Launch Vehicle Project

The A Team Inc.
Launch Vehicle Project
October 17, 2012
EGR 101 20DB The A Team Team Leader: Brandon Reichert Cristian Denegri, Sabique Islam, Phat Le
Submitted to: Professor Godbey
The A Team Inc.
Table of Contents:
Article I. Article II.
Section 2.01 Section 2.02 Section 2.03 Section 2.04 Section 2.05 Section 2.06 Section 2.07 Section 2.08 Section 2.09 Section 2.10 Section 2.11 Section 2.12 Section 2.13 Section 2.14 Section 2.15 Section 2.16 Section 2.17
Project Introduction Details of the Design Calculations

Introduction Pay Load Orbit Selection & Velocity Required Launch Site ISP Thrust to Weight Ratio Fuel Weight Required Vehicle Weight Empty Vehicle Gross Weight and Thrust Engine Selection Recalculate Gross Weight and Thrust Propellant Weight Fuel Volumes Tank Volumes Overall Height Cost Conclusion
(Page 5)
(Page 5) (Page 5) (Page 6) (Page 6) (Page 7) (Page 7) (Page 7) (Page 7) (Page 8) (Page 8) (Page 9) (Page 9) (Page 10) (Page 10) (Page 11) (Page 12) (Page 12) (Page 13)
Article III. Launch Mount Calculations

Section 3.01 Section 3.02 Section 3.03
Introduction Column Design Structural Analysis
(Page 13) (Page 13) (Page 14) (Page 15)
The A Team Inc. Section 3.04 Section 3.05

Cost Estimated Conclusion

(Page 17) (Page 17)
Article IV. Umbilical Boom Design

Section 4.01 Section 4.02 Section 4.03 Section 4.04 Section 4.05 Section 4.06 Section 4.07 Section 4.08 Section 4.09 Section 4.10 Section 4.11 Section 4.12 Section 4.13 Section 4.14
Introduction Boom Length Center Line to Boom Tower Pressure Load Boom Dimensions Total Load Centroid of the Distributed Load Diagram Plume Bending Moment Weight Bending Moment Total Bending Moment Material Type Section Modulus Required Cost Conclusion
(Page 17) (Page 17) (Page 18) (Page 18) (Page 18) (Page 18) (Page 18) (Page 19) (Page 19) (Page 19) (Page 19) (Page 20) (Page 20) (Page 20) (Page 21)
Article V.
Section 5.01 Section 5.02 Section 5.03 Section 5.04 Section 5.05 Section 5.06 Section 5.07
Fuel Delivery System Design

Introduction On Ground Storage Tanks Determining Flow Rate Locating the Storage Tank Designing Piping System Pump Calculations and Considerations Cost Considerations
(Page 21) (Page 21) (Page 21) (Page 22) (Page 22) (Page 22) (Page 23) (Page 25)
The A Team Inc. Section 5.08

Conclusion

(Page 25)
Article VI. Rocket Launch Sequencer

Section 6.01 Section 6.02 Section 6.03 Section 6.04 Section 6.05
(a)
(Page 26) (Page 26) (Page 26) (Page 27) (Page 27) (Page 28) (Page 28) (Page 30) (Page 31)
Introduction Sensor Specifications Cost Conclusion Diagram

Pseudo Code
(b) Hardware Design (c) Activity Diagram
Article VII.
Total Overall Cost
(Page 32) (Page 32)
Section 7.01 Launch Vehicle Total
Article VIII. System Integrations Article IX.

