APOLO 3.5 - The Diary

Project #1 : APOLO 3.5

The Diary

26 Dec 2008 – Meeting with the Design in Mind

Time	9:00 pm
Place	Agilent Instrumentation and Measurement Laboratory, School of Mechanical Engineering
Attendee	David Chew Vee Kuan; Chong Siu Hou; Too Jun Lii; Fow Jun Yan; Dillion Tan Shi Sheng;  Low Hock Soon; Ho Gim Beng; Edward Goh Chin Yuan.

 

A day after Christmas, the APOLO Project meeting was held. The goal of the mee

ting was to put forward their respective multi-stage bottled-water rocket design and generate a new design from ideas garnered from the designs.

David and Jun Lii proposed their rocket designs. David’s rocket has 2 stages and it consisted of 3 primary boosters placed linearly with a secondary booster on top of the centre primary booster. On the other hand, Jun Lii’s rocket was a 3-stage rocket consisting of 3 primary boosters placed on triangular vertices of an imaginary hexagon, another 3 secondary boosters on the other triangular vertices of the hexagon aloft from the ground, and a tertiary booster at the centre of the hexagon at the peak. Each of the boosters is attached to each other in a way such that the top view shows the connections carving out somewhat like the 60’s “Peace” sign. Eventually, David’s idea became the basis for the design.

After much discussion about solving the design problem, especially the stage joint, lock mechanism, and air prw1essure piping system, all of them had decided on a much simpler design of the multi-stage rocket as a start. Based off fro

m David’s initial design, they removed the 2 primary boosters to leave only a primary booster and the secondary booster on top of it. 

Both boosters will be separately pressurized by using David’s existing launcher and a fabricated mini-launcher.

Before the meeting ended, they listed out the items available and needed to be bought for the fabrication of the rocket the next day.

27 Dec 2008 – Fabrication Time!!!

Time	10:00 am
Place	Kafe Lembaran, Engineering Campus; Engine Laboratory, School of Mechanical Engineering
Attendee	David Chew Vee Kuan; Chong Siu Hou; Too Jun Lii; Fow Jun Yan; Low Hock Soon; Ho Gim Beng

All of them gathered at Kafe Lembaran for a briefing on the items to prepare for the APOLO Project. They were to meet back at the Engine Laboratory in the School of Mechanical Engineering at a later time. After preparing all of the materials and posing for a picture, the rocket fabrication work started.

Prior to the development of the multi-stage rocket, David briefed the team again on the design and on the fabrication processes of the prototype rocket to ensure a unified idea.

Fun and laughter filled the Engine Laboratory during the fabrication, especially after one unexpected “accident”. Jun Lii and Hock Soon were testing out David’s 2-year-old launcher by inserting it to an empty 100-Plus bottle booster and pumping it with an air compressor. They did not check the pressure but it was believed to be about 30 psi. After a few seconds, the booster did not launch itself. Instead, a loud shot was heard and the launcher’s top fired between Jun Lii’s legs and to the back of the Engine Laboratory. Fortunately, no one was injured. The top was found intact after twice attempts to search for it.

Later in the afternoon, Siu Hou came back from Penang and helped out with the fabrication. The connector (a large tube using Kikapoo bottle’s body to connect the two boosters and enclose a mini launcher in between) was made. The 2 parachutes made out of low-density polyethene garbage bags and cotton strings was prepared. Additionally, the lock for the secondary booster was made.

There were many problems concerning the reliability of the launcher, the mini launcher, and the boosters. The connections between the boosters and the two launchers were too tight which prevented the boosters from launching properly under pressure (as what had happened previously). Also, the mini launcher had a leakage around the pressure valve. The connection issue was addressed by filing and brushing the launchers with metal files and abrasives. As for the mini launcher, the valve was replaced. Once it is complete, they tested out the prototype outside.

