Launching the Vulcan Rocket For the First Time - Smarter Every Day 297

In this video, we will walk up to a huge

rocket

on the launch pad. Not only are we going to walk there, but we're going to walk to the hottest and naughtiest parts. That's what I call it. We have two liquid motors and two solid motors. They have been in development for a long

time

. And not only are we going to get there, but we're going to get there with the guy from the entire company who made it, Tory Bruno. Tory Bruno is a legend in the

rocket

ry community. He is extremely intelligent, he is an engineer by training and knows what he is doing.

Here in the United States we are right in the middle of an explosion of aerospace development. SpaceX and Blue Origins and all these other companies are developing all kinds of rockets, and they're making new rockets, which is incredible. That we live in an era where new rockets are being developed and launched for the

first

time

. This rocket that we will see today is called Vulcan Rocket and this is the

first

time it has flown. You may remember that in a previous episode of Smarter Every Day we got to see how the Vulcan Rocket was made. In fact, these are some of the chips that came off some of those mills that were cutting that ortho-grid pattern that would eventually become the rocket.

They hit them, they roll them, they turn them into big cylinders. The rocket that we are about to see launched, we saw being manufactured in the factory. Oh, those big plates you saw machined, bent and anodized have to be friction welded and shaken in a barrel to form an atlas gusset. Or in the case of what you see there, right now it's the liquid oxygen tank from Vulcan's first flight. That's all. Well, that's Vulcan's first vertical mount. Good. And now let's see it fly. The Vulcan rocket is especially important to ULA because they are retiring their Delta and Atlas class rockets.

These are workhorses of the American launch industry and both have an excellent track record as reliable launch platforms. Yes, Tory Bruno is the CEO of United Launch Alliance and this is the first launch of the Vulcan rocket. All that said, there is speculation in the industry that someone could buy United Launch Alliance. If they do, we don't know who will launch Vulcans in the future. We know Vulcan will persist, but we don't know what company name they will fly under. With all that said, I want you to understand something about Tory Bruno. He is a rocket fan through and through.

I've had private conversations and he's very friendly and he's excited about other industry rockets when the cameras are off. So don't think you're watching a rocket ride on the pad with the CEO of a company. He thinks you can get close to a really cool new rocket and you're doing it with one of the smartest and most knowledgeable rocket nerds in the country. He is a nerd's nerd and is a very fun person to tour a space platform with. Another thing that makes this really special for me is that my dad will come and help me by being the second cameraman.

If you've seen my dad in previous videos, you know that he is very smart. I mean, he loves to build things and he worked on the James Webb Space Telescope. So being able to share this with him is something very special to me. So let's go to the Cape Canaveral Space Force Station in Florida. Two days left until the launch. The only way we could accommodate this for Tory is if we did it very early in the morning. So we find a time just after sunrise or during sunrise, actually, and it's very windy. It was a little difficult to record the sound, but the rocket reveal is just amazing.

So, here we go. Let's get

smarter

every

day and go to the platform and learn about the Vulcan rocket. Well, here we are before dawn in Florida. Look at this. That looks very good. Yes, the lights make it look amazing. That is incredible. While we were driving in the Vulcan, I was amazed at how amazing this machine is. And to know that we had seen it built in the factory, it is just incredible. As we were driving, we had to show someone our credentials. But I also want you to notice that there are large towers of lightning protection systems around the rocket.

This is probably the best chance we'll have of that. So remember that for when Tory talks about it later. Also, talking to Tory, there's a guy around here somewhere with a cowboy helmet. We just have to find it. Hello, Tory. Oh, today we're going to wear a mustache. Someone on staff has to develop one, and no one stepped forward. So it's you. So this is Volcano. Can we just go look? Yes, we can walk there. I've never seen a BE4. I think I may have seen one in Decatur. We can go right below. Can we really?

Yes, I'll take you under the platform. Are we going to do that? Yeah come on. Sounds great. You have the patented Tory helmet. Yes. I think at some point they're going to force me to wear a helmet, right? Yes, once we reach the yellow line, we will put a helmet on you. Okay, before we continue here, can I see this? So we have the Vulcan here. Let me make sure my approach is working. So we have the Vulcan here. Is that cable above the lightning protection system? Yes, so you see the four towers and the two sets of cables.