Section 9.01 Section 9.02 Section 9.03 Section 9.04 Section 9.05
(Page 32)
Appendix
Launch Vehicle Drawing Launch Mount Drawing Umbilical Boom Drawing Fuel System Drawing Experimental Log
(Page 34) (Page 34) (Page 35) (Page 37) (Page 39) (Page 40)
The A Team Inc.
Article I.
Project Introduction
The engineers demonstrated much excitement conceptualizing a launch vehicle design. The launch vehicle created, is designed to carry a payload of 3100 pounds. The vehicle will reach a low orbit of 180 nautical miles. The payload has a height of 10 feet with a diameter of 6 feet. The design was made with safety as a number one priority. Along with safety, the engineers incorporated a sleek and cost efficient design. In order to create enough thrust for the vehicle to reach orbit five engines were incorporated into the design. The vehicle is planned to be launched from Kennedy Space Center to maximize efficiency and take advantage of the Earths rotational speed.
Article II.
Details of the Design Calculations
Section 2.01 Introduction: The payload is the carrying capability of the satellite launch vehicle. It is associated with the weight of systems and equipment. For this specific launch vehicle the chosen payload is exactly 3100 Lbs and the dimensions are set for cylindrical shape with a diameter of 6 feet and length of 10 feet. In payload is 1.10 times the satellite weight calculated plus the weight of some undisclosed piece of hardware that is classified by the government and is for only authorized personnels eyes only. The configuration of is of a cylindrical body with two rectangular solar cell panels protruding out of the opposite side. The solar panels are folded up and enclosed inside the launch vehicle. Getting a vehicle into orbit, whether it is earth orbit or interplanetary orbit, is fundamentally a matter of getting it to go fast enough. This consists of the complex interaction of size, weight, and engine thrust. Single stage rocket with 2 different engines, a total of 5 boosters, was determined to be the optimal design for the rocket for a given amount of propellant after choosing orbital height and payload.
5
The A Team Inc.
Single stage propulsion was chosen because it has a lower operational cost, improved safety, and it is more reliable. The ISP or specific impulse of propellant or how much fuel burnt per seconds time is a total of 300 seconds. The fuel chosen was RP-1/LOX for both engines and was more cost effective than using LH2. RP-1 is denser than LH2, therefore, it will require less space in the rocket. The engines that were best for the orbital height chosen were the Atlas Sustainer and the Atlas II Booster which uses RP-1 and LOX. The main design consists of four Atlas II booster strategically place around the outside of the fuselage with the Atlas Sustainer which is inside the vehicles center.
Section 2.02 Initial Payload: 3100 lbs Section 2.03 Orbit Altitude: 180 NM {Points 1 and 2 were chosen arbitrarily.
Orbital Speed: V = orbit velocity Re = radius of the earth g = accel. of gravity h = orbital altitude
V = Re [ g / (Re + h) ]
V = (20.92 * 106 ft) [ 32.17 ft/s2 / (20.92 * 106 ft + 1093701.6 ft)]
V = 23,948.55 ft/s
{Orbital Speed it the speed which must be maintained in order to stay in orbit at a certain velocity.
6
The A Team Inc.
Section 2.04 The launch site is Kennedy Space Center {This site was chosen in order to take full advantage of Earths rotational velocity.
Section 2.05 Specific Impulse: 300 s {Points 2.05 and 2.06 were chosen arbitrarily. Section 2.06 Thrust to Weight Ratio: 1.5
Section 2.07 Fuel Weight Required: Isp = Specific Impulse
n = weight at engine startup/ weight at engine shut off T/Wg = thrust to weight ratio V = required velocity Wp = payload weight V = gIsp [(ln(n) [(n 1) / (T/Wg)n]]
V = (32.17 ft/s * 300 s) [(ln(22) [(22 1) / (1.5 * 22)]]
V = 23,690.11 ft/sec
7
The A Team Inc.
Wp = 3100 lbs * 1.1 = 3410lbs {Based on the velocity needed to gain lift off, the team was able to determine the weight of fuel needed to get the vehicle there. {The weight of the fuel needed to get the rocket to the desired altitude and maintain orbit.
Section 2.08 Vehicle Weight Empty: We = vehicle weight empty
We = 1000 + 4.61(Wp) We = 16720.1 lbs {The weight of the empty vehicle can be approximated through this equation.
Section 2.09 Vehicle Weight Gross: Wg = vehicle gross weight
Wg = n(We + Wp) Wg = 442,862.2 lbs {The gross weight of the rocket can be estimated through this equation.
Thrust: T = thrust
T = Wg (T / Wg) T = 664,293.3 lbs {The thrust needed to get the rocket off the ground based on the gross weight
8
The A Team Inc.
Section 2.10 Rocket Engines Used
4 * { MA 5A (Atlas II Booster) T = 208,500 lbs Isp = 290 Fuel = RP 1/LOX
Ox Fuel Tank Volume Ratio(%) = 61.5 38.5 Length = 115 in DIA = 54 in Weight = 1392 lbs
1 * { MA 3A B (Atlas Sustainer) T = 85,200 lbs Isp = 309 Fuel = RP 1/Lox
Ox Fuel Tank Volume Ratio (%) = 61.7 38.3 Length = 90 in DIA = 43 in Weight = 1019 lbs
{This combination of rockets worked best based on the amount of thrust needed.
Section 2.11 Recalculate Gross Weight and Thrust: EW = Engine Weight New Wg = n(EW + We + Wp) New Wg = 22(6587 lbs + 16720.1 lbs + 3410 lbs)
The A Team Inc.
New T = Wg * 1.5 New T = 881,661 lbs {The gross weight must be recalculated now after adding the rockets.
Section 2.12 Propellant Weight: Wf = propellant weight Wfuel = fuel weight Woxy = oxidizer weight Wf = Wg We Wp Wf = 587,774 lbs 23,307.1 lbs 3410 lbs Wf = 561,056.9 lbs
Wfuel = (1 / Mass Ratio + 1) Wf Wfuel = ( 1 / 2.56 + 1) * 561,056.9 lbs Wfuel = 157,600.25 lbs
Woxy = (Mass Ratio/Mass Ratio + 1) Wf Woxy = (2.56 / 2.56 + 1) * 561, 056.9 lbs Woxy = 403,456.65 lbs {These equations will give the team the weight of the fuel and oxidizer.
Section 2.13 Volumes: Vfuel = fuel volume Voxy = oxidizer volume

