UAV Design: System Architecture, Mechanical Elements, Testing, Study notes of Aerospace Engineering

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TJ Chace Luke Hartwig Andrew Mohler Chris Ellerhorst Kimberly Kroh Matt Olson Eli Grun Shawn Kruse Brian Taylor 1  RFA  Objectives  Requirements  Design  Model  Functional Block Diagram  System Level Analysis  Prototype Briefing Overview and Content 2  Mechanical  Aerodynamics  Flight Dynamics  Structures & Materials  Propulsion  Electrical  Electronics and Control  Payload  Software  Data Handling  Model Verification System Architecture Design Elements Integration and Test Plans Program Management  Integration Plan  Assembly Flow Diagram  Functional Test Plan  Critical Path  Test and Verification Plan  Safety  Risk  Organization  Work Breakdown  Schedule  Budget  Facilities  Team URL Radio controlled 7’ x 7’ footprint 55 lbs max 60 knot dash 45 knot stall 6000’ density altitude 12 VDC @ 10 amps Requirements Overview System Architecture 5 7’ 7’ Concept of Operations System Architecture 6 Storage Ground Station Landing Cruise/Payload Takeoff Assembly Transport Disassembly Transport Payload Data Acquisition Radio Control 1. Preflight 2. Taxi 3. Takeoff 4. Climb 5. Cruise 6. Loiter 7. Descend 8. Land/Taxi Flight Profile System Architecture 7 System Level Analysis System Architecture Parameter Design-To specs Build-To specs Footprint 84 x 84 in 75.8 x 84 in Empty Weight 40 lbs 35 lbs Stability Appropriate derivatives Level 1 Lift 55 lbs 156 lbs at max lift Fuselage Bending σYield = 70,000 psi 366.6 psi at 3 g Wing Bending σYield = 70,000 psi 3500 psi at 3 g Rear Landing Gear Survivable +4 g landing with crosswind Verified through design and prototype testing 13% weight margin Rear landing gear strut  Impact force Static side force to simulate crosswind Test rig allowed gear to drop and to swivel Accelerometer and oscilloscope determined g force Prototype System Architecture 11 Impact force results Tested with a calculated local weight of 15.4 lbs Strut length of 10 ¾ in Dropped at increments of 0.5 g up to 4 g without failure Prototype System Architecture NACA 4412 airfoil CL = 0.4 at α = 0° Wing design S = 11 ft2, AR = 4.4 3° Wing incidence angle Achieve sufficient lift at TO speed of 50 knots 5° Dihedral for lateral stability -3° Twist from root to tip to reduce tip stall Aerodynamics Mechanical Design Elements 15 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 0 0.05 0.1 NACA 4412 Airfoil x/c CFD analysis of wing Tapered wing  α = 17° Aerodynamics 16 Mechanical Design Elements Reduced taper α = 17° Tip stall occurred first due to low Re Root stall occurred first Root Tip Design-To specifications Customer requires a stable platform Appropriate longitudinal and lateral stability derivatives Rate of turn of 360 degrees in 2 minutes at 60 kts, 6000 ft density altitude High lift devices for takeoff and landing CL Stall speed of 45 kts at 6000 ft Can be flown by an average RC pilot Flight Dynamics Mechanical Design Elements 17 Structures - Materials Mechanical Design Elements Fuselage Function Airframe Constraints Outer diameter 8.25” Objectives Maximize stiffness Minimize weight Free Variables Wall thickness, Material Index Bulkheads Function Structural Support Constraints Outer diameter 8.125” Objectives Maximize stiffness Minimize weight Free Variables Material thickness, Material Index  3 1 E Front landing gear Function Strut Constraints 10” in length Objectives Maximize stiffness, Minimize weight Free Variables Wall thickness, Material Index  2 1 E  2 1 E Young's modulus - Density} Technical ceram 8 Longituditisal wave speed _ - materials |_10* mis | - ao a © Ww a a 3 £ o > & = 6 a Density,» (Mg/m®) Fuselage design