First, they tested out the primary booster only to see whether it can launch properly under 35 psi. Then, they tried the assembled prototype with the same pressure. Pumping both boosters separately was a cumbersome task. The secondary booster was pressurized first before attaching it to the primary booster. After that, the primary booster was pressurized. For the first time, the initial launch of the prototype was a success. However, the secondary booster did not fire at the apogee but fired upon impact on the ground. The problem persisted for the whole tests (estimated to be about 6 tests).

Nevertheless, the team were overjoyed and guffawed throughout the day. At 6:00 pm, the team called it a day.

28 Dec 2008 – Refinement #1

Time	10:00 am
Place	Engine Laboratory, School of Mechanical Engineering
Attendee	David Chew Vee Kuan; Chong Siu Hou; Too Jun Lii; Fow Jun Yan; Low Hock Soon; Ho Gim Beng

 

On a fine cloudy day, we were contemplating about the problems of yesterday. We also realized that the way we launch the rocket was dangerous as we were dealing with high pressure. Our hands cannot replace a launching base for a good vertical take-off (Gim Beng was almost hit by the rocket launching at an angle above him).

The most disturbing problem of all was the locking mechanism itself. We used a cut plastic bottle as a spring for the launcher’s lock. That spring proved to be extremely unreliable in holding the lock in place until it is manually triggered.

But the problem was soon solved when a pile of chairs with rollers were found in a junk yard. The roller stand had a polymeric tube that encloses the chairs’ piston. Its springy shape is an ideal replacement for the lock’s spring. Soon, the chair was ripped of its roller stand and the Refinement of the rocket began.

With another luck falling on our lap, we found out that our launcher fits nicely in the roller stand. That had saved us a couple of hours and money on launcher’s base.

Once we have replaced the launcher’s spring and cleaned the roller stand, we went out to do some tests.

With the roller stand in hand, we were able to try out higher pressure input. At 80 psi, we decided it was high enough. After a few tests, the results were just as horrendous as yesterday’s test. Although the rocket managed to launch at higher altitude, the secondary booster still did not launch in mid-air. The same problem still persists.

We still thought that the connection between the bottle and the mini-launcher was still tight. We went back to the laboratory and made some adjustments to it by filing the bottle’s mouth. We also had to fix the locking mechanism of the launcher because it broke during the launch at 80 psi.

After making adjustments to the rocket, we tested out the system again. The launch is successful but yet again, the lock to the secondary booster still failed us.

As the sun starts to set, we had to call it a day.

29 Dec 2008 – Refinement #2

Time	10:00 am
Place	Engine Laboratory, School of Mechanical Engineering
Attendee	David Chew Vee Kuan; Chong Siu Hou; Too Jun Lii; Low Hock Soon

It was Awal Muharram, the day the Muslims celebrate their new year. Thus, it is an opportunity for us to try to make APOLO 3.5 a success one more time.

David and Siu Hou had a synchronized idea. They proposed the primary booster is to be fitted with a pair of tennis balls each stuck inside a 500ml bottle. They hoped that by increasing the weight of the primary booster, the weight will pull the primary booster to the ground faster than the secondary booster at the apogee.

After fitting the pair of tennis balls to the primary booster, we went to test it again with great anticipation. The launch went just as well as before.

However, the two boosters still stuck to each other and fell vertically, near to David who launched it. Fortunately, David was safe. Unfortunately, the rocket was severely damaged. The lock to the mini-launcher came off the assembly and a crack was prominent in the primary booster’s mouth. Obviously, the secondary launched had failed again and that cost a lock and a bottle. They were fixed later on in no time.

Pondering long and hard, David finally had a solution to the secondary booster launch problem. He proposed what he would call “The Fishing Method”. Siu Hou also came up with another solution, dubbed “The Rocket with a Skirt Method”. Both ideas seemed feasible at that moment. Then, out in the blue, both David and Siu Hou challenged each other to see which method works the best.