10
The A Team Inc.
Pfuel = fuel density Poxy = oxidizer density
Vfuel = Wfuel / Pfuel Vfuel = 15760.25 lbs / 50.5 lbs/ft3 Vfuel = 3120.8 ft3
Voxy = Woxy / Poxy Voxy = 403,456.65 lbs / 71.3 lbs/ft3 Voxy = 5658.58 ft3 {Based on the weight and density of the fuel/oxidizer, the team can calculate the volume that will be needed to create the fuel tanks.
Section 2.14 Tank Diameter = 81.6 in = 6.8 ft Sphere Radius = 3.4 ft
Height of Cylinder (fuel tank) = 20.15 ft Height of Cylinder (oxidizer tank) = 20.15 ft
Fuel Tank Height = 26.95 ft Oxidizer Tank Height = 44.4 ft
Total Height = 71.35 ft
11
The A Team Inc.
{Based on the volume of fuel needed, the team can accurately calculate the size of the fuel/oxidizer tanks.
Section 2.15 Total Heights: Hp = Payload Height He = Engine Stack Height Hf = Fuel Tank Height Hv = Total Vehicle Height
Hv = 1.1(He + Hf + Hp) Hv = 1.1(7.5 ft + 71.35 ft + 10 ft) Hv = 97.735 ft In addition the team added a total of 190 cm in space for the Structure, Guidance, Telemetry, Power, Pumps and Valves. Along with the nozzles the total height is 110.4ft. {Based on the height of the tanks, engine, and payload; the team can calculate the total height of the rocket.
Section 2.16 Cost WE=$900/lb. Engine=$20/lb. of Thrust
Liquid Hydrogen= $25/lb Liquid Oxygen= $1/lb
Density= 4.46 lb/ft3 Density= 71.3 lb/ft3
WE= 23,307.10 * $900 = $20,976,390 T= 881,661 * $20 = $17,633,220

