in series with the actuators red V+ leadwire. PWM Mode: This mode allows control of the actuator using a single digital output pin from an external microcontroller. The desired actuator position is encoded as the duty cycle of a 5 Volt 1 kHz square wave on actuator lead 2, where the % duty cycle sets the actuator position to the same % of full stroke extension. The waveform must be 0V to +5V in order to access the full stroke range of the actuator.

Option SBasic 2-wire interface

WIRINg: 1 (red) Motor V+ (5 V or 12 V) 2 (black) Motor ground When the actuator moves to a position within 0.5mm of its fully-retracted or fully-extended stroke endpoint, a limit switch will stop power to the motor. When this occurs, the actuator can only be reversed away from the stroke endpoint. Once the actuator is positioned away from its stroke endpoint, normal operation resumes. For custom orders, limit switch trigger positions can be modified at the time of manufacture, in 0.5mm increments.

Option RRC Linear Servo

WIRINg: 1 (white) RC input signal 2 (red) Motor V+ (6 VOC) 3 (black) ground The R actuators or linear servos are a direct replacement for regular radio controlled hobby servos. Operation is as above in RC servo interface mode (option I). The R actuators are available in 6 volt and 30, 50 and 100 mm strokes only.

Option PPosition feedback signal

WIRINg: 1 (orange) Feedback potentiometer negative reference rail 2 (purple) Feedback potentiometer wiper (position signal) 3 (red) Motor V+ (5 V or 12 V) 4 (black) Motor ground 5 (yellow) Feedback potentiometer positive reference rail The P actuators offer no built-in controller, but do provide an analog position feedback signal that can be input to an external controller. While voltage is applied to the motor V+ and ground leads, the actuator extends. If the polarity of this voltage is reversed, the actuator retracts. Actuator stroke position may be monitored by providing any stable low and high reference voltages on leads 1 and 5, and then reading the position signal on lead 2. The voltage on lead 2 will vary linearly between the two reference voltages in proportion to the position of the actuator stroke.

Miniature Linear Motion Series L12 Firgelli Technologies Inc. for more info call 1 (888) 225-9198 or visit [Link]

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Miniature Linear Motion Series L12 Firgelli Technologies Inc. for more info call 1 (888) 225-9198 or visit [Link]