Renaming actuation -> actuator. Readme updates and outline
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n/a
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223
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70
README.md
70
README.md
@ -1,49 +1,51 @@
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# Ground Control System for Hybrid Rocket Engine Static Tests
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||||
# Purpose
|
||||
The Texas A&M Sounding Rocketry Team designs, builds, and flies its own hybrid rocket.
|
||||
As part of its design cycle, static cold flows and static engine tests are performed to chacterize the engine's oxidizer tank,
|
||||
fluid system, and combustion process.
|
||||
|
||||
## Overview
|
||||
# Overall System Design
|
||||
During a static engine test, we load solid HTPB fuel into the combustion chamber. As part of the test procedure, we load nitrous oxide into the run tank via the fluid panel. We then ignite the starter, and open the ball valve actuation system (BVAS) to begin our combustion cycle.
|
||||
|
||||
This project showcases a custom-built ground control system designed for static engine tests of a hybrid rocket engine, created for the Texas A&M Sounding Rocketry Team. It replaces an older, unreliable, and overly complex system, offering a dedicated and streamlined solution for controlling critical components in rocket engine testing.
|
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## Concept of Operation
|
||||
|
||||
|
||||
The system manages the nitrous oxide fluid panel, controlling several valves and relays, including the fill valve, vent solenoids, and the main engine valve. It also handles igniter control and includes built-in safety features that mitigate risks during testing.
|
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## Control Box
|
||||
The control box is responsible for taking in operator inputs and sending them to the actuator box over CAN. The control box also receives feedback from the actuator box and updates the assortment of LEDs and the LCD screen on the indicator panel.
|
||||
|
||||
### Key Features
|
||||
- **Nitrous Oxide Fluid Control**: Manages multiple valves that control the filling and venting of the engine's run tank.
|
||||
- **Main Valve Control**: Supports both pneumatic and servo-driven valves.
|
||||
- **Igniter Management**: Controls a relay for the ignition system during engine start.
|
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- **Failure Handling**: If communication between control components is lost, the system automatically pauses and will abort safely after a timeout period.
|
||||
### Logic Diagram
|
||||
|
||||
|
||||
## System Components
|
||||
### Power Diagram
|
||||
|
||||
|
||||
### Control Box
|
||||
The control box serves as the user interface for managing the test systems. It includes:
|
||||
## Actuator Box
|
||||
The actuator box is responsible for actuating valves on the oxidizer fluid panel, main throttle valve on the engine, and igniting the starter system. During a test when avionics is deployed, the avionics stack handles engine control while the actuator box controls ground support systems.
|
||||
|
||||
- **Control PCB**: Hosts an Arduino microcontroller and switch inputs.
|
||||
- **Status Display**: An additional PCB with LED indicators and an LCD screen provides real-time status updates.
|
||||
- **Compact Design**: Housed in a small, portable case with 3D-printed panels for switches, LEDs, and the display.
|
||||
### Logic Diagram
|
||||
|
||||
|
||||
This box gives the operator full control over the fluid systems and igniter, with clear visual feedback on system states.
|
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### Power Diagram
|
||||
|
||||
|
||||
### Actuator Box
|
||||
The actuator box handles the execution of commands from the control box, controlling the physical hardware of the rocket engine. It features:
|
||||
# Physical Design
|
||||
## Control Box
|
||||
### Display PCB
|
||||
|
||||
- **Power Conversion**: Multiple buck converters for 5V, 3.3V, and 7.4V power systems, and a boost converter for 24V avionics power.
|
||||
- **Custom PCB**: Hosts the Arduino, relays, transistors, Ethernet, and CAN bus module.
|
||||
- **Relay Control**: Includes latching and non-latching relays to operate valves, with voltage monitoring for added safety.
|
||||
- **Igniter Continuity Check**: Verifies igniter circuit integrity by measuring voltage across a resistor.
|
||||
### Main PCB
|
||||
|
||||
### Communication
|
||||
The control and actuator boxes are connected using a peer-to-peer CAN bus network, ensuring robust and low-latency communication during critical test phases.
|
||||
### Housing and Switch Panel
|
||||
|
||||
## Safety Features
|
||||
One of the standout features of this system is its built-in failure handling. If the connection between the control and actuator boxes is lost, the system automatically pauses, halting the fill process. If the connection isn't restored within 10 minutes, the system will perform an emergency abort, depressurizing the entire system by opening the main valve.
|
||||
## Actuator Box
|
||||
### Actuator PCB
|
||||
|
||||
## Design and Build
|
||||
This system was designed with simplicity and reliability in mind, using custom PCBs and Arduino-based microcontrollers to handle various control and monitoring tasks. The modular design of the control and actuator boxes allows for easy troubleshooting, upgrades, and integration with other systems.
|
||||
### Actuator Box Housing
|
||||
|
||||
## Conclusion
|
||||
This dedicated ground control system vastly improves the reliability and safety of hybrid rocket engine tests for the Texas A&M Sounding Rocketry Team. It simplifies operations while introducing advanced safety measures, ensuring smooth and controlled static engine tests.
|
||||
# Arduino Software
|
||||
## Control Box
|
||||
|
||||
# TODO
|
||||
1. Get rid of duplicate or extraneous files
|
||||
2. Better file organization
|
||||
3. Design links in readme
|
||||
## Actuator Box
|
||||
|
||||
# System Upgrades After Initial Design
|
||||
## Servo Motor Main Valve for Throttling
|
||||
|
||||
## MODBUS TCP Communication for Integration in Ignition SCADA
|
||||
BIN
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readme_media/conops_with_av.png
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readme_media/conops_without_av.png
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readme_media/control_box/control_logic.png
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readme_media/control_box/control_power.png
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BIN
readme_media/control_box/control_software_1.png
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readme_media/control_box/control_software_1.png
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BIN
readme_media/control_box/control_software_2.png
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readme_media/control_box/control_software_2.png
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Loading…
Reference in New Issue
Block a user