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Blog #4 Spring 23

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In terms of completing the proposed project work, Team 7 has completed manufacturing and assembly of the CCS design. Team 7 has also completed thermal oven validation testing. Six tests were conducted in total, with two tests each at 100°F, 110°F, and 120°F. These tests were run for 60 minutes in total, with effectiveness measured at both the 40 and 60 minute marks. The goal of the project is to keep the internal CCS temperature between 32-77°F for a period of 40 minutes at an external temperature of 110°F. The graphed results of temperature data recorded for the second run of thermal oven tests conducted at 110°F and 120°F can be found in Figures 1-2. Figure 1: Thermal Oven Test at 110F (Run 2) Figure 2: Thermal Oven Test at 120F (Run 2) Team 7 has yet to complete shake table (vibrations) testing. The team has begun analysis of flight data gathered from SCR’s most recent competition rocket, Zenith. Team 7 will provide Iron Ring Technologies with a Frequency vs ASD (acceleration spectr...
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Blog #3 Spring 23

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  Figure 1 below shows the final implementation of the camera cooling system. The key design features include an insulating case that houses a cooling material and a GoPro, a removable aerogel layer for the insulation as shown in Figure 2, a lid with GORE sealant for an airtight seal, and a steel rod design that will secure the lid and the case together while allowing it to mount onto the existing payload housing design. The insulating case is machined out of aluminum, and the cooling material is a water-based cooling gel.  Figure [1] - CCS Structural Profile Overview Figure [2] - CCS Aerogel Insulation Team 7 has not yet completed any of its planned thermal oven or shake table validation tests. The team therefore does not currently have any validation data to assess whether thermal or structural goals/specifications are met by the fabricated CCS. Team 7 has weighed and measured the dimensions of the device to ensure mass and volumetric constraints have been fulfilled. Figure...
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Blog #2 Spring 23

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Over the work period of February 4 - February 18, the team continued to make small tweaks to the design in order to more easily manufacture various components. All materials necessary to begin machining the device have been acquired, and have been handed off to the machinist at Iron Ring Technologies. The team is currently waiting for the components to be machined. Iron Ring has guaranteed these items to be machined by the end of February at the latest. Team 7 has also updated CAD designs and drawings for various parts of the Camera Cooling System (CCS). This includes the external aluminum rod casing (Figure 1), the removable case lid (Figure 2), and the polycarbonate sheet lens (Figure 3). For the removable case lid (Figure 2), a lip was added to allow the lid to be more securely attached to the body of the case.  A challenge for Team 7 during this work period was altering the existing design so that the components can be machined. To get around this issue, Team 7 worked directly ...
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Blog #1 Spring 23

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Over the work period of Jan. 17 - Feb. 4, materials were ordered from the budget list in order to begin manufacturing the cooling system. 90% of the materials are currently in possession as shown in Figure 1, and the materials will finish delivering by February 4th. Figure 2 shows the budget list with the items in possession highlighted green.  For thermal oven validation testing, Team 7 acquired a wireless thermometer, small enough to be inserted in the Camera Cooling Device above the Go-Pro. This thermometer will be used to measure the temperature inside the cooling case throughout thermal oven testing and will be used to evaluate the cooling effectiveness of the design. With the wireless thermometer acquired, the team was able to begin testing the device to ensure it can accurately collect temperature data within the range required (up to 110 °F). The thermometer was put on a layer of wax paper on top of a metal baking sheet and put in an oven. The oven was set to 170 ° F, and t...
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Blog #4

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  Over the work period of Nov. 12 - Nov. 26, progress has been made for heat transfer and force calculations, and the analysis is complete. The team is confident that the final design will sustain an internal temperature within the desired range of 32°F to 77°F for 40 minutes, and withstand the forces from the rocket’s flight. Using the temperature equation found from the previous analysis, the team was able to calculate the total energy from heat transfer to the design after 40 minutes and compared it to the energy required to melt the phase change material. Figure 1 shows the equations used to calculate the energy. The projected energy to be transferred into the case was found to be 3581 kJ/m^2 while the energy required to melt the PCM is 3690 kJ/m^2. If perfectly designed, this would mean the internal temperature of the insulating case will remain at a constant 35°F for 40 minutes. The 3D model for the final design is complete and was used for FEA on the forces experienced durin...
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Blog #3

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Over the work period of Oct. 29 - Nov. 12, progress has been made for the heat transfer and vibration calculations. The 1D transient heat conduction is being used to model the cooling system as a sphere, and the team is still working on incorporating a cold substance into the calculations to get a more accurate result. Figure 1 shows the model we used for the heat transfer calculations. Originally, the team planned to conduct vibration calculations on the screws that will secure the cooling system to the payload housing. After discussing with the team’s advisor, Alex Blick, the team decided that the cooling system will require threaded rods to constrain the case instead of screws. Instead of doing hand calculations for the rods, the team will now perform finite element analysis on the design to find the forces transferred from the rods to the cooling system. Team 7 visited the Iron Ring Technologies facility to discuss the project with Alex Blick, and view the equipment available to th...
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Blog #2

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Our project goal is to develop a camera cooling system that will allow the camera to record for at least 40 minutes at room temperature (70°F to 77°F) while it undergoes external temperatures ranging from 97°F to 110°F. We plan to have the camera cooling system weigh under 3 lbs, be capable of withstanding the forces experienced throughout flight (recorded maximum of 15 G’s), and fit in a 4x4x6 inch space. The time and temperature range chosen is based on the temperature data from Zenith’s launch shown in Figure 1. The graph shows a steady increase in temperature before launch and a sharp decrease once the rocket launches.  Figure 1 - Zenith Flight Temperature Data There have been minor updates to Team 7’s project problem statement and project goals. In particular, the team has slightly modified its definition of room temperature to be within 70°F to 77°F. Previously, the team defined room temperature to be 68°F to 72°F, however, both Team 7 and SCR have agreed that a higher temper...
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