Initial Questions
Version 33 (Jeremy Wright, 03/31/2013 07:03 pm) → Version 34/35 (Jeremy Wright, 10/07/2013 07:15 am)
h1. Shepard Test Stand Initial Questions v1.1
{{toc}}
Below is a list of questions and proposed answers to help us narrow down the requirements for this project. You can view the original forum discussion "here":https://opendesignengine.net/boards/4/topics/38 .
This is a newer document based on "this one":https://opendesignengine.net/projects/shepard-ts/wiki/Initial_Questions_v1_0 , and you should refer to that original version if you want to see the revision history.
h3. Q1. Why are we making this?
*A1*. _The Shepard Test Stand is the first step toward developing an open source test stand for flight capable rocket engines. It's focus on low power, commercially available amateur rocket motors is intended to provide a safe first experience for both designers (low power and low cost lead to little penalty for failing to meet design goals the first time around) and operators (low power leads to lower cost if accidentally misused during early training). Additionally, as one of Mach 30's earliest open source hardware projects, it will give us practical experience in open source hardware development and managing projects on Open Design Engine (ODE). Finally, we have received interest in performing live demonstrations of the test stand as part of educational and outreach activities, so it is expected the test stand will become an educational and marketing tool._
h3. Q2. Who is this for?
*A2.* *A2*. _The Shepard Test Stand is for anyone wanting to learn about measuring the performance of rocket motors. This includes open source spaceflight designers who will design and build future test stands (at Mach 30 or elsewhere), Mach 30 operators who will use future test stands in other Mach 30 projects, students and educators who want to bring rocket engineering into the classroom, and anyone else interested in how rockets are tested. To ensure the Shepard Test Stand will be accessible to the entire user community, including users with no experience in spacecraft engineering, the Shepard Test Stand team has selected a representative user with limited experience in spacecraft engineering and testing hardware. This representative user is a middle school (6th through 8th grade in the U.S.) teacher who does not have the support of an IT department, and who does not have computer expertise beyond how to connect a USB cable and install software, but has the desire to introduce their students to rocket science in a safe and hands-on way._ tested._
h3. Q3. How will this be used?
*A3*. _The final test stand will be used for verification of typical motor performance metrics such as thrust and casing temperature. The thrust metric will be compared against benchmark values provided in the "Estes motor documentation":http://www2.estesrockets.com/pdf/Estes_Time-Thrust_Curves.pdf . The test stand will then be used as a tool to teach rocket engineering in classrooms, and to do demonstrations at various conferences and educational events (outdoor only)._
h3. Q4. What features does it need to have (now)?
*A4.* The *A4*. _The test stand needs to: to:_
* _Be easily set up and torn down for demonstration purposes._
* _Be easy to package for shipment to any event at which it will be used._
* _Provide a stable base on which to test model rocket motors._
* _Accommodate Estes rocket motor sizes A through E._
* _Provide the ability to measure motor thrust while keeping an accurate timestamp for each data point._
* _Provide the ability to measure and motor case casing temperature or flame temperature while keeping an accurage accurate timestamp for each data point._
* _Allow for the thermal sensor to be moved so it can either measure case temperature or flame temperature. Note, when measuring the case temperature the DAQ will need to collect data for longer than the thrust duration to capture the temperature change in the case after the motor finishes firing._
* _Keep cleanup and maintenance to a minimum between consecutive test firings._
* _Have a motor mount which will survive motor failure or be relatively easy to replace in the event of a motor failure._
* _Be easily set up and torn down for demonstration purposes. Specifically, the setup and tear down procedures should be tool-less, or at a maximum require simple tools such as screwdriver and/or hammer rather than something like a masonry drill bit._
* _Be easy to package for shipment to any event at which it will be used. Be particularly aware of dimensions and weight and how they impact shipping costs. Note, CCSSC intends to use up to 10 test stands at a time, so transportation considerations should also take into account transporting multiple test stands._
* _Conform to the "safety requirements":https://opendesignengine.net/projects/shepard-ts/wiki/Requirements_Document requirements (STSR 3.4)":https://opendesignengine.net/projects/shepard-ts/wiki/Requirements_Document as outlined in section 8.3 of the "NAR Standards & Testing Committee Motor Testing Manual Version 1.5":http://www.nar.org/SandT/docs/ST-MotorTestingManual.pdf ._
* _Be "hackable" so users and makers are encouraged to experiment with the design of the test stand._
* _Provide space for labels to be added for safety warnings, branding, etc._
* _Have desktop control software that will run on all three major PC platforms (MS Windows, Mac OS X, and Linux)._
* _Include a DAQ system that uses standard connections back to the control software (for example, USB, Ethernet, or similar connections)._
h3. Q5. What features does it need to have (later)?