That is the lightning protection system. It's bigger than it looks. When you look at that inner square, it looks tight, but it really isn't. Actually? But that's the only thing that, astronauts tell me, makes them nervous. They feel like that feels small. A lockdown? But is not. We'll go through the center of that. Oh, it's amazing. Well, what is this tower here? They are the four towers. The four towers are grounded and then electrically connected to these cables that surround the entire launch pad. So all that is lightning protection. Well. This tower, that tower, that tower, that tower.

I understand. It looks small. It's not. Everything is bigger than it seems because around here there is nothing to measure it by. That rocket is 202 feet tall, so it's 20 stories tall. 20 stories high? Yes, good. And about 18 feet in diameter, 5.4 meters in diameter. Evidently it has not yet received fuel, except solid fuel. So we have two solids hanging there. Those are the GEM 63XL, extra long. They are about 7 feet longer than the GEM 63s we have been flying at Atlas so far. What does 63 mean? 63 inches in diameter was the original design of the original rocket motor from which they were designed.

These are the longest monolithic rocket motors ever flown. So they are not segmented? Not segmented. One piece. Which is good because no cracks appear in... I didn't know that. I thought these... Yeah, so you don't have to seal them. There are no large O-rings like there were on the shuttle segments or the Artemis solids. So it's much more weight efficient, so you don't have that big joint in there. And they are faster to make. That's 109,000 pounds of propellant in each of them. So there's a lot of energy invested in these guys. And all that, 50 tons of propellant are expelled in less than two minutes, approximately one minute and 50 seconds.

And its thrust vector, the nozzles... No, these are fixed nozzles because we have two BE cores in the liquid core. So that's enough control authority for us all to pitch, yes and roll. Actually? Yes, good. So that's unique, right? Because most of the solids, like the ones you see on SLS and the ones you see on the shuttle, were carded. Yes, they are often carded. When we flew the Delta with its solids we had it fixed or gimbled depending on what we did and how many, and the same in Atlas. But for these, we don't need that.

We have a lot of control authority over liquid motors. Well. So dad came here with me to play role B, right? Oh yeah. Can you see the rocket? That's great. I can see. I think it's time to wear a helmet. Well. I have you. Can it be tightened in the back? I have it. Did you understand it? Alright. Alright. I have to take a photo of your dad. Well. Let's do that. You work with James Webb, right? I did, yes sir. Earring. You can hold down the camera, dad. Well. One two three. Brilliant. Remember the gray part here?

That is the MLP or mobile launch platform. You can see all four sets of rails. There are rails here. Yes. Obviously, the rocket is not powered by liquid propellants when we move it here, but the mobile launch pad still weighs two and a half million pounds. The rockets weigh 100,000 pounds empty, plus the solid ones, which weigh 117,000 pounds each. Well, is it pressurized? Only the upper stage. Is the SENTAR pressurized at this time? Good. Yes. It absolutely has to be. You have to stretch it and hold it mechanically or pressurize it because it's very, very thin, as thin as 14,000 stainless steel.

So it's a balloon tank. The first stage is rigid. That's that ortho-grid, the rigid aluminum frame, the 2000 series frame that you saw at the factory. So it's OK. But you have to pressurize the upper stage. And all this was in the VIF behind you. The doors are closed right now. Yes, right there. Ula at the top. That's where we put this all together because it's too big to ship this way from Decatur. So the first stage, the upper stage, the payload and the intermediate stage all come separately here on the rocket. They go into that building, we stack them vertically, then we bring in the solids, we stack them, and then the last thing we do is put the fully encapsulated payload, in this case Paragren, underneath the payload.

Go to the moon. Go to the moon. Which is great. Super cool. That's great. And then that adds up. Everything is on top of the mobile launch pad. Then, when

every

thing is done, the doors open and he rolls out here at a breakneck speed of two and a half miles per hour. That's funny. It takes us a couple of hours to do it because we arrive very slowly to clear the building and then we take off. We are being careful. Someone asked me the other day, how long does it take to go from vif to pad?

And I said, oh, about eight years. Eight years? Yes, a lot of time has been spent on that, hasn't it? It was, yes. Yes. So, if you go up the upper duct a lot, that white one that looks bent, it's a flexible duct, what we call ECS or Environmental Control System. That's air conditioning. That's for the payload. Temperature, humidity, things like that. Certain payloads, especially optical ones, must be kept super dry. And then below that, as you descend, you have umbilicals for the thrusters. You have umbilicals for all the electrical systems and the data and the power until we get to the internal power.

