Avionics Bay
Avionics Bay
Avionics Bay CAD
Jan 2023 - Dec 2023
The avionics bay houses the electronics components for Icarus, a liquid bipropellant rocket currently in construction and testing by the Boston University Rocket Propulsion Group.
Icarus is a 7-inch diameter rocket that uses nitrous oxide and isopropyl alcohol. The rocket engine, Iron Lotus, outputs 2500 lbs of thrust over a burn time of about 5 seconds and has a specific impulse of about 211 seconds. The rocket's apogee is predicted to be about 30,000 ft.
Avionics Bay 1st Design: 3/8-16 Threaded Rods
The avionics bay is designed to interface with the ox-dome, which includes six 3/8-16 Helicoil inserts. It houses the flight computer, a battery, a radio, a GPS, and a pegboard.
The Daedalus flight computer is mounted on a removable tray that slides into 3-D printed linear rails, allowing quick accessibility and removability. The battery is mounted on and strapped to 3-D printed battery holders.
The electronics are mounted between two circular aluminum plates forming the avionics bay. This bay is 4 inches above the ox dome. In addition, an aluminum ring is mounted on the ox dome. In the first iteration, the plates were mounted and secured on six 3/8-16 rods that traveled from the ox dome through the avionics bay. I used CNC machining and a waterjet to create the aluminum plates. The fuselage is tank stock that is cut in half to form two half-shells. The shells are load-bearing and have thru-holes, allowing them to be fastened to the subsystem plates. One fuselage panel is removable, allowing access to the avionics bay components. Furthermore, the load-bearing fuselage helps the subsystem better resist torsion caused by moments on the rocket fins.
The avionics bay's final design included a much smaller battery, allowing the Daedalus flight computer to be mounted horizontally, reducing the subsystem height. Though I did not develop the final avionics bay design due to my co-op at Electric Boat, the prototype project helped me better understand structures and provided experience in manufacturing. For a final design with a smaller battery, I would mount the flight computer horizontally using the removable tray mechanism, allowing the length of the vertical threaded rods to be greatly decreased and resulting in a higher factor of safety against buckling. Ensuring that the rods are strictly load-bearing, I would use sheet metal as the fuselage.
Av Bay and Icarus Image Gallery
Daedalus Flight Computer Mounted on Av Bay
Avionics Bay on Rocket Mounted Vertically
Cold Flow of Icarus