The nosecone of the launch vehicle (LV) shall host the payload.
This document is divided into two sections: the test specification and the test procedure.
To define and validate the structural integrity of the nosecone assembly that houses the payload.
To guide the engineering and testing teams through the necessary procedures to ensure that the nosecone meets mission safety and reliability standards.
This document covers the nosecone structure of the 2024 rocket. It does not include testing related to avionics, separation systems, or other payload components.
The purpose of this test is to verify the mechanical compatibility between the nosecone bay and the payload. The goal is to ensure that the payload can be properly inserted into the bay without interference, deformation, or misalignment, and that it can be securely fastened according to the assembly requirements.
This is a fit check and visual inspection test. It does not involve applying loads, pressure, or instrumentation. The following characteristics will be assessed:
The test is scheduled for TBA, and will be conducted by members of the Structures and Payload sub-teams.
This procedure describes the step-by-step integration check between the payload and the nosecone bay.
Equipment required:
Location and conditions:
The test will be conducted in the assembly area of the EPFL Rocket Team workspace, under ambient room conditions.
Step-by-step procedure:
The test is considered successful if the payload can be inserted and removed without difficulty, all interfaces match, and the fastening procedure can be completed without issue.
TBDone
| Term | Definition |
|---|---|
| PL | Payload – The equipment or experimental system carried by the rocket and hosted inside the nosecone bay. |
| LV | Launch Vehicle – The rocket structure designed to transport the payload during ascent. |
This test aims to verify the mechanical compatibility between the nosecone bay and the payload. The primary objective is to ensure that the payload can be physically inserted into the bay without interference and that all mounting points align correctly.
This is a fit check and visual inspection test, which does not involve instrumentation, load application, or functional testing. The integration will be performed under ambient laboratory conditions in the EPFL Rocket Team assembly area.
The test item is the flight nosecone structure, mounted in a vertical orientation. The payload may be a mock-up representative of the final dimensions and mounting interfaces.
The procedure consists of inserting the payload into the bay, visually checking clearances, and verifying alignment with fastener holes. Once aligned, nominal fasteners will be used to secure the payload temporarily.
Main Tools and Resources:
The results of the test will confirm whether design tolerances and integration procedures are adequate for final assembly.
No constraints on the testing activities sequence were identified. The payload can be inserted and removed multiple times if needed.
The test is considered passed if all criteria above are met. Otherwise, it is marked as failed.
The test will be conducted by members of the Structures and Payload sub-teams of the EPFL Rocket Team.
The test is expected to take place soon.
The schedule is dependent on the production of the nosecone, which is currently being finalized. Testing cannot proceed before its delivery.
| Sub-System | Part Name/ID | Type of Part |
|---|---|---|
| Structure | Nosecone | Flight hardware |
| Pay Load | PayLoad bay | Model |
| Packed ? | Equipment | Packed in | Packed by |
|---|---|---|---|
| ☐ | Nosecone structure | Large crate | Structures |
| ☐ | Payload mock-up | Wooden box | Payload |
| ☐ | Fasteners + tools | Toolbox | Structures |
| ☐ | Inspection mirror/light | Hand carry | Payload |
| ☐ | Gloves & cleaning wipes | Plastic box | Structures |
| Responsible for: | Name |
|---|---|
| Equipment Checklist, Data Gathering | - |
| Safety | - |
| Documenting/Reporting | - |
| Preparing the test on-site | - |
| Safety Concern | Probability | Impact | Severity | Mitigation | Post-Mitigation Probability | Post-Mitigation Impact | Post-Mitigation Severity |
|---|---|---|---|---|---|---|---|
| Payload does not fit inside the bay | Medium | Delayed schedule | Medium | Check geometry in CAD beforehand | Low | Low | Low |
| Scratching or damaging internal surface | Medium | Structural weakening | Medium | Use protective gloves and soft contact zones | Low | Low | Low |
| Missing fasteners or tools | Low | Incomplete test | Low | Prepare checklist and verify before test day | Very low | Low | Very low |
| Safety Concern | Probability | Impact | Severity | Mitigation | Post-Mitigation Probability | Post-Mitigation Impact | Post-Mitigation Severity |
|---|---|---|---|---|---|---|---|
| Finger injury during payload insertion | Medium | Minor hand injury | Low | Wear gloves and ensure stable mounting of the nosecone | Low | Low | Low |
| Dropping the payload | Low | Equipment damage | Medium | Use two-person lift technique and handle with caution | Very low | Low | Very low |
| Nosecone tipping over | Low | Injury / damage | Medium | Secure nosecone in vertical jig or support fixture | Very low | Low | Very low |
| Done ? | Task | Time | Operator |
|---|---|---|---|
| ☐ | Transport nosecone to test area | 10m | - |
| ☐ | Transport payload to test area | 10m | - |
| ☐ | Clean and inspect both parts | 15m | - |
| ☐ | Prepare tools and checklist | 10m | - |
| Done ? | Step | Tool |
|---|---|---|
| ☐ | Set nosecone vertically and stabilize it | Wood stand |
| ☐ | Clean inside of nosecone bay with soft cloth | Cloth |
| ☐ | Lay out fasteners and alignment tools | Toolbox |
| Done ? | Task | Time | Operator |
|---|---|---|---|
| ☐ | Insert payload into the bay | 5m | - |
| ☐ | Verify fit and alignment | 5m | - |
| ☐ | Install fasteners | 5m | - |
| ☐ | Take pictures and notes | 5m | - |
| Done ? | Step | Tool |
|---|---|---|
| ☐ | Lower payload carefully into the bay | Hands only |
| ☐ | Check for interferences during descent | Visual |
| ☐ | Align holes and insert fasteners | Allen key |
| ☐ | Document fit and potential issues | Camera |
| Done ? | Task | Time | Operator |
|---|---|---|---|
| ☐ | Remove payload | 5m | - |
| ☐ | Inspect both parts | 5m | - |
| ☐ | Pack and store components | 10m | - |
| ☐ | Write report and upload photos | 15m | - |
| Done ? | Step | Tool |
|---|---|---|
| ☐ | Gently remove payload from bay | Hands only |
| ☐ | Inspect all interfaces for scratches or deformation | Flashlight |
| ☐ | Place components in their respective storage containers | Foam box |
| ☐ | Upload photos and notes to shared drive | Laptop |