Troy Holly

Feed System Manifolds

UCI Rocket Project – Liquids

During cold flow tests leading up to our rocket’s fourth vertical test fire, it became clear our system was overcomplicated and could be greatly simplified.

Our propulsion team and I would frequently spend hours during tests diagnosing and fixing feed system leaks.

Additionally, our preexisting feed system would not have come close to fitting within the full rocket’s diameter.

I addressed these issues by designing, machining, and testing three custom manifolds to simplify our feed system architecture, minimizing leak points and reducing the feed system’s profile to fit within the rocket.

Design & Analysis

Initial pressure vessel calculations to determine material and sizing
COPV Manifold CAD
COPV Manifold in feed system CAD
LOX Manifold CAD
LOX Manifold in feed system CAD
LNG Manifold CAD
LNG Manifold in feed system CAD
COPV Manifold FEA
LOX Manifold FEA

Manufacturing

Aluminum stock cut to size, first NPT port drilled and tapped
Fully machined LOX and COPV manifolds
1st LNG manifold, unfortunately I had spec’d some of the NPT taps too deep, rendering it unusable
Remachined (2nd) LNG manifold – this one is on the system now!

Testing and Integration

LOX Manifold proof pressure test setup (A)
LOX Manifold proof pressure test setup (B)

All three manifolds mounted on the system

Manifolds looking chilly after a cold flow test

Results

Fittings and tubes replaced by the manifolds

I’m quite happy with how these turned out!

They have greatly streamlined our tests, saving hours spent torquing fittings or taking apart the system to fix leaks.

They will also save us time when we fully disassemble and clean the system leading up to our next static fire, as the manifolds have replaced over 30 individual fittings and tubes on the system.

Timelapse of a cold flow test with the manifolds on