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UCIRP Liquids Team Q1 Report for 2024
Written by Kai Meyers
UCI Rocket Project (UCIRP) Liquids Team
Management Overview:
Over the Fall Quarter, the UCI Rocket Project (UCIRP) Liquids Team identified three objectives that would help the Project accomplish its goal of breaking the collegiate methalox altitude world record of 13,205 feet.
These include:
- Decreasing the weight and size (decreases drag)
- Decreasing horizontal velocity (fly straighter)
- Increasing thrust (by optimizing engine efficiency)
In order to fulfill these objectives, much of Q4 of 2023 was spent identifying technical improvements to increase our altitude and emphasizing the importance of documentation. With PTR’s cycle time having been 6 years long, there was useful and beneficial information that never made its way to our current generation of rocket engineers due to poor documentation. However, by implementing a structured design process with standard design review phases (CoDR, PDR, and CDR), we are ensuring that there is written documentation for all of our designs, allowing our future engineers to better understand how we approached the development of our second liquid rocket, MOCH4.
Some important terms used in our Design Review Process include:
1. CoDR: Conceptual Design Review
2. PDR: Preliminary Design Review
3. CDR: Critical Design Review
4. Level 1: System (Management ownership)
5. Level 2: Major Subsystem (Leads ownership)
6. Level 3: Minor Subsystem (Member ownership)
Our priority for Q1 of 2024 was to develop, simulate, and test the technical enhancements we outlined in Q4 of 2023. As we aim to complete a cold flow by the end of the year (Q2 2024), our subteams have conducted developmental testing to ensure that we accomplish our objectives.
Cold Flow: A test conducted on the rocket’s propellant feed system to verify that all propulsion components function nominally in a fully integrated system, simulating test fire / launch conditions as close as possible without using actual reactive propellant. Cold flows allow us to verify system pressure and temperature profiles, test operations, and check for leaks or other potential issues.
Throughout the first quarter of 2024, our subteams have made remarkable strides, and we are thrilled to publicly showcase our achievements. The knowledge we aim to impart for every subteam follows a chronological timeline divided into three distinct phases: Phase 1 (Weeks 2–4), Phase 2 (Weeks 5–7), and Phase 3 (Weeks 8–10) with a thesis detailing our achievements with reasoning behind every action.
Propulsion
The Propulsion subteam is responsible for developing the dual cryogenic propulsion system, which combusts liquid oxygen (LOX) and liquid natural gas (LNG) to generate thrust, enabling our rocket to overcome Earth’s gravitational pull. Their primary objective for Q1 of 2024 was to attempt a Dry Flow test of their system.
Dry Flow: The primary purpose of a Dry Flow is to test and verify that all the components of the rocket’s systems (like the valves, pumps, sensors, etc) are working correctly and to identify any potential issues or glitches before attempting a live launch.
Phase 1 was dedicated to completing Level 3 Conceptual Design Reviews (CoDRs) and Level 2 Preliminary Design Reviews (PDRs) for various components of the rocket’s lower half. These reviews addressed critical considerations and established conclusions regarding:
– Injector: A machined aluminum triplet impinging injector will enhance engine efficiency, contributing to higher altitudes.
– Nozzle: Evaluating the optimal design between a conical or Rao’s nozzle configuration.
– Ground Support Equipment (GSE) Panel: Regulating filling procedures, employing a pneumatic system for valve actuation, and ensuring cryogenic compatibility for propellant-interfacing components.
– Propellant Tanks: Collaborating with the Launch Vehicle subteam to seamlessly integrate the tanks into the vehicle’s structure.
– Feed System: Optimizing the fluid system’s mass and efficiency.
– Engine: The ULTRA engine, incorporating injector and nozzle upgrades, aims to reach the target apogee of 16,000 feet.
During Phase 2, building upon the considerations and conclusions from Phase 1, the subteam focused on developing Computer-Aided Design (CAD) models to facilitate the manufacturing process. These CAD models served as comprehensive digital representations, enabling thorough analysis and verification of the component designs prior to physical fabrication.
– Tanks: As the tanks are a component integrated with the Launch Vehicle subteam, there was ongoing collaboration to finalize the proposed design of machining the tank dome and skirt as a single piece, subsequently welding it to the cylindrical tank section.
– Feed System – GSE Panel: With a finalized piping and instrumentation diagram (P&ID), the CAD models for the Feed System and GSE Panel ensure efficient testing and weight optimization of the rocket’s Feed System through the GSE’s aluminum panel which sits on the test stand, external from the rocket
– Injector: After conducting a decision matrix analysis for the two injector designs, the Snowflake design emerged as the optimal choice due to its reduced interpropellant and total seal requirements, similarity to the proven PTE design, and suitability for Computer Numerical Control (CNC) manufacturing.