12
The A Team Inc.
Liquid Hydrogen = 157,600.25 * $25 = $3,940,006.25 Liquid Oxygen = 403,456.65 * $1 = $403,456.65 Total Cost = $42,953,072.90 {The total cost required to build the rocket itself.)
Section 2.17 Conclusion: Having safety as the first priority and getting the launch vehicle into orbit was the most tedious task the engineers faced. Keeping efficiency in the planning has kept the cost of the vehicle relatively low. The weight of the payload plays as the most important variable when calculating the design. Reaching the low orbit with maximum efficiency forced the engineers to use multiple engines in the design. Incorporating a payload weight of 3100 pounds with an ISP of 300 kept the engineers having to reiterate the calculations multiple times. Having completed all the calculations has been a top achievement and reaching orbit safely is the engineers main goal.
Article III.
Launch Mount Calculations
Section 3.01 Introduction: The launch mount is an engineering ground support structure that is designed to serve one general purpose only. The successful operation of the launch mount is mandatory. Failure can result in catastrophic failure of the rocket and the launch pad, and possible loss of life and billions of capital in flight and ground hardware and operation equipment.
The primary objective of the launch mount is to secure the rocket in an upright position in the launch platform for suitable ground operations. Other purposes are to position the rocket at a proper elevation and location over the flame bucket. It also provides the means of leveling the
13
The A Team Inc.
rocket during assembly. The launch mount also helps to restrain the rocket at the launch pad. This is mainly done by some sort of embellishment or explosive bolts until the required thrust for take-off is generated by the engines. For the launch mount design the team will be using explosive frangible bolts. Section 3.02 Column design: 1. Number of Columns (N): For the launch mount the team decided to use 4 columns. Each column spaced by 90o between each other. 2. Material of the Column: The material that the team has chosen is High Strength Steel. The yield stress, yeild , is given to be 58,000 lbs/in2, and Youngs Modulus, E, is given to be 29,000,000 lbs/in2.
3. Column Angle (): The angle between the column and the ground is taken to be 61.04o. Found by trigonometry method of using Sin (Sine) and using L as Hypotenus and h as the opposite side of a right angle triangle. 4. Column Length (L): The required column length, L, is taken as 20 ft by the team 5. Vertical height of Column: The vertical height of the column, h, above the ground is calculated using the formula,
E
Where HE is the overall engine height (combustion chamber and nozzle). Hence,
= 32.36 ft. 6. Column inside and outside diameters: Inside Diameter (Di) = 15 in. Outside Diameter (Do) = 16 in. Value founded from the table about the piping used: Wall thickness = 1 in. Volume = 292.168 in3
14
The A Team Inc.
7. Cross Sectional Contact Area: In this case the team is using as variables Inside Diameter (Di) = 15 in. Outside Diameter (Do) = 16 in. A = (Area of the outside circle with diameter Do) (Area of inside circle with diameter Di) = (82) (7.52) = 24.3474 in2 Section 3.03 Structural Analysis: As the team moves on with the report on structural analysis, variables that represent the loading conditions are defined as followed: W = Maximum operational weight of the rocket and payload. W* = the portion of W that is resisted by each launch mount. T = 95% of the maximum thrust developed by the main engines. T* = The portion of T that is resisted by each launch mount. W // *= the vector force of W* that is acting parallel to the launch mount in the downward direction. T// *= the vector force of T* that is acting parallel to the launch mount in the upward direction.
From the design considerations and calculations the team can determine that: W = 584,774 lbs W* = T= T*= ( ) W // * = T // * = ( )
Incorporating the safety factor: For the launch mount design the team choose to use, = 2. By using this safety factor it will be able to ensure applied < allowed
15
The A Team Inc.
