EML 4905 Senior Design Project A B.S. THESIS PREPARED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING NANOLAUNCH REACTION CONTROL SYSTEM Final Report David Dominguez Gianni Jimenez Genesis Vasquez Advisor: Professor George Dulikravich November 24, 2014 This B.S. thesis is written in partial fulfillment of the requirements in EML 4905. The contents represent the opinion of the authors and not the Department of Mechanical and Materials Engineering. 1 ETHICS STATEMENT AND SIGNATURES The work submitted in this B.S. thesis is solely prepared by a team consisting of David Dominguez, Gianni Jimenez, and Genesis Vasquez and it is original. Excerpts from others’ work have been clearly identified, their work acknowledged within the text and listed in the list of references. All of the engineering drawings, computer programs, formulations, design work, prototype development and testing reported in this document are also original and prepared by the same team of students. David Dominguez Gianni Jimenez Genesis Vasquez Team Leader Team Member Team Member Dr. George Dulikravich Faculty Advisor 1 TABLE OF CONTENTS ETHICS STATEMENT AND SIGNATURES ............................................................................................ 1 TABLE OF CONTENTS .......................................................................................................................... 2 LIST OF FIGURES .............................................................................................................................. 4 LIST OF TABLES ............................................................................................................................... 5 ABSTRACT .................................................................................................................................... 6 1. INTRODUCTION ................................................................................................................... 7 1.1 PROBLEM STATEMENT .......................................................................................................... 7 1.2 MOTIVATION ......................................................................................................................... 9 1.3 LITERATURE SURVEY .......................................................................................................... 10 1.3.1 CUBE SAT ........................................................................................................................ 10 1.3.2 NASA’ S NANOLAUNCH PROGRAM .................................................................................. 10 1.3.3 ATTITUDE CONTROL ....................................................................................................... 13 1.3.4 TYPES OF ACTUATORS .................................................................................................... 14 1.3.4.1 MOVEABLE FINS .......................................................................................................... 14 1.3.4.2 THRUST VANES ........................................................................................................... 15 1.3.4.3 GIMBALS ..................................................................................................................... 16 1.3.4.4 VERNIER ROCKETS ...................................................................................................... 17 1.3.5 ROTARY VALVES ............................................................................................................ 18 2. PROJECT FORMULATION ................................................................................................ 19 2.1 PROJECT OBJECTIVES .......................................................................................................... 19 2.2 DESIGN SPECIFICATIONS ..................................................................................................... 20 2.3 ADDRESSING GLOBAL DESIGN ............................................................................................ 23 2.4 CONSTRAINTS AND OTHER CONSIDERATIONS ..................................................................... 24 3. DESIGN ALTERNATIVES.................................................................................................. 26 3.1 OVERVIEW OF CONCEPTUAL DESIGN .................................................................................. 26 3.2 DESIGN ALTERNATE 1 ........................................................................................................ 28 3.3 DESIGN ALTERNATE 2 ........................................................................................................ 30 3.4 FINAL PROPOSED DESIGN ................................................................................................... 32 3.4.1 MANIFOLD ...................................................................................................................... 32 3.4.2 VALVE ............................................................................................................................. 33 3.4.3 STEPPER MOTOR ............................................................................................................. 35 3.4.4 ON/O FF VALVE ............................................................................................................... 36 3.4.5 RCS CONTROLLER .......................................................................................................... 36 3.4.6 ASSEMBLY ...................................................................................................................... 37 3.5 PRODUCTION OPTIONS ........................................................................................................ 38 3.5.1 TRADITIONAL MACHINING .............................................................................................. 38 3.5.2 3D PRINTING ................................................................................................................... 38 4. PROJECT MANAGEMENT ................................................................................................ 41 4.1 OVERVIEW .......................................................................................................................... 41 4.2 GANTT CHART FOR THE ORGANIZATION OF WORK AND TIMELINE ..................................... 41 4.3 BREAKDOWN OF RESPONSIBILITIES AMONG TEAM MEMBERS ............................................ 41 4.4 POTENTIAL FOR COMPETITION ............................................................................................ 42 5. ENGINEERING DESIGN AND ANALYSIS ...................................................................... 43 5.1 OVERVIEW .......................................................................................................................... 43 2 5.2 ENGINEERING CALCULATIONS ............................................................................................ 43 5.3 STRESS AND PRESSURE SIMULATIONS ................................................................................. 46 5.4 COST ANALYSIS .................................................................................................................. 48 6. PROTOTYPE CONSTRUCTION ........................................................................................ 49 6.1 PROTOTYPE SYSTEM DESCRIPTION ..................................................................................... 49 6.2 COMPLETED PROTOTYPE DESIGN ....................................................................................... 50 6.2.1 VALVE AND MANIFOLD ................................................................................................... 51 6.2.2 PIPING ARANGEMENT ...................................................................................................... 51 6.2.3 TESTING APPARATUS ...................................................................................................... 52 6.3 PARTS LIST ......................................................................................................................... 55 6.4 PROTOTYPE COST ANALYSIS .............................................................................................. 56 7. TESTING AND EVALUATION .......................................................................................... 58 7.1 OVERVIEW .......................................................................................................................... 58 7.2 DESIGN OF EXPERIMENTS ................................................................................................... 60 7.3 TEST RESULTS AND DATA ................................................................................................... 61 8. DESIGN CONSIDERATIONS ............................................................................................. 62 8.1 ASSEMBLY .......................................................................................................................... 62 8.2 DISASSEMBLY AND MAINTENANCE ..................................................................................... 62 8.3 ENVIRONMENTAL IMPACT ................................................................................................... 63 8.4 RISK ASSESSMENT .............................................................................................................. 64 9. DESIGN EXPERIENCE ....................................................................................................... 65 9.1 OVERVIEW