Parameters 1/8 in thick 43 in long E-glass G10 8.25 in outer diameter Cantilever beam Structures Mechanical Design Elements )( 4 44 io rrI   Applied Load P(x) Applied Torque M(x) Wing tip bending Structures Mechanical Design Elements RIB LOCATION Ansys: y = .024 in Hand: y = .023 in Error: ~ 2% Vertical Displacement of Wing Tip 0 0.5 1 1.5 2 2.5 3 3.5 0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 Vertical Dis lacem nt Across Half-Span Distance Along Span [Feet] W in g D is p la c e m e n t [I n c h e s ] 2/100" Thick Material 3/100" Thick Material Rear landing gear Parameters 10 ¾ in long 5/8 in diameter tube Buckling Structures Mechanical Design Elements 26 Front landing gear Parameters Composite construction Exceeds lateral tip-over requirement Applied Load Design-To specifications Gas powered engine Sufficient power at takeoff 350 ft runway (STOG) 5,300 ft density altitude Rate of climb: 500 ft/min Dash at 60 knots from 6,000 ft density altitude Fuel for dash speed condition at 24 min (20% reserve) Propulsion Mechanical Design Elements 27 Engine accessories Custom pusher propeller XOAR 24x18 3 blade Propulsion Mechanical Design Elements Prop Diameter (in) Pitch (in) No. Blades Static Thrust (lb) 30 10 2 89.6 24 18 3 89.6 30 Design–To specifications 12VDC clean, 10 Amps for 24 minutes to payload Power for aircraft controls for 40 minutes Proper servos for all aircraft controls Receiver to communicate with standard RC ground transmitter Electronics and Controls Electrical Design Elements 9-Channel transmitter Pulse Code Modulated (PCM) Electronics and Controls Electrical Design Elements 32 Component Selection Servo Futaba S3305 Receiver Battery Hobbico Hydrimax 6.0V Transmitter/Receiver Futaba 9CAPS Switch Switch w/LED Charge Port Connector 2-Pin Deans Ultra Plug Wire 20 AWG Red/Black Payload Battery ProLite 6 Ah 18.4 V Electronics and Controls Electrical Design Elements 35 Ground Operations Flight Operations Payload Electrical Design Elements 36  Design-To specifications  Located on the nose of aircraft  Weight: 15 lbs  Aircraft to supply 12 VDC and 10 amps to payload  Goals  Develop a test payload  Same weight  Same power draw  Verify stability models Measurement Sensor Accelerations Linear Accelerometers Angular Rotation Rotational Gyros Speed GPS Unit Altitude GPS Unit Outside Air Temperature GPS Unit Selected IMU System Design Payload Electrical Design Elements 37 Microstrain 3DM-GX1 (Temperature Comp.) IMU Gumstix Data logger +12 VDC Via a MultiMemoryCard (MMC) Basix 400xm MATLAB analysis after flight C Code (C.Fowler help) Payload - GPS Software Design Elements Connect Data Recorder to computer via USB Download data with provided Windows application Plot data either in Excel or MATLAB Configure Dashboard to show preferred data Data Recorder starts once powered View Dashboard to confirm required airspeeds and altitudes are met GPS: -Altitude -Position -Ground Speed Pitot-Static: -Altitude -Airspeed Phase 1: During Flight Phase 2: Post Flight Outside Air Temp. Sensor Wing Assembly Fuselage Assembly Payload Assembly Connect Wing Servos Connect Deans Plugs to Receiver for Payload Power Mount Wing to Mount Payload to Fuselage Fuselage || Function and Fit Test Ready for Operations Aerodynamics Aircraft Dynamics Test and Verification 42 Test Verify Modified ASEN 3128 dynamic code (MATLAB) Wind Tunnel Testing (KU) Flight Testing Design Aircraft Analysis software (AAA) CFD software (PowerFLOW) C.B.O, Chris Ellerhorst Webmaster Kim Kroh Program Manager Luke Hartwig Co. Project Manager Andrew Mohler TJ. Chace Safety Eng. Brian Taylor Systems Eng. Test Eng. Eli Grun Shawn Kruse Manuf. Eng. Aero Team Electronics/ Controls Lead Matt Olson Propulsions/ Fuel Systems