And then, of course, up there in the middle, you have a wind buffer on the ground because it's a 20-story building. That's a mechanical coupling. Well. Because the winds can be quite strong here. Today it is supposed to be. We don't want the rocket to rock. Here, how many hours are we here now? We're going at 2:18 on Monday morning, so we're far away. We are about 30-odd hours away. Well. So that's the terrestrial wind damper. And on top of that was all the propellant, energy, electricity and data. I see. Then as we go back down we get more of the same.

So this is also different than what you're used to on the shuttle or even Artemis or even Delta IV heavy, where we have mechanical arms that move away when it's time to launch. These will disconnect and then fall off, some of them passively, so that we don't have that complicated set of systems and hydraulics that we have on a heavy Delta IV. How close can we get here? We will continue until someone stops us. We will continue until someone stops us. I like it. Alright, I'm going to go back to wide angle. Alright. Remember the water suppression system?

Yes. That's for acoustics, correct? For acoustics. That's why we call it Acoustic Water Suppression System. We're going to throw, I guess we're going to throw about 10 pools in the first minute here. Well. And that's all about the acoustic energy that would come from the Rockets, exhausted and reflected on the floor. Water is just about the best acoustic energy absorbing material you can have. Well. And the reason this is important is because where we are now, we would be reaching 300 decibels. So if the fire didn't reach us, the sound alone would kill us right here. Shake us.

Shake us. We suffered a massive brain hemorrhage and stuff. But the most important thing... Yes, the most important thing. Without all that absorption, that energy would reflect directly back to the rocket and likely damage the spacecraft. Well. That's what it's really about. Can I walk here this way? Yes. We are in a place right now. That is incredible. Yes, we are. That rigid platform will disappear. This disappears at the bottom. Yes. That rating you see disappears. And below us is the trench of flames. Well. And if you look to your right, that's the exit to the flame trench right there.

All the fire goes there. Yeah. And he gets out of that thing and blows up the grass, knocks down the fence. But it's Florida, so the grass will be back five minutes later. Sounds great. And then you can... Those are the two BE4 engines. With them we will obtain about a million and a half pounds of thrust. Wow.They are grounded right now. Grounded, Okay, let me switch to my tightest lens. Okay, so the GEM 63s are tilted. Gem 63, XL. They are inclined. Yeah, that way we get their center of gravity through the average center of gravity because you know that stops the rocket, that's in motion because we're going to dump all that propellant in five minutes.

That core will be empty. So we choose the optimal place to pass the solid's thrust vector so that the BE force doesn't have to fight too hard on the way up. I was surprised to find that these solids are fixed and tilted because many solids on big things like shuttle and SLS have nozzles that move so you can do what is called thrust vector control. But they don't do that on Vulcan, and the reason is quite interesting. Look back at the bottom of the rocket. Those two silver things right in the middle, are the BE4 liquid engines, oxygen and methane.

If we think about what's going on here, you can really move them. They have thrust vector control in liquid engines. And what you can do with that is fascinating. You can vary the thrust to be able to turn the vehicle in one direction or another. I'm going to shoot you. You can also do things like this. I mean, it's hard to describe, but you can see what I'm doing. You can even roll the vehicle based on the way you move these bells, which is fascinating. Now, I think the design choice they make is very elegant and very simple.

They are pushing the solids through the CG of the rocket. When you first start, if you look at a cross section of the rocket, you load the liquid, you load the solid. It is a very heavy rocket and the CG is very high. It's towards the front of the solids because you think about how long the rocket is, and you have the centaur upper stage, and it's fully loaded. So the CG is over here. But as you start burning and throwing dough out the back, the CG will slowly walk forward. That's fascinating. And then you would think, okay, well, if I'm a design engineer designing the system, I'll just average and film the center of where the CG starts and where the CG ends.

And that's where I'm going to launch my solid rocket boosters. And the reason they do it is because they don't want to dominate, so to speak, those liquid engines in the middle. If you're pushing through the CG of the vehicle, you're not trying to turn the vehicle and rock it or anything like that with your solids. You are just trying to add forward momentum to the vehicle. This is how they do it. I think that's very smart. The fact that they have tilted it, by the way, means that if they have it, let's say it's three degrees in the solids.

