Caleb Farrelly - Hybrid Rocket Test Stand

Hybrid Test Stand Cold Flow test using liquid CO2

The Hybrid Rocket Test Stand was one of my main projects as Hybrid Propulsion lead of the Cornell Rocketry team. I was responsible for bringing the test stand from clean sheet to cold-flow testing in one semester.

Project Overview:
The purpose of this test stand is to allow the propulsion team to test all aspects of hybrid engine design under a controlled environment while collecting data on key variables, such as thrust, fluid system pressure, and oxidizer mass flow rate. The hybrid test stand will allow the Cornell Rocketry Team to test hybrid rocket engines producing up to 1000 lbf of thrust.

The test stand features Marotta PLV-34 and MV-524 solenoid valves, semi-active tank pressurization, a servo valve, and a nitrogen purge system.

Key Action Items:

Lead creation of hybrid propulsion test stand from preliminary design to successful cold flow testing in one semester
Designed fluid system and created piping and instrumentation diagram (P&ID) for hybrid propulsion test stand
Presented fluid system design reviews to Cornell aerospace industry alumni and Marotta Controls' aerospace division
Guided team members in the creation of shop drawings and assisted in machining their components
Verified N2O flow rates and purge/pressurization performance using thermodynamics and fluid dynamics calculations
Guided members in designing modular N2O oxidizer injector, mechanically actuated valve, and oxidizer vent system

Skills: Project management, Bridgeport Mill machining, Solidworks CAD assemblies and components, drawings, pressure vessel design, fluid system design, creating propulsion testing procedures, MATLAB