Ignitor Team: Go!

[This is an update from the Ignitor Senior Design team.]

Welcome back! This week, we will walk you through our preliminary plans.

Chosen Method:

After weighing out the risks and benefits of all potential methods, our team chose an industry standard ignition method known as the augmented spark plug system. In short, a portion of the fuel will be diverted from the combustion chamber and injected into a smaller sub-chamber for ignition via spark plug. This resulting fireball will then travel down a channel into the primary combustion chamber and create the thrust necessary to get our rocket off the ground and up to the Karman Line.

Below is an extremely simplified initial diagram:

As you can see, this system will require quite a bit of design overhaul on original build. However, we hope that the hours of sweat and tears we put into this system will result in a reusable, economical, and safer rocket.

Project Updates:

Currently, we are working on the first iteration of this new injector. Recently, we started modeling the new sub-chamber which will house the augmented spark igniter system. We are simultaneously working on the chamber geometry, injection elements, and creation of the spark plug itself.

Each of these tasks offer their own set of chanllenges, but we can’t wait to solve them. Past them, we will move on to finalizing the first iteration using SolidWorks. We will then move onto inert water flow tests before actual combustion.

We can tell this project will be a lot of work which will push us to our technical limits. Particularly, crunching all the numbers associated chamber geometry and flow characteristics will take some time. But we plan to give this project everything we have to develop an innovative injector/ignitor system — and get this rocket to space.

…This is Ground Control

[This is an update from the Ground Control Senior Design Team.]

Greetings from Castle Point Rocketry’s Ground Control team! The team consists of five team members: Martin Gilmartin (MechEng), John Hamill (MechEng), Ed Minnix (CySec), Nicholas Yarbrough (CompEng), and Charles Zwicker (CompEng).

We’re currently working on Revision 2.0 of the Ground Infrastructure Support and Control Systems in order to increase its capabilities, make it more reliable and redundant, and make its operations more logical and streamlined.

Here are some of the improvements we’re making.

Ground Control Station (GCS)

This is the main station that we will use to control the launch sequence, view our camera feeds and telemetry from the rocket (velocity, altitude, etc.), and manually actuate any valves in the event of emergency.

This subsystem will be an upgrade over last year’s setup. We are integrating the control and monitoring into a single unit as opposed to last year’s iteration which was handled by a separate laptop. The combination of these systems with a more powerful computer will lead to easier setup and transport. Furthermore, the new computer will run an enterprise-grade Linux distribution, providing further stability.

The GCS will be upgraded to redundantly store all of the data being streamed in realtime from the Ground Support Station and run for over eight hours on battery power, with a backup generator we can switch to without interruption. We will also waterproof the entire case and its connections so rain won’t hinder our progress.

We’re also constructing an antenna rotator in order to accurately track the rocket as it is airborne and achieve a more reliable signal.

Ground Support Station (GSS)

The GSS will roll all of the pre-launch hardware, which needs to be near the rocket, into one enclosure, streamlining it from its previous iteration. In addition, a large number of the GSS’s computational systems will be integrated directly into the GCS, reducing the hardware required at this location. We will upgrade the cameras and tripods in order to receive a higher quality video. This subsystem will also be battery powered for over eight hours.

Conclusion

We’re currently working with Nathan and Ben in the design and planning phase, ironing out the details before we pull the trigger and begin our first round of purchases. Our next steps include designing initial prototypes in CAD which we will then build and test followed by detailing the components of each system down to the minutia.

“When is Launch?”

We get that question a lot. So, rather than keep everybody waiting, here is a quick update.

The short answer is, “Coming soon.” The long answer is much more complicated and balances quite a few variables.

The biggest factor in play is our lack of components. When the team finished testing this summer, it was due to a hairline fissure in our liquid oxygen (LOX) tank. Though barely noticeable to the naked eye, this defect could have caused a catastrophic explosion with further testing. We returned the tank to its manufacturer for analysis and remanufacture, which can be a lengthy process. Additionally, the fins and nose cone arrived after testing. Though not necessary for testing, they need to be added to the rocket before we can launch.

Castle Point Rocketry is also in the middle of a transition. Since the founders are no longer Stevens undergraduates, we are navigating the challenges associated with acquiring real estate and transferring funds. (All while pursuing graduate school or full-time jobs!) Luckily, we have three great senior design teams to help tackle further engineering projects.

The final challenge to a set launch date is the same as last year: permits. Until the rocket passes our eight-step testing process, we cannot apply to launch. Even after applying, we will need to wait for approval — and maybe return for more tests.

The primary objective is still to put a liquid-fueled rocket beyond the Karman Line. We have some more help getting there, but testing is still in a temporary holding pattern.

So all that is to say: “Soon. Very soon.”

New Senior Design Teams

Last month, we mentioned the most exciting news from Castle Point Rocketry. In short, the company is sponsoring three new senior design teams to work on the rocket.

These interdisciplinary teams incorporate students from all across Stevens Institute of Technology. Chemical (CHE), Computer (CPE), Electrical (EE), and Mechanical (ME) Engineers will work with Cyber Security (CS) students to help us reach the Karman Line.

