Liquid Rocketry Test Stand

Rose Propulsion Laboratory (RPL) is participating in the Collegiate Propulsive Lander Challenge, with the goal of creating a self-landing vehicle. In the process of designing the vehicle, RPL must test its feed system and engine. The test stand is the structure containing the feed system designed for nitrous oxide and isopropyl alcohol that the team uses as propellants to test liquid rocket engines.

Design

During the design phase of this project, I was given a piping and instrumentation diagram along with selected off-the-shelf components. With these resources, I was tasked with designing the test stand in SolidWorks PDM. As I worked through the CAD, I worked with members of the team to make edits to the P&ID to better suit it for the hot fire test. I also researched sheet metal manufacturing and JIC, NPT, and Swagelok fittings. I performed manufacturing tests and wrote documentation to aid in the design. I created a manufacturing plan and performed a failure modes and effects analysis of the structure and fluid system. Lastly, I presented the design with my team at a design review and safety review with the institute.

Manufacturing

After the design was complete, I became the test stand structural lead and worked to teach others the manufacturing skills that I had learned and instruct them in the manufacture of the test stand. I worked with sheet metal, aluminum extrusion, and stainless steel piping and fittings. I spent time in the machine shop creating manufacturing processes and teaching them to new members. During the manufacturing process, I gained experience with pipe bending and flaring as well as cleaning for oxygen-safe systems.

Testing

After manufacturing was complete, I created the club's testing schedule as the program manager. I wrote operational procedures for all of the tests and test procedures for the igniter test. As a club, we performed igniter, hydrostatic, injector, cold flow, and hot fire tests. As program manager, I coordinated with the institute and with rocketry leadership on scheduling, safety, test materials, transportation, and documentation.

Takeaways

Through this project, I gained experience all the way from the design phase through to the testing phase.

Lessons learned:

  • Front-end design work is essential.  For example, attention to component selection and manufacturing feasibility will save time later on.

  • It is important to frequently review work and request feedback from peers to get other points of view for possible solutions.

  • When scheduling, ordering, and creating test timelines, it is beneficial to add in buffer time.

  • As a team leader, effective communication is key.   Information must be transmitted in a streamlined and easy-to-read way on time.