44 lines
3.4 KiB
Markdown
44 lines
3.4 KiB
Markdown
# Ground Control System for Hybrid Rocket Engine Static Tests
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## Overview
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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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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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### Key Features
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- **Nitrous Oxide Fluid Control**: Manages multiple valves that control the filling and venting of the engine's run tank.
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- **Main Valve Control**: Supports both pneumatic and servo-driven valves.
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- **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.
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## System Components
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### Control Box
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The control box serves as the user interface for managing the test systems. It includes:
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- **Control PCB**: Hosts an Arduino microcontroller and switch inputs.
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- **Status Display**: An additional PCB with LED indicators and an LCD screen provides real-time status updates.
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- **Compact Design**: Housed in a small, portable case with 3D-printed panels for switches, LEDs, and the display.
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This box gives the operator full control over the fluid systems and igniter, with clear visual feedback on system states.
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### Actuator Box
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The actuator box handles the execution of commands from the control box, controlling the physical hardware of the rocket engine. It features:
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- **Power Conversion**: Multiple buck converters for 5V, 3.3V, and 7.4V power systems, and a boost converter for 24V avionics power.
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- **Custom PCB**: Hosts the Arduino, relays, transistors, Ethernet, and CAN bus module.
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- **Relay Control**: Includes latching and non-latching relays to operate valves, with voltage monitoring for added safety.
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- **Igniter Continuity Check**: Verifies igniter circuit integrity by measuring voltage across a resistor.
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### Communication
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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.
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## Safety Features
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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.
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## Design and Build
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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.
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## Conclusion
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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. |