As with last year’s marathon goal, a diverse set of subsystems is on the docket. Here is a quick look.

Flight Computer Team

Redundant hardware is beneficial for most projects. If one component on a flight computer fails, the entire system may shut down. (Or, in the case of a rocket, end catastrophically.) This team will incorporate fallback systems into the current computer in order to make a more robust rocket.

The Flight Computer Team will design a leaner flight computer for Castle Point Rocketry. Composed of two EEs and a CPE, they are well-equipped for the task.

Ground Systems Team

The Ground Systems Team will remodel the ground infrastructure required to launch the rocket. Suitably, two CPEs, two MEs, and one CS are tackling this sprawling project.

Most radically, upgrades will be made to on-site telemetry systems and relay boxes. These changes will allow the team to communicate with the rocket more reliably and more securely. This is necessary both pre- and post-launch.

Given the time, the team will also build a stronger ground control center to provide instant feedback on the rocket.

Igniter Team

Expanding on last year’s prototype, the Igniter Team is designing a new igniter. After all, our current igniter is not reusable — though it looks spectacular in action. The goal of this project is to make it reusable and safer.

Two CHEs and two MEs will make it happen. Already, a series of meetings has been very productive. If all goes well, it could even be on the next injector model!

Future Blogs

In the future, both the company and these new teams will provide blog updates. That way, we can keep everyone informed of the latest news at Castle Point Rocketry!

The Faces of Castle Point Rocketry

It’s high time we re-introduce everyone who makes up this team. After all, once we test this thing and get our big media break, you’ll want to know who we all are.

Team Members

A core group of eight have been with this project since the beginning. We have four Mechanical Engineers (ME), two Chemical Engineers (CHE), one Computer Engineer (CPE), and one Computer Scientist (CS). Pictures and short blurbs below.

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Abe is our Aerodynamic Design and Mathematics Specialist. He helped solve the regenerative heating problem and worked with Tom and Will on many manufacturing tasks.

Tom also specializes in computer-aided design (CAD). He spent innunerable hours modeling an injector to Monica’s and Dakota’s specifications before tackling other projects.

Faris, working on Electronics, Signals, and Avionics, was integral to designing the team’s circuit boards and developing how those systems fit into the rocket.

Unfortunately, Abe, Tom, and Faris are unable to join the other members of the team for testing. However, we are still very proud to call them members of the Castle Point Rocketry team — we couldn’t have done it without them!

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Ben is Lead Programmer, meaning he has literally written the code for our testing procedure. Recently, Ben has also branched out to become our resident electronic hardware expert.

Will is formally the Machining Specialist, but he has extensive knowledge of (and a quippy remark for) for nearly every facet of the project. He also played a large role in designing the plumbing system.

Nathan is the true Renaissance Man of the group. As Team Lead, it’s his job to ensure every subsystem is stitched together — on top of serving as Point of Contact for purchasing and inquiries.

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Monica and Dakota, Propulsion Specialists, collaborate to fill our propulsion and PR needs.

Monica, who is also our Safety Officer, designed our plumbing system with Will and Dakota, manages our social media presence, and interfaces with many of our top donors. Dakota mainly focused on the engine, but he also manages the project’s blogs and attends to the tasks that fall in the ever-present gray areas.

Ben, Will, Nathan, Monica, and Dakota are all on site for this week’s testing procedures.

Team Volunteers

As you may have noticed around campus and online, Castle Point Rocketry has put out a call for volunteers. Two excited Stevens students have come to our aid, and we are very grateful!

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Rodrigo is a graduate student in ME who joined us in early February. His extensive background in fabrication and manufacturing have come in handy many a late night.

Dan, a rising junior in CPE, joined us at the beginning of the summer. He has been a great help to Ben in preparing our electronic systems for integration and testing.

Rodrigo is on site for this week’s testing procedure, and Dan may be coming down over the weekend.

Industry Advisors

We are also lucky to have had the input of two professional aerospace engineers. Rich Kelly from Valcor Engineering and Luke Colby from Triton Space Technologies have thankfully withstood a barrage of phone calls and emails from the team.

Rich and Luke are both on site for this week’s testing procedures.

Dolly Upgrade!

Initially, we built a dolly out of 80/20 aluminum to wheel about the rocket. This dolly proved to be too short as our rocket got longer. So, we decided on an upgrade — wood! This new dolly is double the length of the previous.

Over time, our rocket has only gotten longer. (At least, after it’s initial shortening when we moved from a two-stage system to a one-stage system.) Our rocket is around 25 feet long. This dolly will be used to transport it around the test and launch sites.

Dry Run Test #2 (Teaser)

It’s June 14th! You’ve caught us mid-test! So, let’s break these last few days down…

4,000 square feet of grass. 2,000 feet of fiber optic cable. 1,200 feet of Caution tape. 770 cubic feet of U-Haul space. 120-volt generator. 30 feet of truss.

10 seconds from the heart of campus. 9 o’clock start time. 8 team advisors. 7 valves. 6 visitors and counting. 5 walkie-talkies. 4 days. 3 structures. 2 tests. 1 fake rocket.

Keep an eye on our Instagram (@cprocketry), Facebook, and blog to see how it goes!