Hence, by incorporating = 2 into the above equation the engineers got: Load //*/ A < yeild (1/ ) In the previous calculations the team determined A the cross sectional contact area of the launch mount columns. As structural engineers the team must make sure that A required preventing failure under the maximum applied loading and ensuring it is smaller than the actual A provided by the mount column. Solving the previous equation for the area and substituting weight in for the load find the area required to prevent failure under compressive loading.(to prevent cracking) Arequired = W //* / yeild =2( = 8.1984 in2 Since the team is using explosive bolts to attach the launch vehicle to the mount, the formula of the area below is the total minimum required cross sectional area of the bolts (bolted to one of the columns) to prevent failure under tension. (to prevent elongation and necking) Arequired = T //* / yeild =2( = 3.98 in2 Finally to make sure that the launch mount does not buckle under compressional loading, W // *, the team made sure of the Euler Buckling Equation, Which states: Arequired = 4 W //*((L/r)2 / (2 E) ) / 58,000 lbs/in2 ) / 58,000 lbs/in2
Where r is the radius of gyration, a geometric property of cross sectional shape. For a hollow circular pipe, the r is given as: r = 0.25 ((Do4 Di4) / (Do2 Di2))0.5 and by taking Do = 16 in. and Di = 15 in. the team got, r = 5.482 Hence, by substituting, =2
16
The A Team Inc.
W //* = L = 20 ft R = 5.482 E = 29000000.
lbs
The team got Arequired to prevent buckling as, Arequired = 0.09 in2 So, Area that the team has = 24.3474 in2. This Area seems to be more than the Arequired to prevent cracking, elongation and buckling of the structure. From this a conclusion can be reached that the launch mount that was designed will not fail.
Section 3.04 COST: The team is using High Strength Steel. With the following specification: Inside Diameter (Di) = 15 in. Outside Diameter (Do) = 16 in. The team has a have Volume of 292.168 in3 per feet length. The team has a specific weight at 0.284 per in3 of volume. Every pound (lb) of specific weight is priced at $ 70.00. The team needs 80 feet of material but 100 feet was ordered for extra usage if needed. So Total Cost of Making Launch Mount in US Dollars =
Section 3.05 Conclusion: Finally the team was able to conclude the section about the launch mount. During the design phase they have clearly stated the design choices they have made and shown the calculations they have performed to make those choices. They have also provided structural analysis of the launch mount including calculations probing that it will be able to withstand the loadings in terms of its cross sectional area. They havent used any extra-things or design embellishments. The cost estimate of the system materials were also provided.
17
The A Team Inc.
Article IV.
Umbilical Boom Design
Section 4.01 Intro: This section focuses on the umbilical boom that will support the pipe as it pumps fuel into the rocket. The calculations are almost entirely based on finding the force being exerted on these booms as the rocket takes off.
Section 4.02 Boom Length: 10 ft { Values 1 and 2 were picked arbitrarily. Section 4.03 Length from Umbilical tower to Center of Launch Mount: 24 ft
Section 4.04 Pressure Load Equation: exh = density of the exhaust gasses Vmax = maximum exit velocity from the engine nozzle CD = coefficient of drag D = length from umbilical tower to center of launch mount Pressure Load = exhVmax2CD (exhVmax2CD / D2) x2 Pressure Load = (1.37 * 10-4 lbs/ft3 ) (716.67 ft/s)2 (.7) [(1.37 * 10-4 lbs/ft3) (716.67 ft/s)2 (.7) / (24ft) 2] x2 Pressure Load = 49.26 - .086x2 {This equation allows the team to equate the total pressure load on the boom from the exhaust. Section 4.05 U. Boom Diameter: Outer = 12.75 in Inner = 8.06 in {This value was picked because it suited the needs better that other values Section 4.06 Total Load: w = width of the boom
18
The A Team Inc.
Total Load = w Total Load = 12.75 ft Total Load = 2230.19 lbs/ft2 { The total pressure exerted on the booms by the rocket exhaust. Section 4.07 Centroid: xc = centroid A = Total Load dA = (w * Pressure Load) dx
xc = (
)/A
xc = ( xc =17.44 ft
)/2230.91
{The center point of the total load.
Section 4.08 Plume Bending Moment: Plume Bending Moment = Total Load (D xc) Plume Bending Moment = 2230.91 (24 17.44) Plume Bending Moment = 14634.77 ft*lbs {Bending Moment due to the exhaust plume. Section 4.09 Weight Bending Moment: Weight Bending Moment = Total Weight (L/2) Weight Bending Moment = 2230.91 (24 17.44) Weight Bending Moment = 14634.77 ft*lbs
19
The A Team Inc.
{Bending Moment due to the weight of the boom. Section 4.10 Total Bending Moment: Total Bending Moment = Plume Bending Moment + Weight Bending Moment Total Bending Moment = 14634.77 ft*lbs + 14634.77 ft*lbs Total Bending Moment = 20.648.07 ft*lbs {Sum of the two types of bending moments.
Section 4.11
U. Boom Material Type: Aluminum (6063 T5) {The team selected this material because there was no need for a strong/expensive material, due to the thickness of the booms.
Section 4.12
Section Modulus:
S = pi [r4 (r t)4] / 4r S = pi [6.3754 (6.375 2.06)4] / 4(6.375) S = 202.95 in3 {Based on the shape of the boom, the team chose a cylinder because it offered the lowest surface area to be affected by the rocket exhaust.