These features will not necessarily make it into any version of Shepard, but should be kept in mind for any of its larger sibling test stands later on.
* High and low speed video capture of the tests from multiple angles.
* Integrated ignition system so the test management software can control the entire test.
* Additional measurements.
* Higher resolution measurements.
* Higher sample rates.
* Accommodation of:
** High power commercial solid motors.
** Small hybrid motors (on the thrust scale of high power commercial solid motors).
** Larger thrust hybrid motors.
** Small liquid engines.
** Medium liquid engines.
** Large liquid engines.
h3. Q6. What are the legacy requirements?
*A6.* _Two features *A6*. _This is the first project of its kind at Mach 30, there are no existing projects it must interface with. However, since the v1.x test stand are very desirable in future versions._
# _The structure system includes desktop control software, that software should easily mount run on all three major PC platforms (MS Windows, Mac OS X, and Linux). Additionally, it should use standard connections back to a concrete block without the need for special tools control software (for example, USB, Ethernet, or modifying the block._
# _The DAQ should use an Arduino as the interface between the sensors and the data collection computer._ similar connections)._
h3. Q7. Who's going to build this?
*A7.* _The *A7*. _It is assumed that initially volunteers within the Mach 30 community will build this test stand. The designs will be open so that anyone, ANYONE, without necessarily a technical education in rocketry, propulsion, or engineering, would be able to build and operate a Shepard Test Stand. Specifically, in order to support the use of the Shepard Test Stand in classrooms, teachers and students should be able to build the test stand from parts or kits._ Stand._
h3. Q8. How many do we want to make?
*A8.* _Previous efforts focused on developing the single initial prototype. *A8*. _One (for now). The success current goal is to create a design variation of this prototype and the very strong interest in the use of the Shepard Test Stand in schools (middle school through college) has led Mach 30 test stand to decide it will sell Shepard Test Stand kits be built as a kit for use in schools, scouting troupes, others to assemble and makerspaces. This means developing operate. In that case there will be as many of the Shepard Test Stand into a finished product. So, the short answer to this question kit design built as there is "as many as the market demands."_ demand._
h3. Q9. What is the budget?
*A9.* _Based on feedback form CCSSC, the final cost for Shepard Test Stand kits needs to be around $200 (though having $200, firm. If there is a data component conflict between function and being reusable like Shepard could allow budget, for higher prices). Using this iteration, budget should trump. Our goal is not to make the standard OSHW cost multiplier perfect test stand, it is to make the first prototype of 2.6, the total cost for parts a test stand and labor needs see what we can learn from that experience (both about test stands, and about our processes). We can always go back and do another iteration to be around $78 (note, meet the most recent experiments in structure design requirements if needed. Holding to a firm budget minimizes the amount of time spent trying to make it perfect (once you are out of money, you have to wrap up the project, successful or not). Even a materials "unsuccessful" prototype will teach us important lessons to apply moving forward. This budget does not include "consumables" such as motors, nor tools, but the $200 cost of about $40). To allow for several additional prototypes while still holding the materials cost down, stand itself keeps the updated structure budget basic project affordable if standard tools found in Hackerspaces/Makerspaces can be used. Any manufacturing that has to be hired out to a threshhold (maximum value) third party will be taken out of $150 the $200 budget, and an objective of $100._ should be avoided to keep this project more practical for groups interested in building the test stand.
h3. Q10. What is the timeline?
*A10.* *A10*. _The v2.0 prototype (completed structure integrated with existing v2.0 prototype DAQ) needs goal is to be complete and have its initial test firing by Dec 31, 2013. This timeline works with the efforts by project within three months of formal launch as an exercise of agile design. However, given the "Coca-Cola Space Science Center":http://www.ccssc.org/ project is also an experiment in open source hardware development and is all volunteer based, we need to develop curriculum for recognize the Shepard Test Stand (as long as they have early access need to new structure prototypes)._ be flexible in this requirement._
h3. Q11. What waste products will be produced by the manufacture and/or operation of this?
*A11.* Spent Estes motors will be a waste product of the operation of this test stand, and any residual materials should be treated as hazardous. Disposal of these motors should conform to all local, state, and federal guidelines. Estes motors are based on black powder propellant, so any motors that do not fire properly or are damaged can be disposed of in an ordinary manner by first soaking them in water until the casing unwraps and the propellant falls apart. Possible electronic waste items may include batteries from the ignition control box, and circuit boards. These must also be disposed of according to all local, state, and federal guidelines. If the frame of the test stand is damaged beyond repair during operation, proper disposal/recycling guidelines must be followed for the materials used in its construction.