If you have a three degree sign, that means you're reducing about 5% of the solid rocket's total thrust, which means the core design has to be able to handle that compression force, which I think is fascinating. And it's even more so when you have six thrusters on the outside of the volcano. Sorry I'm going crazy right now, but this is a very complicated and very interesting problem. Another thing to think about is that when you're at sea level, a four-degree tilt on your rocket, the nozzles on your rocket, that's going to twist the vehicle to some degree.

But when you rise five miles into the atmosphere, you have less mass and less aerodynamic pressure. So with the same movement of the nozzles, you will get a very different response to the vehicle at altitude. So they're probably not averaging that thrust point between the beginning and end of the CG because the response is different as you go up in altitude. They probably have an optimized place, and that's where they're moving forward, which I think is fascinating. It's a very simple and elegant solution to make these solids just a fixed nozzle at a certain angle. And it almost makes me empathize with the challenge that guidance and control engineers face in trying to figure out this control algorithm.

But we're not going to do that because those are people of guidance and control. And everyone knows that solid propulsion and liquid propulsion people, that's where it's at. That's where the good is. I'm kidding right now. Anyway, obviously this is an awesome problem and I'm excited to hear Tory talk about it because I'm learning and I hope you're learning too. And so we'll get about 450,000 pounds of thrust from each of those solids, plus the 1.1 million from the combined pair of BE4. So this rocket will weigh just under a million and a half pounds, fully fueled at liftoff.

We'll have about 2 million pounds of thrust, so it won't jump like it has a solid six. Then you'll see it gently peel off the pad and walk away. Solid six, that's maximum volume and handling. That's the maximum, yes. Is this simply a structural limit or simply a physical position? It is the physical space around the rocket. But obviously, the structure is designed for that because we knew it would be that way. You don't want to waste mass with extra structure. Let me ask you about the BE4s. I know you wanted those things forever. They took a long time to deliver them to you.

Did. You're excited to have gotten them, right? Excited we got them. We love them. They are good engines now that we have them. I understand, and don't let me hurt your feelings too much with this question, Tory. As I understand it, in testing those things have a lot of horizontal trigger time, but not much vertical. From what I understand, one or two of them have four seconds of vertical thrust time, right? Very fast. This is what I was asking Tory. A horizontal rocket motor test is when you have a huge reaction mass and you horizontally mount that rocket motor against that mass and fire it up and measure the thrust, the pressures, the flow rates and all that.

A vertical test test is when you hang the engine from your reaction mass like this, and you can test it in the configuration it is going to launch. Normally, you want to do that because that's how the rocket will fly. What's really more important than whether they're horizontal or vertical is how they interact with the rest of the rocket because you're moving around a lot propelling it through that thing. Remember, you're going to get rid of all this, right? We have 86,000 pounds of LOX. We have 73,000 pounds, gallons, 1 pound, 86,000 gallons of LOX, 73,000 gallons of methane. All of that disappeared in five minutes.

So the flow through these motors is enormous. And the orientation of the liquid rocket motor at its pumps is really not a determining factor at all. What really matters is how it interacts with the rest of the rocket. And of course, that's the only thing that can't be tested until Monday morning when we actually test it. Things like Pogo's interactions with large fluid columns. What does Pogo mean? Pogo is the tendency of a long column of fluid to want to oscillate like an organ pipe, except with a liquid. And that's one of the things we have to worry about with these big, long, liquid-fueled space launch vehicles because they're very big and long.

There are a hundred... Is it like a water hammer over and over again? It's water hammer, right? So this thing oscillates as we flow it through the pumps in the rocket motor and accelerate up and down, that column of fluid wants to take all that energy and it wants to isolate or oscillate. And that's why we have absorbent Pogo features in this design. That's what really needs to be tested here in the rocket, how it interacts with the structure, which is another potential source, by the way, of combustion instability. You can have Pogo where the feed to the pressure, the feed to the motor oscillates because that column of fluid oscillates.