In “The Fishing Method”, David’s idea was simple. Simply tie the primary booster to the roller stand with a raffia string. When the rocket launches to a certain height, the string will pull the primary booster down and triggers the secondary booster.

As for “The Rocket with a Skirt Method”, Siu Hou used the top part of a 5-L plastic bottle and segmented it to become flaps. These flaps were then attached around the secondary booster, making the booster looked like it was wearing a “skirt”. The rationale behind it was the flaps, while closed when the rocket launches upward, opens up when the rocket falls down and generates air resistance. That would hopefully allow the secondary booster to fall slower than the primary booster, thus triggering the mini-launcher.

While Siu Hou and Jun Lii were busy making and attaching the “skirt”, the others went outside of the laboratory to try out “The Fishing Method”.

There was silence. Then, screams of joy broke the still air. Siu Hou was speechless for the moment as he never thought that David’s idea would work. Nevertheless, he was determined to test out his idea.

When his “skirt” was completed, we went out to test it. At first, it failed. Probably the “skirt” was too small. After modifying the “skirt” by adding a larger one on top of it, the secondary booster successfully launched in mid-air. Siu Hou was blissfully yelling at David, “YEAH! Mine works, IN YOUR FACE!”

The cheer was short-lived, however. Heavy rain started pouring down after lunch time. We were forced to stay in the Engine Laboratory until the rain subsides. By then, it was time to go back to our dormitories.

3 Jan 2009 – 3… 2… 1… & LIFTOFF!

Time	10:00 am
Place	Engine Laboratory, School of Mechanical Engineering
Attendee	David Chew Vee Kuan; Too Jun Lii

 

One week had past. Hock Soon was down with a fever & was not able to come. Gim Beng had to be unavailable for an urgent matter. Jun Yan went for his camp. Siu Hou was outstation.

But one would have never thought that this might be the day Neil Armstrong’s proclamation resonated again for APOLO 3.5.

With David and Jun Lii left on a cloudy Saturday, David’s rocket received the final touchup. We added a pair of fins and also a parachute to the secondary booster.

Once it was done, we made our first launch.

This was the moment of great anticipation. David manned the launch, Jun Lii videotaped the event. At 80 psi, David started filling up the rocket with air. The rocket was zealously raring to go. 3… 2… 1… And at a pull of a trigger, it lifts off. In just a blink of an eye, the secondary booster successfully launched itself into the air as high as 4-storey building. That was not all. At the apogee, the parachute deployed perfectly and the rocket made a safe and gentle landing.

A torrent of bliss filled the space. At last, SUCCESS has finally come after 5 days of making it work! It was time for an emotional celebration. HALLELUJAH!

Of course, we did not stop right there. We made a few more launches in an attempt to recreate the successful launch, but much better.

However, all of the launches were unsatisfactorily lower than the first. Jun Lii had a blooper moment, too. The primary booster was already leaking out water and pressure. Because of that, the rocket flew too low and the whole piece started crashing down extremely near to Jun Lii. It was a blessing he did not get hit by both the rocket and the secondary booster that fired upon crashing.

Then, a special guest came to the Engine Laboratory. Our Faculty Advisor of our club, Prof. Horizon came to check up on his students’ work. Seizing the opportunity, we invited him to watch the spectacular launch demonstration.

The launch did went well, albeit the unsatisfactory altitude gain. Nevertheless, Prof. Horizon was very pleased with our commitment to making the project a success. In the future, he will be giving us the real deal such as the Autonomous Trash Collecting Boat Project.

To conclude his words, we have SUCCEEDED!

 

 

Brought to you by

TOO JUN LII
Secretary (2008/09)
USM SAE Collegiate Chapter

Engineering Campus
Universiti Sains Malaysia
Seri Ampangan, 14300 Nibong Tebal
Seberang Perai Selatan, Pulau Pinang
Malaysia.

Mobile : +60-12-5010539

Primary E-mail : tjl100912@student.usm.my 

Secondary E-mail : toojunlii@gmail.com