{{toc}}
Below is a list of questions and proposed answers to help us narrow down the requirements for this project. You can view the original forum discussion "here":https://opendesignengine.net/boards/4/topics/38 .
This is a newer document based on "this one":https://opendesignengine.net/projects/shepard-ts/wiki/Initial_Questions_v1_0 , and you should refer to that original version if you want to see the revision history.
h3. Q1. Why are we making this?
*A1*. _The Shepard Test Stand is the first step toward developing an open source test stand for flight capable rocket engines. It's focus on low power, commercially available amateur rocket motors is intended to provide a safe first experience for both designers (low power and low cost lead to little penalty for failing to meet design goals the first time around) and operators (low power leads to lower cost if accidentally misused during early training). Additionally, as one of Mach 30's earliest open source hardware projects, it will give us practical experience in open source hardware development and managing projects on Open Design Engine (ODE). Finally, we have received interest in performing live demonstrations of the test stand as part of educational and outreach activities, so it is expected the test stand will become an educational and marketing tool._
h3. Q2. Who is this for?
*A2.* *A2*. _The Shepard Test Stand is for anyone wanting to learn about measuring the performance of rocket motors. This includes open source spaceflight designers who will design and build future test stands (at Mach 30 or elsewhere), Mach 30 operators who will use future test stands in other Mach 30 projects, students and educators who want to bring rocket engineering into the classroom, and anyone else interested in how rockets are tested. To ensure the Shepard Test Stand will be accessible to the entire user community, including users with no experience in spacecraft engineering, the Shepard Test Stand team has selected a representative user with limited experience in spacecraft engineering and testing hardware. This representative user is a middle school (6th through 8th grade in the U.S.) teacher who does not have the support of an IT department, and who does not have computer expertise beyond how to connect a USB cable and install software, but has the desire to introduce their students to rocket science in a safe and hands-on way._ tested._
h3. Q3. How will this be used?
*A3*. _The final test stand will be used for verification of typical motor performance metrics such as thrust and casing temperature. The thrust metric will be compared against benchmark values provided in the "Estes motor documentation":http://www2.estesrockets.com/pdf/Estes_Time-Thrust_Curves.pdf . The test stand will then be used as a tool to teach rocket engineering in classrooms, and to do demonstrations at various conferences and educational events (outdoor only)._
h3. Q4. What features does it need to have (now)?
*A4.* The *A4*. _The test stand needs to: to:_
* _Be easily set up and torn down for demonstration purposes._
* _Be easy to package for shipment to any event at which it will be used._
* _Provide a stable base on which to test model rocket motors._
* _Accommodate Estes rocket motor sizes A through E._
* _Provide the ability to measure motor thrust while keeping an accurate timestamp for each data point._
* _Provide the ability to measure and motor case casing temperature or flame temperature while keeping an accurage accurate timestamp for each data point._
* _Allow for the thermal sensor to be moved so it can either measure case temperature or flame temperature. Note, when measuring the case temperature the DAQ will need to collect data for longer than the thrust duration to capture the temperature change in the case after the motor finishes firing._
* _Keep cleanup and maintenance to a minimum between consecutive test firings._
* _Have a motor mount which will survive motor failure or be relatively easy to replace in the event of a motor failure._
* _Be easily set up and torn down for demonstration purposes. Specifically, the setup and tear down procedures should be tool-less, or at a maximum require simple tools such as screwdriver and/or hammer rather than something like a masonry drill bit._
* _Be easy to package for shipment to any event at which it will be used. Be particularly aware of dimensions and weight and how they impact shipping costs. Note, CCSSC intends to use up to 10 test stands at a time, so transportation considerations should also take into account transporting multiple test stands._
* _Conform to the "safety requirements":https://opendesignengine.net/projects/shepard-ts/wiki/Requirements_Document requirements (STSR 3.4)":https://opendesignengine.net/projects/shepard-ts/wiki/Requirements_Document as outlined in section 8.3 of the "NAR Standards & Testing Committee Motor Testing Manual Version 1.5":http://www.nar.org/SandT/docs/ST-MotorTestingManual.pdf ._
* _Be "hackable" so users and makers are encouraged to experiment with the design of the test stand._
* _Provide space for labels to be added for safety warnings, branding, etc._
* _Have desktop control software that will run on all three major PC platforms (MS Windows, Mac OS X, and Linux)._
* _Include a DAQ system that uses standard connections back to the control software (for example, USB, Ethernet, or similar connections)._
h3. Q5. What features does it need to have (later)?