Lead Andrew Mohler Materials/ Structures Lead Shawn Kruse Payload Lead Chris Ellerhorst A/C Dynamics Lead Kim Kroh Aerodynamics Lead TJ. Chace  Program Management Aero Electronics & Controls Propulsion System Materials & Strutures ‘Customer Contact Human Resources ~—— Flight Dynamics Stability & — Control Analysis —Control Surfaces Testing |_Fusselage Testing }-Transmitter {—Connections. Testing [Engine |_Propeller [— Fuel Tank | Fuel & Fuel Lines “Testing }--Material Selection [Landing Gear |_Engine Integration _Uiting Bodies |_ Fuselage Testing Mechanical Interfacing Electrical Intarfacing |_Data Acquisition Testing Manufacturing | Engineer Safety Engineer Physical Aircraft ‘Systems: Engineer  Task Name = | Finish [Pre |Dec'07 | Jan ‘08 [Feb‘08 | Mar 08 | Apr’08 | May 08 = SHARC Spring Semester + Part Procurement ~ Fabrication Rear Gear Bracket Foam Prototype ‘Wing Molds Firewall Fuel Tank Holders ‘Wing Rib ‘Wing Spar Fuse CS Molds Wing Skin Front Gear ‘Control surfaces Bulkheads ‘Cervo Mounts Battery Mounts Payload Comp Mounts Last Machinging Day + Integration ~ Testing * Phase 1 * Phase 2 = Project Milestones Spring Interim Review 4 Interim Review 2 I Review ITLL Spring Design Expo Mon 12/10/07 Mon 12/10/07 Tue 12/18/07 Tue 12/18/07 Mon 1/7/08 Tue 1/15/08 Mon 1/24/08 Mon 1/24/08 ‘Mon 1/24/08 Tue 1/22/08 Wed 1/23/08 Thu 1/24/08 ‘Mon 1/28/08 ‘Mon 1/28/08 ‘Mon 1/28/08 Tue 1/29/08 Thu 1/34/08 Fri 24/08 Mon 2/4/08 Fri 3/14/08 Mon 1/14/08 Mon 3/17/08 Mon 3/17/08 Mon 4/14/08 Mon 1/14/08 Mon 2/4/08 Mon 3/3/08 ‘Mon 1/14/08 Sat 4/26/08 Thu 5/1/08 ne 2 | 9 [16[23]30] 6 foe 3 [1017 [24/2 | 9 [16 [23[30] 6 [13|20[27] 4 [11/18 ]25 ea SSS Fri 5/2/08 Mon 1/21/08 Fri 3/14/08 Tue 12/18/07 Fri 1/11/08. Thu 117/08 Mon 4/21/08 Mon 4/21/08 ‘Mon 4/24/08 Tue 1/22/08 Wed 1/23/08 Fri 1/25/08 ‘Mon 4/28/08 ‘Mon 1/28/08 Wed 1/20/08 Wed 1/30/08 Thu 1/34/08. Fri 21/08 Mon 2/4/08 Fri 314/08 Fri 4/4/08 Fri 5/2/08 Fri 4/4/08 Fri 5/2/08 Thu 5/1/08 Mon 2/4/08 Mon 3/3/08 Thu 5/4/08 Sat 4/26/08 Thu 5/4/08 1) ANSYS (Software). Released by Ansys Inc. 2007 2) Abbott, Ira H., and Albert E. Doenhoff. Theory of Wing Sections. 2nd ed. New York: Dover Publications, Inc., 1959 3) "Academy of Model Aeronautics." AMA. 2007. 25 Sept. 2007 <http:///www.modelaircraft.org> 4) Advanced Aircraft Analysis Version 3.1 (Software). Released by DARcoporation 2005 5) Bertman, Michael. Digital image. [SNC Payload Bay]. 2007. Sierra Nevada Corporation. 27 Sept. 2007 6) Bertman, Michael. Request for Proposal. 2007 Sierra Nevada Corporation. 2007 7) Cengel, Yunus A. Introduction to Thermodynamics and Heat Transfer. 3rd ed. New York: McGrawHill 8) Ledford, Noah. Ansys assistance. 25 Nov. 2007. 9) MATLAB (Software). Released by The MathWorks Inc. 2007 10) Pingen, Georg. PowerFLOW aassistance. 25 Nov. 2007. 11) PowerFLOW (Software). Release by EXA company 2007 12) Shevell, Richard S. Fundamentals of Flight. 2nd ed. New Jersey: Prentice Hall, 1989 13) SolidWorks (Software). Release by SolidWorks Corporation 2007 References ey Noc\ \%, on i © ous a oie, Seating: lense ieee Mealy 4-5 Ot November 29", 20 Side force results Loaded strut to 4 g (62 lbs) Effective length of 10 ¾ in Survived side loading Prototype 52 Aerodynamics Mechanical Design Elements Design Test Verify Aircraft Analysis software (AAA) CFD software (PowerFLOW) Wind Tunnel Testing (KU) Flight Testing 55 NACA 4412 Airfoil Max camber: 4% chord Max camber located at 40%of chord line from LE Max thickness: 12% chord Expected stall angle: 15° at Re = 300,000 Airfoil – Back up Mechanical Design Elements 56 CFD: Treats continuous fluid in discrete fashion Lattice-Boltzmann Method Equivalent to Navier-Stokes for Mach<0.3 Discretize spatial domain into small cells to form