Humming noises can occur when the motor interacts with the structure and this affects the flow to the motor. You can get squeal, we'll call you. What's it called? Scream. Scream. This is an acoustic phenomenon within the combustion chamber of the engine, which was one of the problems we had to solve on this engine because no one had successfully overcome Screech in a large methane engine before. What frequencies are we talking about? Thousands of hertz. Thousands of hertz. Yeah, because it's something that happens right in the front of the flame, where you spray into this combustion chamber, the LOX and the methane, and it starts to burn, and you get these little combustion cells where they mix, and it's like small detonations.

This is a huge amount of acoustic energy and transverse or radial standing waves can be generated within the combustion chamber. Not so much longitudinally, because the end of the chamber is open. That's where the gas came out. Then there is nothing to reflect on. But those other modes can kick in at tens of thousands of hertz. And if you let that happen, you can destroy the combustion chamber in a second or two. Actually? So that was part of what took a while to get the BE4s and solve that problem. And the way to address that squealing problem in a combustion chamber is by carefully controlling the mixture, carefully controlling the pressures at which it operates, but also by putting baffles and elements on the face plate of the injector to interrupt that resonance.

Just like Apollo engineers did with F1. Exactly. Yes, this is not a phenomenon exclusive to methane. It was particularly challenging for methane. Because? Why is it harder than, say, kerosene? Due to the chemistry The energy of that combustion of methane and oxygen. It just tends to be a lot livelier, so to speak. In that fast, rough combustion zone, much more acoustic energy can be generated rather than the energy being converted to heat and expansion. Okay, wow. Stoichiometrically, what are we looking at? Oxygen to... This is a ratio close to three to one. In practice, the stoichiometric ratio is always.

Ideally, it should always be different, but you cannot have 100% combustion efficiency. You can back it up. I'm not going to tell you because he is the owner. But you can guess because I told you how much propellant was in the LOX tank and the methane tank. So do you use film cooling in these motors? Yes. Yes, that's part of it. So I would say cooling the film is when you make it rich. Yes. Yes, this is an Ox rich engine. Well. Yes. So it is not a rich fuel. We use fuel inside the hoods to cool the hood and to cool the outside of the combustion chamber.

Is this as far as we can get towards the engine? Yes. That's probably it. So let me zoom in real quick here. I have... That's Incanel, right? I probably shouldn't tell you. You're not supposed to tell me what that is. Okay, well, I'm an aerospace engineer and it looks like Incanel. Then don't tell me. But I think most... I don't know. All I know is... I know there has been a lot of research done recently on Incanel. I know. That's a very aerospace alloy, INCO. That was for what? X15, right? So we were able to do our first super- Even the blankets in F1.

They used that. It's interesting. The reason I mention this is because INCENEL is very, very heavy. It looks like a heavy engine. It is not a light engine. Well. I will say that the weight is not that bad. It's obviously working in this app. Then there is a whole program that Blue Origin is involved in now with us to continue to reduce the weight of the engine and make it more structurally efficient. I see. Because right now, looking at it, I can say that I've looked into it a little bit. I'm not going to pretend I haven't.

As I understand it, in the past, with many of the Apollo engines, they welded tubes in there. You would pass the fuel through the thing itself. This one is welded on the outside. It's my understanding. You don't have to say you don't have permission. Well, we can talk in general terms. Let's talk in general terms. Okay, so you don't use LOX to cool the combustion chamber or hood because it has poor heat transfer properties. You always use the fuel. That's true here too, although it's not kerosene because it's simply a better heat transfer element. Is it heat capacity or heat transfer coefficient?

Both. It is the thermal capacity and conductivity of the fluid. When we look at an upper stage engine like the RL10, in this RL10, you still see those welded tubes, which is absolutely the most weight efficient way to circulate that coolant, like the radiator in your car. However, that is a hand-made operation, craftsman and expert who bends small tubes and welds them individually. So ultimately you want to move to machine channels or additively manufactured channels, even better, so it's almost as good, but much faster and much, much cheaper. And that's why this engine doesn't have little welded tubes like an RL10 or an F1.

It has channels. And even our RL10-Rectacular. Yes interesting. And even that upper stage, the RL10 that is dying as an air rocket, now L3, will move in our CX upgrade in a couple of years to that configuration, and we will eliminate those tubes. So it cost us a little bit of weight, but we gained a lot of speed and cost by doing it that way. 3d print? Yes, 3D printing. The interesting thing about 3D printing is the surface finish of the metal, which will create turbulence inside, and you wantturbulence inside. You do. That's very good.