Section 4.13 Welding Cost: Welding Cost = 5,000 + (10tLn) Welding Cost = 5,000 + (10 * .17 * 10 * 2) Welding Cost = $5,034.00 {Amount in U.S. dollars that the welding of the U. Booms will cost. Material Cost: Aluminum weight = 434.11 lbs (per boom, the team has 2)
20
The A Team Inc.
Cost for 2 booms = $40,553.80 {Cost based on the type, and amount of material that was used
Total Cost: Total Cost = Welding Cost + Material Cost Total Cost = $5,034.00 + $40,553.80 Total Cost = $45,587.80
{Amount of U.S. dollars that it will take to build the Umbilical Booms.}
Section 4.14 Conclusion: Through the calculations it was founded that the forces exerted on the booms do not exceed the booms allowed stress. And it was founded that the cost is relatively low. All-in-all, the umbilical booms are a great success.
Article V.
Fuel Delivery System
Section 5.01 Introduction: The propellants (fuel and oxidizer) are never stored onboard the spacecraft. The fuel and oxidizer, which is mostly cryogenic, must be kept at low temperatures and is only pumped into the launch vehicle only few hours prior to lift-off. This requires that the propellants must be stored in storage tanks on the launch pad and a fuel delivery system is used to pump the fuel and oxidizer through the umbilicals into the launch vehicle. Designing an efficient fuel delivery system is very essential to the project as it ensures that the right amount of fuel is delivered to the launch vehicle at the right time.
21
The A Team Inc.
Section 5.02 On Ground Storage Tanks Sizing the tanks: Volume of On Ground Storage Tanks fuel = = 1.50 3120.80 ft3 = 4681.20 ft3 Volume of On Ground Storage Tanks oxydizer = = 1.50 5658.58 ft3 = 8487.87 ft3 The size of on ground storage tank is 150% more than the launch vehicle storage tanks because the on ground storage tanks must be able to store more fuel in order to create pressure for the fluid into the onboard fuel tanks. Section 5.03 Determining Flowrate: To determine the flowrate (Q) with respect to time in seconds, take the total time take for each storage tank to pump propellant as t = 1800 seconds. Qfuel = Qoxydizer = Section 5.04 Locating the Storage Tanks: Horizontal Distance from the Launch vehicle storage tanks for Fuel and Oxidizer tanks = 1600 ft. Vertical Distance from the Launch vehicle storage tanks for Fuel tank = 50.09 ft. Vertical Distance from the Launch vehicle storage tanks for Oxidizer tank = 96.10 ft NOTE : Both the tanks will be housed at a ground level. Section 5.05 Designing the Piping system: Calculating total piping length (L): = 1.73 ft3 / s = 3.14ft3 / s
oxydizer fuel
22
The A Team Inc.
Lfuel = Horizontal Distance + Vertical Distance + Length of Umbilical Boom (D) = 1600 ft + 50.09 ft + 24 ft = 1674.09 ft Loxidizer = Horizontal Distance + Vertical Distance + Length of Umbilical Boom (D) = 1600 ft + 96.01 ft + 24 ft = 1720.10 ft So Total Piping Length required for the entire fuel delivery system = (1674.09+1720.10) ft = 3394.19 ft Pipe Diameter (D): From the table of Standard Schedule Piping in the book, the team chose the piping diameter (outside) to be 8.625 in. which has a wall thickness of 0.322 in. and is available in 20 ft lengths. Each 20 ft piece is priced at USD $300.
Fittings: The fittings the team has chosen to incorporate into the fuel delivery system: Fittings Globe Valves 90 degrees Elbows Open Swing Check Valve Angle Valve Venturi Meters Couplings Quantity 2 4 2 4 2 172 Total KL (Coefficient of loss) of Fitting ( Quantity KL ) 20 3.6 4 20 1.2 13.76
Note: the KL values for each fitting was acquired from the graph in the book Introduction to Engineering, Page 195.
Section 5.06
Pump Calculations and Considerations: To determine which pumps the team is going to use the team has to first calculate Head Loss and Total Head for both the Fuel Delivery Line and Oxidizer Delivery Line.
23
The A Team Inc.
Calculating Total Head Loss: Here D will be, inside diameter in feet = ( ) ft.
The for minor head loss is derived from the Fittings table on the previous page. For the fuel delivery line the team decided to use 85 couplings and for the oxidizer delivery line the team used 87 couplings. We didnt integrate the extra fittings we used for parallel lines because even though the head loss increased the use of parallel pumps compensated for that. htotal loss fuel = hmajor loss fuel + hminor loss fuel hmajor loss fuel = hminor loss fuel = ( ) ( ) = ( )
htotal loss fuel = 110.029 ft htotal loss ozidizer = hmajor loss ozidizer + hminor loss ozidizer hmajor loss fuel = ( ) ( )
hminor loss fuel =
( )
htotal loss ozidizer = 355.753 ft
