Overview:
The purpose of the payload bulkhead is to connect the mission package tube (with the avionics tower within) to the nose cone, each of which have a 6" outer diameter. The payload bulkhead is divided into two parts: the payload tubecoupler and the payload platebulkhead. The payload tube has two sections but is one part, made from the same tube stock: the mission package section, and the nose cone section. Below is a table showing the dimensions of the mission package tube and the nose cone, which affect the dimensions of each section of the payload tube. The payload plate is a round aluminum disk attached to the tube via bolts. It has a square indent on the mission package side, into which one end of the piston fits, and holes to attach the "payload stack" (a tiered assembly supporting the data acquisition, video downlink system, and other necessary items) that is located in the nose cone. coupler is a 4" length of G10 (fiberglass) tube, and the payload bulkhead is an aluminum stepped bulkhead that bolts into the coupler.
-insert picture of CAD and Solidworks files
Manufacturing plan:
-waterjet holes
-turn on lathe
The original plan was to bore out the entire payload bulkhead out of a single piece of aluminum stock, but this would both be a waste of material and technically challenging, as the thickness of the bulkhead is 1/8" (0.125"). Therefore, the bulkhead, as described earlier, will be made out of two pieces: a thin disk attached to a tube via bolts.
| Item | Measurement(in.) |
|---|---|
| ID of MP Tube | 5.814-5.816: |
| Expected thickness of NC | 0.125 |
| OD of NC | 6.000 |
| Expected ID of NC | 5.750 |
OD of Payload Plate | 5.800 |
| Thickness of Payload Plate | 0.380 |
| OD of Payload Tube(Mission Package section) | 5.800 |
| Length of Payload Tube(Mission Package section) | 2.000 |
| Length of Payload Tube( Nose cone section) | 2.000 |
| OD of PayloadTube(Nose cone section) | 5.730 |
#10 Bolt head diameter | 0.440 |
| #10 Thread diameter | .190 |