Through the development of these comprehensive manufacturing plans, the Propulsion subteam has positioned itself for success in conducting a Dry Flow test.
In order to conduct a Dry Flow for Phase 3, the subteam needed to:
– Manufacture the GSE Panel
– Assemble the Feed System
– Machine and test the Injector
– Test the MVAS (Main Valve Actuator System)
– Test the Vent Valves
The ultimate objective of conducting a Dry Flow test during this quarter could not be realized as intended due to unforeseen supply chain disruptions. This situation served as a valuable learning experience, highlighting the paramount importance of proactively addressing potential supply chain challenges for critical components in the upcoming quarters and, especially, as we prepare for the construction and launch of the rocket in the subsequent year. The inability to procure essential materials, such as the aluminum sheet required for the Ground Support Equipment (GSE) Panel, posed a significant impediment to our progress. Without access to these crucial components, our meticulously planned two-year timeline faces the risk of substantial delays and setbacks. This scenario underscores the criticality of adopting a proactive and resilient approach to supply chain management, ensuring the timely availability of all necessary resources.
Avionics
The Avionics subteam is responsible for developing the Engine Control Unit (ECU), which serves as the central brain of the entire rocket, and the Avionics Flight Sensors (AFS), a crucial subcomponent that controls the deployment of the drogue and main parachutes once the rocket reaches apogee.
During this quarter, our focus was on ensuring the proper functionality of the AFS on SR-1 and enabling the Telemetry Radio System (TRS) to communicate between Ethernet and Long Range (LoRa) based radio transceivers.
As previously mentioned, the AFS is one of the two embedded systems located in the rocket’s bulkhead, responsible for deploying the drogue and main parachutes, as well as storing telemetry data such as position, velocity, acceleration, temperature, and the magnetic direction of the rocket. Following the successful launch and recovery of SR-1, a Critical Design Review (CDR) identified some issues that need to be resolved for future solid rockets (SRs) and perfected for MOCH4.
– Faulty Inertial Measurement Unit (IMU): The IMU is a sensor that measures the orientation, velocity, and gravitational forces acting on the rocket. We recognized a fault in the pad connectivity, and by purchasing a new IMU component, we are confident in our ability to better determine the orientation of the next SR.
– Printed Circuit Board (PCB) Pin Placement and Silkscreen: When constructing a PCB, adherence to best practices is crucial, including using the correct grid spacing, keeping traces as short and direct as possible, and properly spacing out components.
– Faulty Inertial Measurement Unit (IMU): The IMU is a sensor that measures the orientation, velocity, and gravitational forces acting on the rocket. We recognized a fault in the pad connectivity, and by purchasing a new IMU component, we are confident in our ability to better determine the orientation of the next SR.
– Printed Circuit Board (PCB) Pin Placement and Silkscreen: When constructing a PCB, adherence to best practices is crucial, including using the correct grid spacing, keeping traces as short and direct as possible, and properly spacing out components.
Operations
The Operations (Ops) subteam plays a pivotal role in integrating cross-functional collaboration among our subteams through a system engineering and business-oriented approach. Their responsibilities encompass corporate outreach, public engagement, and financial analysis to ensure the successful development and production of MOCH4 and future endeavors.
The Corporate Outreach initiative within the Ops team is dedicated to establishing strategic partnerships and fostering collaborations with industry-leading corporations. Our members actively participate in prominent events such as CES 2024 in Las Vegas and ATX 2024 in Anaheim, networking and proactively engaging with potential partners through targeted outreach campaigns. Additionally, they evaluate specialized small businesses whose expertise and production capabilities could contribute to the successful production of our rocket.
Through these efforts, we aim to acquire invaluable knowledge and build alongside these professionals, while simultaneously bridging our financial gap by welcoming corporate guests and sponsors to witness firsthand the innovative spirit that drives our efforts within the lab. We aim to foster a collaborative environment that encourages knowledge-sharing and mutual growth. Looking ahead, we will also be reaching out to High Net Worth Individuals (HNIs) and have made contact with a few Venture Capital firms in Southern California.
As we approached the end of Q4 2023, our data analysis revealed a significant level of public interest in our project, evidenced by the remarkable 500,000+ views on our Instagram platform. However, we recognized an opportunity for improvement in maintaining an engaging connection with our audience, as our last post or reel on our public accounts had been over 45 weeks prior. To effectively build and sustain a strong rapport with our diverse following, including rocket enthusiasts, high school students exploring their interests in UCI Engineering, and the global community at large, we must prioritize consistent and captivating public engagement. To address this, we have quietly launched a monthly newsletter article and video interview, and are strategizing how to improve the process of writing and publishing our work to build a strong public identity.