These features will not necessarily make it into any version of Shepard, but should be kept in mind for any of its larger sibling test stands later on.
* High and low speed video capture of the tests from multiple angles.
* Integrated ignition system so the test management software can control the entire test.
* Additional measurements.
* Higher resolution measurements.
* Higher sample rates.
* Accommodation of:
** High power commercial solid motors.
** Small hybrid motors (on the thrust scale of high power commercial solid motors).
** Larger thrust hybrid motors.
** Small liquid engines.
** Medium liquid engines.
** Large liquid engines.
h3. Q6. What are the legacy requirements?
*A6.* _Two features *A6*. _This is the first project of its kind at Mach 30, there are no existing projects it must interface with. However, since the v1.x test stand are very desirable in future versions._
# _The structure system includes desktop control software, that software should easily mount run on all three major PC platforms (MS Windows, Mac OS X, and Linux). Additionally, it should use standard connections back to a concrete block without the need for special tools control software (for example, USB, Ethernet, or modifying the block._
# _The DAQ should use an Arduino as the interface between the sensors and the data collection computer._ similar connections)._
h3. Q7. Who's going to build this?
*A7.* _The *A7*. _It is assumed that initially volunteers within the Mach 30 community will build this test stand. The designs will be open so that anyone, ANYONE, without necessarily a technical education in rocketry, propulsion, or engineering, would be able to build and operate a Shepard Test Stand. Specifically, in order to support the use of the Shepard Test Stand in classrooms, teachers and students should be able to build the test stand from parts or kits._ Stand._
h3. Q8. How many do we want to make?
*A8.* _Previous efforts focused on developing the single initial prototype. *A8*. _One (for now). The success current goal is to create a design variation of this prototype and the very strong interest in the use of the Shepard Test Stand in schools (middle school through college) has led Mach 30 test stand to decide it will sell Shepard Test Stand kits be built as a kit for use in schools, scouting troupes, others to assemble and makerspaces. This means developing operate. In that case there will be as many of the Shepard Test Stand into a finished product. So, the short answer to this question kit design built as there is "as many as the market demands."_ demand._
h3. Q9. What is the budget?
*A9.* _Based on feedback form CCSSC, the final cost for Shepard Test Stand kits needs to be around $200 (though having $200, firm. If there is a data component conflict between function and being reusable like Shepard could allow budget, for higher prices). Using this iteration, budget should trump. Our goal is not to make the standard OSHW cost multiplier perfect test stand, it is to make the first prototype of 2.6, the total cost for parts a test stand and labor needs see what we can learn from that experience (both about test stands, and about our processes). We can always go back and do another iteration to be around $78 (note, meet the most recent experiments in structure design requirements if needed. Holding to a firm budget minimizes the amount of time spent trying to make it perfect (once you are out of money, you have to wrap up the project, successful or not). Even a materials "unsuccessful" prototype will teach us important lessons to apply moving forward. This budget does not include "consumables" such as motors, nor tools, but the $200 cost of about $40). To allow for several additional prototypes while still holding the materials cost down, stand itself keeps the updated structure budget basic project affordable if standard tools found in Hackerspaces/Makerspaces can be used. Any manufacturing that has to be hired out to a threshhold (maximum value) third party will be taken out of $150 the $200 budget, and an objective of $100._ should be avoided to keep this project more practical for groups interested in building the test stand.
h3. Q10. What is the timeline?
*A10.* *A10*. _The v2.0 prototype (completed structure integrated with existing v2.0 prototype DAQ) needs goal is to be complete and have its initial test firing by Dec 31, 2013. This timeline works with the efforts by project within three months of formal launch as an exercise of agile design. However, given the "Coca-Cola Space Science Center":http://www.ccssc.org/ project is also an experiment in open source hardware development and is all volunteer based, we need to develop curriculum for recognize the Shepard Test Stand (as long as they have early access need to new structure prototypes)._ be flexible in this requirement._
h3. Q11. What waste products will be produced by the manufacture and/or operation of this?
*A11.* Spent Estes motors will be a waste product of the operation of this test stand, and any residual materials should be treated as hazardous. Disposal of these motors should conform to all local, state, and federal guidelines. Estes motors are based on black powder propellant, so any motors that do not fire properly or are damaged can be disposed of in an ordinary manner by first soaking them in water until the casing unwraps and the propellant falls apart. Possible electronic waste items may include batteries from the ignition control box, and circuit boards. These must also be disposed of according to all local, state, and federal guidelines. If the frame of the test stand is damaged beyond repair during operation, proper disposal/recycling guidelines must be followed for the materials used in its construction.