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Student Training Program

The Pennsylvania State University - Student Space Programs Laboratory

Development of an atmospheric data-gathering payload for use on a model rocket

September 2020 - December 2020

This project is a payload development project created for a club’s introductory training program. Given the problem, a team of students and I developed a solution, budgeted it, and wrote a Critical Design Review for review.

Download the full proposal document
Model CDR
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SSPL Training Program Project
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Background

The Student Space Programs Laboratory (SSPL) at the Pennsylvania State University allows undergraduate and graduate students the opportunity to design, fabricate, and integrate space systems. The SSPL provides hands-on projects to apply classroom knowledge to real-world, interdisciplinary settings. SSPL students experience working through a complete design cycle and must develop a systems engineering mindset in addition to their component-level experience.

SSPL offers the Student Training Program (STP) to new members each semester. The goal of STP is to provide aspiring underclassmen with a chance to complete a challenging and rapid design cycle before moving on to other projects in the organization. In the program, students form teams that design, construct, and fly a small rocket payload. The payload collects data, including video, as it ascends in a rocket and descends via parachute. This design-build-launch program introduces students to space systems engineering fundamentals. Students gain the satisfaction of being involved with the end-to-end life cycle of a complex engineering project, from conceptual design, through integration and test, the actual operation of the system, and concluding with a post-mission summary and debrief.

The following are the constraints students must adhere to when designing their payload:

  • The payload shall cost less than $300 ​
  • The mass shall not exceed 500 grams. ​
  • The center of gravity (CG) shall be within 0.3 cm of the axis. ​
  • Must fit inside the cylindrical payload section of the rocket defined by the cylindrical envelope of 60 mm diameter and 160 mm in length. 
  • No static protrusions beyond the defined envelope are allowed. ​
  • Must release a parachute upon descent. ​
  • Must have external power control with confirmation of the payload power state. ​
  • A buzzer shall sound upon landing. 
  • Must log the following time-stamped data sent in real-time: ​
    • The GPS position (latitude and longitude) of the payload to within 10 meters ​
    • Number of GPS satellites tracked ​
    • Altitude of the payload calculated by means other than GPS to within 4 meters ​
    • Temperature of the payload ​
    • Voltage and current draw of the payload battery 
  • The payload shall include one or more sensors to measure an observable of your choosing. This observable should be a part of an explicitly defined science mission. ​
  • Wireless transmission of mission data is optional. ​

Due to Covid-19 and resulting laboratory restrictions, the program was completed virtually. The assembly and launch of the payload are delayed until restrictions are lifted, but the rest of the process was accomplished.

 

My Involvement

I was placed on the Mechanical Team of my STP group, where my focus was on the housing of the payload. For the Preliminary Design Review (PDR), the Mechanical Team created a CAD model of the payload structure, as pictured above. We decided that it would be best to 3D print the casing due to its cost, weight, and customizable nature. 

In addition, the group as a whole had to choose the electronics and parts we would use. We had to justify each part, keep track of the costs and masses, and consider where it would be placed in the payload. We also had to create an operational concept plan and electronics schematic. 

For the Critical Design Review (CDR), the Mechanical Team had to create a more detailed and construction-ready plan for the housing. After getting input from the PDR, we had to adjust the CAD model a little bit. After creating a more easily accessible lid, we fine-tuned the positioning of the walls. We also decided we will use a 60% infill when we eventually get to 3D print the housing. In addition, I was in charge of keeping track of the parts and recording critical information (purpose of part, product ID, mass, and cost). 

Once the Electronics and Programming Teams finalized their plans, the Mechanical Team created an Assembly and Testing plan. Once Covid-19 restrictions are lifted, we plan on putting together the payload and launching it. 

Links

SSPL website: https://sites.psu.edu/sspl/

SSPL STP page: https://sites.psu.edu/sspl/student-training-program/