While the mission statement of the project is to build a bi-propellant rocket that breaks the collegiate methalox altitude record, we understand the significant financial burden associated with research and development (R&D), manufacturing, and testing. By conducting a deep dive into the Google Drive and compiling all financial data from the “Legacy Quarters” section of the drive, into one centralized Google Sheet, we aim to understand and analyze where we should be innovating and manufacturing in-house versus outsourcing. We recognize that while many components of the rocket need to be purchased, we operate within a tight financial budget constraint, necessitating innovative approaches.
Launch Vehicle
The Launch Vehicle (LV) subteam has the task of designing and constructing the rocket’s aerostructure (body) and recovery system. After last year’s Preliminary Test Rocket (PTR) successfully launched but couldn’t be recovered, the LV team is leaving no stone unturned to ensure they can retrieve the rocket after launch.
Phase 1 started with a bang – the successful launch of Solid Rocket-1 (SR-1) to around 1,400 feet! This achievement not only validated their hard work since last spring but also confirmed the proper functioning of the ejection system, recovery harness, and recovery bulkhead.
Key results from the SR-1 launch:
– Ejection System passed with flying colors! Based on a pre-launch test, the nose cone and recovery harness ejected smoothly, and neither the drogue nor main parachute had any black powder or scorching which is a big improvement from PTR (where the drogue and main parachute were burnt).
– Recovery Harness deployed without issues, though the main parachute bag opened too early at apogee since it wasn’t secured tightly enough.
– Recovery Bulkhead withstood the intense ejection forces, shock, and heat like a champ! However, the main’s early deployment prevented measuring transition shock between drogue and main parachutes.
– Two tender descenders (descent slowing devices) worked as intended, but the main again opened prematurely due to the unsecured bag.
The rest of Phase 1 focused on the nose cone design review, creating detailed airframe CAD models, and researching materials/methods for the all-important fins.
Phase 2 built on SR-1’s success, with the team already developing SR-2 (a load cell vehicle for testing).
The exciting times included:
– Nose Cone: Collaborating with the Operations team, they partnered with 3D printing experts, Source Graphics. With their help, molds were created for SR-2’s 4-inch and MOCH4’s 8-inch diameter nose cones.
– Fins: Choosing the perfect fin design (shape, airfoil, angle, aspect ratio) required serious research, primarily reviewing the previous design. The team designed and prototyped fin mounts from wood/foam and recognized the need for finite element analysis (FEA) software to predict real-world fin forces.
Despite supply delays for the nose cone molds, the LV team powered through during Phase 3, innovating on the airframe, fins, and recovery components:
– Airframe: To further emphasize the importance of documentation, LV created a 64 page PDR diving into how this new Airframe will optimize aerodynamics and decrease the mass for a higher apogee. LV worked closely with the Propulsion subteam to consider internal components like fuel tanks, feed system (top and bottom), injector, engine (sizes, configurations, and assembly). This Semi-Monocoque Airframe ensures the Aluminum skins are well secured to the airframe body with multiple fastening points throughout the frame. The strength and rigidity of the rocket will therefore increase because the bending and buckling loads are transferred to the skin (whereas PTR’s skin did not do this).
– Fins: Simulations showed swept-back trapezoidal fins are best, pushing the center of pressure back. With the center of pressure behind the center of gravity, future rockets will be ultra-stable and resist weathercocking (tilting into the wind).
– Recovery Bulkhead/AV Bay: The recovery bulkhead interconnects the recovery and avionics bays. The avionics bay initiates recovery at apogee. Using six L-brackets, simulations showed the bulkhead can distribute stress from intense shock forces experienced during recovery deployments.
The LV subteam’s innovative spirit and grit are propelling them towards creating a rocket bodacious enough to soar high and return safely.
Conclusion
The first quarter of 2024 has been a period of remarkable progress and learning for the UCI Rocket Project (UCIRP) Liquids Team. Despite facing challenges, such as supply chain disruptions that prevented the completion of the intended Dry Flow test, the team’s unwavering determination and proactive approach have paved the way for future success.
Through comprehensive design reviews, simulations, and developmental testing, each subteam has made strides in achieving the project’s overarching goals of decreasing weight, improving horizontal stability, and increasing thrust.
The Propulsion team’s design efforts, including optimized injector and nozzle configurations, have laid the foundation for a more efficient propulsion system.
The Avionics team has addressed critical issues related to sensor functionality and communication, ensuring reliable data transmission and recovery deployment.
The Operations team has excelled in corporate outreach, public engagement, and financial analysis, fortifying the project’s foundation for long-term success.
The Launch Vehicle team’s innovative spirit has been evident in their cutting-edge airframe design, fin simulations, and recovery system enhancements, all aimed at maximizing altitude and ensuring safe retrieval.
As the team looks ahead to the upcoming 4 academic quarters until Launch, the lessons learned from this quarter’s challenges have reinforced the importance of proactive supply chain management and documentation. With a steadfast commitment to continuous improvement, we are well-positioned to achieve our goal of breaking the collegiate methalox altitude world record.