Total Head, H, Requirement: Hfuel = htotal loss fuel + helevation = 110.029 + 50.09 = 160.119 ft Hoxidizer = htotal loss ozidizer + helevation = 355.753 + 96.1 = 451.853 ft
Pump: The team considered that for each delivery line the pump should be able to produce 10% of the Total head (H) the team found. Hence Pumpfuel should be able to produce 16 ft of H. With a capacity of about 776 GPM which is just the conversion of Qfuel found in section 5.03.
24
The A Team Inc.
Pumps used for the Fuel Delivery Line: Pump Manufacturer: Hypro Pumps Type: Gas Engine-Driven Transfer Pumps 2 in. & 3 in. Cast Iron. Series 1530. Model: 3430-0674CSP. Head: Upto 20 feet. Max Capacity: 330 GPM Price: $ 6000 Per Unit. The team is using 2 of these pumps in parallel to add up the capacity to about 760 GMP. Pumpoxidizer should be able to produce 45.1 ft of H and a capacity of 1409 GMP. Which is also the conversion of Qoxidyzer found in section 5.03. Pump used for the Oxidizer Delivery Line: Pump Manufacturer: Ohler Pumps. Type: Solid Capacity Transfer Pumps. Model: OPSCTP Model 650 Head: Upto 140 feet. Max Capacity: 1550 GPM. Price: $11,500 per unit.
Section 5.07 Cost Considerations: Calculate Cost of System: Cost of fittings: Globe valves = 2 $200 = $800 90 Degree elbows = 4 $250 = $1000 Open Swing check valves = 2 $400 = $800 Angle valves = 4 $400 = $800 Venturi Meters = 2 $2500 = $5000 Couplings = 172 $200 = $34,400 Pumps = (2 $6000) + (2 $11,500) = $35,000 Fuel Storage tank cost = 4000 (3 16.7) = $200,400 Oxidizer Storage tank cost = 4000 (3 20.4) = $244,800 Total Cost For Propellant Delivery System= $ (800 + 1000 + 800 + 800 + 5000 + 34,400 + 35,000 + 200,400 + 244,800) = $523,000
25
The A Team Inc.
Section 5.08 Conclusion: While designing the fuel delivery system the team basically divided it into two sections, one for the fuel delivery line and the other for the oxidizer delivery line. The storage tank for the oxidizer delivery line is larger than the fuel storage tank. And the team has placed them 1600 feet in both directions from the launch pad for safety considerations. The team has also incorporated fittings for more efficient fuel delivery in 300 seconds which was determined at the beginning of this article. Since the oxidizer is cryogenic so fueling only commences few minutes before takeoff. The pumps used are Gas Engine-Driven Transfer Pumps 2 in. & 3 in. Cast Iron. Series 1530 and Solid Capacity Transfer Pumps.
Article VI.
Rocket Launch Sequencer (see page 28)
Section 6.01 Introduction: In respect to the Rocket Launch Sequencer (RLS), the lead engineer exhausted all the resources into keeping safety the highest priority. The engineer placed many sensors, switches, gauges and logic gates into the system to assure the systems safe execution. Section 6.02 Sensor Specifications The system is comprised of: 3 Logic Gates 1 Ultrasonic Distance Sensors 3 Grip Position Sensors 5 Switches 2 Pressure Gauges 6 Flow Sensors 1 Engine Sensor (Thrust Sensor) $5.00 $29.99 $150.00 $50.00 $350.00 $600.00 $300.00 (prices are averages and not exact)
26
The A Team Inc.
Logic gates serve in the reason that only the next procedure will occur if all procedures previous went successfully. Distance sensors will determine when the hood is raised and retracted. The grip sensors will detect the umbilical cord removal, oxidizer tank closing and when the tank boil off vent is closed. The switches will turn certain systems into operating mode. Two pressure gauges will determine pressure in the oxidizer tank and to bring the tank to flight pressure. The flow sensors will notify when water is being poured onto the pad. The engine sensor will be a crucial factor, it will determine whether the engine has reached 90 percent thrust level. Sources: http://ab.rockwellautomation.com/Sensors-Switches --- Sensors and Switches
http://www.aliexpress.com/price/logic-gates-price.html -- logic gates http://www.parallax.com/tabid/768/ProductID/92/Default.aspx ----Distance sensor
Section 6.03 Cost:
Total Cost: $1,484.99
Section 6.04 Conclusion: Included in this section is a hardware design for the sequencer (starting at T-7 minutes and 30 seconds down to T-0 seconds), an activity diagram for the software system (starting at T16 seconds down to T-0 seconds), and a complete pseudo code for the software system (starting at T-16 seconds down to T-0 seconds). Every step of the process was tested repeatedly to assure safety in the final procedure.
27
The A Team Inc.
Section 6.05 Diagrams:
28
The A Team Inc.
29
The A Team Inc.
30
The A Team Inc.
31
The A Team Inc.
Article VII.
Total Overall Cost:
Launch Vehicle: $42,953,072.90 Launch Mount: $580,829.98 Umbilical Boom: $45,587.80 Fuel Delivery System: $523,000 Sequencer: $1,484.99 Total Overall Cost: $44,103,975.67
Article VIII. Systems Integration Content 1.