That's very good, Destin. I forgot about your fascination with laminate and turbulent flow. That's how it is. In fact, we've been a bit. I'm not going to talk specifics about any of the engines, right? Well. But we were a little surprised as we developed that, that we were getting superior heat transfer and superior cooling conditions when we additively manufactured the channels that we really weren't expecting. It is largely due to that phenomenon. The roughness of the surface. Yes. You're compensating a little for the weight by getting better performance because that affects performance, especially on an expander cycle like the RL10, which is subject to the square cubes limitation on how much thrust you can get out of it.

That's great. I love talking to Tory. It's so good. It's so fun. Tell me about the red paint on the side. Yes. Are you going to continue like this? We will do it from time to time. So the next release won't have it because we were in a rush to build that booster and it takes a little time. We do this right now. We do this by hand. We take it to the paint booth and mask everything off, and the guy goes in there and paints it. And it's not that bad, but it takes a little time to make.

The weight is fine. For missions like this, we have a lot of extra weight. I mean, that's less than a couple hundred pounds of paint right there. But in the future, we're looking at other ways to do it, maybe automatic sprayers and things so we can do it quickly and whenever we have the weight margin to do it. You'll see this, one in every three, one in three will do the paint job. That's great. It's good. It's lovely. But this mobile launch pad is deeper, the structure that you see here, and it's much more ergonomically friendly.

The one we have for the Atlas, when you want to keep all the pipes and plumbing and data lines and stuff that's on the base, when you're on the Atlas, you're lying on your back with a hatch, reaching up. and doing... You can't go up there, and it's horrible. That thing is built so we can walk inside. It's like being in a submarine, there are hatches. Inside the thing, right here. Yes. If this was in the VIF, we would open a hatch and you could go in there, walk around and do things. Is this new? Yes, this is new for Volcan.

Everything is new? All the thing. Ah I did not know it. Yes. It was great to be so close to the rocket, but we had two days until launch, and before that all kinds of things happened. The first thing that happened is that Tory took the time to explain to me how cryogenic rocket fuel works. And that's so awesome that I'm going to make a whole video about it. Now, cryogenic refueling in orbit will be a big problem for the future of space exploration. So first I wanted to understand how a rocket is cryogenically fueled here on Earth in 1G.

To be able to see that, Tory let me into the control room and we learned about the sequence and how things are done. It's a complicated process and I learned things I had no idea were of concern. So I'm excited to show it to you in a future video. If you want to see that, consider subscribing to Smarter Every Day. I think you'll like it. Some other interesting things Dad and I did with our time. We went to the NASA Kennedy Space Center Visitor Center. That was amazing. We saw the space shuttle Atlantis. That was incredible.

We also got to do something that was really special for me in particular. When I was a kid, my dad took me to Disney's Epcot Center, and there's an attraction that has something to do with the figment of your imagination. There's a little dragon going around and you're thinking about all your senses and all this kind of stuff. I remember that with my dad when he was a kid and I really wanted to experience that with dad. Now that I'm an adult, I just want to feel like a kid again. So we did it. We rode this ride together and it was so much fun.

It was just dad and I hanging out. It was amazing. I don't know why, but doing this with dad made it that much more special. And when it came time to watch the launch, I had never been this close to a full-scale rocket launch, nor had I filmed one in slow motion. We did it this time. Before I show you that, I want to thank today's sponsor. This episode of Smarter Every Day is sponsored by Factor. Now, Factor is a pretty good service. They leave these meals at your door and they are not frozen. They come in this insulated box.

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Thank you. The launch occurred very early in the morning, at 2:00 a.m. m. early. We were very excited because I had seen this thing being built. We had seen him on the launch pad and we were together. Dad and I walked across the base to a site about five miles from the launch pad. There was basically nothing but water between us and the rocket, so the view was incredible. There it is, very far away. We posted and I set up the high-speed camera and did my best to try to focus so I could capture a takeoff.

Here we go. We are ready to launch. I have a Phantom Miro right here, 1,000 frames per second. It meant a lot to see this release, and it meant even more because I was watching it with my dad. Wow. Do you see when they tank the rocket? Can we find something where I can see how they do it? No, we have a plan for you. In fact, I have personally selected a screen compatible with the detection field for you to see. Sounds great.