thrustMIT's turbulent triumph

 

The team members at thrustMIT embarked on an intricate journey, meticulously designing a rocket motor that aimed to set new standards for performance. The focus was on crafting an M Impulse KNSB-based motor, a culmination of six months of relentless preparation. The pinnacle of this journey arrived on November 6th when the creation was poised for its inaugural trial at the Vertical Test Bed at End Point in Manipal.

It was one of those days when the weather in Manipal is just perfect—clear skies and cool air. The team assembled the motor bed two days prior to the test. On the day, the avionics and propulsion subsystem were working on some last-minute tweaks anticipating the arrival of the director Cdr. Dr. Anil Rana. With bated breath, the team leader counted down from 3, 2, 1, the director pushed the switch on the key arm ignition and the M class motor erupted into the air at approximately 3:04 PM.

The motor test unfolded as a rollercoaster of emotions for the team, with the dynamic leadership of the team lead steering through the highs and lows. In the face of unexpected challenges, the avionics team emerged as a beacon of success—delivering seamless telemetry and showcasing the strength of collaborative efforts.

The avionics subsystem managed wireless ignition and provided a live video feed for the testbed. Unexpectedly, the nRF24L01+ radio telemetry systems failed weeks before the deadline. Despite time constraints, we replaced them with XBee-based RF modules, extending the system range to over 200 meters. Challenges included obtaining thrust data with a Pancake Load Cell and Nozzle Strain measurement with a BF350 Strain Gauge. On the test day, wireless ignition succeeded flawlessly, but the live video feed cut off, and testbed data recovery was partial. Looking forward, we aim to establish smooth bidirectional communication, refine PCB designs, and prepare reliable redundant systems.

The day preceding the much-anticipated motor test was fraught with concerns as heavy rain swept through Manipal. The persistent rain prompted last-minute adjustments to the avionics and propulsion subsystems, heightening the stakes for the impending trial. Moreover, the atmospheric conditions posed an additional hurdle with the propellant cooking process, crucial to the motor's performance. This heightened the complexity of the preparations, demanding swift and strategic responses from the team to ensure the success of the impending motor test under less-than-ideal weather conditions.

"As the team lead, I feel a blend of anticipation and acceptance. The motor didn't perform as expected, but our avionics team shone—seamless telemetry and no delays. It's a bittersweet moment – disappointment for the setback, pride in our collective effort," shared the team leader.

The unexpected Catastrophic Failure (CATO) prompted a shift in perspective for the team, transforming disappointment into an opportunity for growth. Instead of dwelling on setbacks, the team embraced the power of learning from failure. Analysis was conducted to unravel the intricacies of the CATO, with the propulsion subsystem spearheading efforts to turn setbacks into stepping stones for improvement.

"I believe in learning from failure's power. We're turning this into fuel for improvement, gearing up for the next test with determination and lessons learned," affirmed the team leader.

The CATO, while a temporary setback, became a crucible for innovation and refinement. thrustMIT's commitment to pushing the boundaries of propulsion technology, under the resilient teamwork, remained unwavering. The root causes of the failure were meticulously examined, paving the way for improvements in motor design, testing protocols, and safety measures. The setback, while disheartening, fueled a determination to convert failures into catalysts for success.

"It was a heart-wrenching moment for the team when the eventual failure occurred.  In one fleeting moment, the anticipation of success turned into a valuable lesson. Despite the six-month grueling effort, we found insights into the setback. The collective efforts endure, contributing to our growth and future success” quipped the propulsion head.

In the aftermath, the team rallied together, incorporating lessons from the CATO into subsequent iterations. The motor design and testing processes underwent rigorous refinement, ensuring that each failure became a stepping stone toward success. The bittersweet moment transformed into a testament to thrustMIT's resilience, adaptability, and unyielding spirit.

Amidst the challenges, it's critical to acknowledge the significant advancements thrustMIT has made in motor testing since 2016. The team has made significant progress in both safety and technical setup, and this achievement was not overlooked. Upon seeing the latest tests, even the alumni expressed amazement and encouragement at the progress made by the team. The motor tests have advanced from their early, risky, and uncertain stages to a more sophisticated and secure testing environment, demonstrating the team's commitment to continued advancement. The journey toward propulsion excellence persisted, with the director's strategic guidance steering the ship through uncharted skies. The setbacks of the motor test became anecdotes in the saga of thrustMIT's pursuit of innovation, reinforcing the notion that true progress is forged in the crucible of challenges.

As thrustMIT continues to refine its propulsion systems, the turbulent triumph of the motor test serves as a beacon, guiding the team toward new heights of excellence. The skies of propulsion technology are vast and ever-changing, but with visionary leadership and a resilient team, thrustMIT stands poised to conquer the challenges and soar to unprecedented achievements in the realms of propulsion innovation.  After all, what good is a day in rocketry without a little potential for scientific improvement?

 

Author-Devika Subash