Gross weight estimate vs. Gross weight with engine weight 442,862.20 lbs. vs. 587,776.20
2.
T/W Provided by Selected Engine(s) vs. T/W Used in Weight Ratio (n) Calculation 664,293.30 lbs. vs. 881,661.00 lbs.
3.
Isp of Selected Engine(s) vs. Isp of Fuel Choice - Values Must Be Within 10% of Each Other MA-3A-B Isp = 309 Isp of fuel choice = 300 MA-5A Isp = 290
4.
32
The A Team Inc.
Boom/Fuel Delivery - Piping Diameter Diameter = 8.625
5.
Fuel Delivery/Launch Vehicle Elevation Head Calc and Top of Vehicle Tanks Elevation head for fuel tank = 50.09 ft Elevation for oxidizer tank = 96.01 ft
6.
Mount/Launch Vehicle - Room in Mount Diameter for Engine 16ft
7.
Mount/Launch Vehicle - Vertical Clearance for Engine Nozzle 32.32ft
33
The A Team Inc.
Article IX. Appendix
34
The A Team Inc.
35
The A Team Inc.
36
The A Team Inc.
37
The A Team Inc.
38
The A Team Inc.
39
The A Team Inc.
Experimental Log
40

Launch Vehicle Project

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Launch Vehicle Project

Uploaded by

Copyright:

Available Formats

The A Team Inc.