volume mesh  solve equations of motion ~15 million voxels (cells) for external aerodynamics Variable resolution regions Results are transient time accurate CFD – Back up Mechanical Design Elements 57 Lift and drag results for the wing Aerodynamics – Back Up Mechanical Design Elements 60 0 10 20 30 40 50 60 70 80 90 0 0.5 1 1.5 2 2.5 3 3.5 Coefficients of Lift and Drag over Time For CFD Simulation on the Left Wing ( = 17) F o rc e C o e ff ic ie n t (n o n -d im e n s io n a l) Simulation Time (non-dimensional) C D C L Cruise: 60 knots CFD AAA CL 1.1 1.03 CD 0.23 Flight Stability – Back up Mechanical Design Elements Component Weight (lbs) X c.g. (ft) Y c.g. (ft) Z c.g. (ft) Fuselage 9.2 3.08 0 0.322 Engine 5.4 5.509 0 0.392 Wing 4 2.72 0 0.67 Fuel 3.38 2.43 0 0.418 Electronics 2.24 2.004 0 0.434 Front Landing gear 1.82 1.167 0 -0.093 Rear Landing gear 1.12 5.276 0 -0.468 Horizontal Tail 0.264 4.827 0 0.378 Vertical Tail 0.25 5.191 0 0.428 Propeller 0.12 5.851 0 0.358 61 Mechanical Design Elements Fuselage Torsion – Back up Mechanical Design Elements 62   180 12 r x E G GJ TL        Rear landing gear design Buckling Single column Structures Mechanical Design Elements 65 8 8.5 9 9.5 10 10.5 11 11.5 12 4.5 5 5.5 6 6.5 7 x 10 4 Required yield stress  as a function of gear length Lateral Test Length of gear (in) Y ie ld S tr e s s o f M a te ri a l (p s i) 8 9 10 11 12 13 14 15 2 3 4 5 6 7 8 9 10 11 12 x 10 5 Youngs Modulus as a function of Length with Diamter of 5/8" Axial Test Length (in) Y o u n g s M o d u lu s ( p s i) 0.055" thickness 0.065" thickness 0.075" thickness Rear Gear – Back up Mechanical Design Elements 66 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.5 1 1.5 2 2.5 x 10 8 Material Requirements for landing Gear Thickness of material (in) M o d u lu s o f E la s ti c it y E ( p s i) Front landing gear design Buckling Normal force Design decisions 55 deg lateral tip-over 24” wide Composite Front Gear – Back Up 67 σ as a function of Gear Thickness Mechanical Design Elements Jett Fuel Tanks Require 60 oz Fuel  BME Cp = 2.5 oz/min  24 minuets of engine operation  Includes +20% endurance Fuel Tank Specifications 5 tanks required 12 oz capacity (60 oz total) Weight 1.8 oz/each (9 oz total) Fuel Tank – Back Up Mechanical Design Elements 70 Engine Mufflers 2 BME Stock Mufflers Weight: 4.5 oz/muffler Engine Ignition Stock Falkon Ignitions Weight: 6.7 oz Engine Accessories – Back Up Mechanical Design Elements 71 Part Nae Futabs $3305 Hobbico Hydrimax 6.@y Sviteh ur LED Deans 2-Pin Ultra Plug Futaba 9CAPS 20 ruc SHARC Receiver’Control Schematic Rev 3.8 ie-e-e0a?, Matt Olson Thermodynamics Microstrain IMU: 12V @ 65mA (0.78W) No ducting needed Payload – Back Up Electrical Design Elements Tests will validate components Following requirement matrix Using theoretical and analytical data Experimental data Test and Verification 76 Fuselage Bending Front Gear Drop Test Rear Gear Drop Test After all components are tested and verified, begin flight test “Flight Test” 3 ground tests 3 flight tests Validating requirements and stability Test and Verification 80 Each component must meet requirements All level requirements are referenced to parent requirements All level requirements ensure success Test and Verification 81 Assemble Build Make Make Wing Servo Ailerons Torque Box Make Spar ‘Cutout Ribs Mold Mounts and Flaps Mold Wing Skin + t Assemble Wing and Assemble Cutout Access Tost Ribs, Spar, Panels in Wing and Torque Skin Box Install Servo Mounts Attach Wing Top Skin ¥ Install wing Servos and Route Wires Install Aileron Hinges and Flap Tracks t Attach Wing Bottom Skin Install Ailerons and Flaps + Install Control Horns and Pushrods + Function and Fit Test To System Assembly