c uav final pres

7/31/2019 c Uav Final Pres

1/79

02/25/031

Final Design PresentationLow-cost Expendable UAV Project

22 April 2003


2/79

02/25/032

Team Members

Atalla Buretta.........

Ryan Fowler...Matt Germroth....

Brian Hayes.

Timothy Miller.

Evan NeblettMatt Statzer.

Materials

PropulsionWeights, Materials

Structures

Aerodynamics, Stability & Control

Configuration DesignLeader, Systems, Mission analysis


3/79

02/25/033

The Lemming Concept

Premise: Provide a low-cost, expendable reconnaissance platform

Alternative to more expensive existing UAV systems

Incorporate aerial launch capability

Designed for the US Navy

Rationale:

UAV will be used for high risk missions

Current UAVs have high loss rates

Aerial launch allows greater service range & extended timeon station

Not returning to base provides greater time over target


4/79

02/25/034

Request for Proposal (RFP)

To create a cheap UAV with the followingcharacteristics:

Launch or drop via air vehicle

Carry 50 pound payload

Fly for 5 hours on a circuit (pre-determined

or directed) Crash


5/79

02/25/035

Design Team Requirements

Navy aircraft Launch capability (primary orsecondary)

Cruise altitude of 5,000 feet

Minimum ceiling of 10,000 feet

Speed range of 65 -140 knots

30-minute positioning time (launch to station)

5-hour loiter time 200 fpm ROC at 5,000feet


6/79

02/25/036

Project Drivers

Cost (UAV must be expendable)

Aerial Launch Capability

Endurance Requirements

Payload Requirements


7/79

02/25/037

UAV Concepts

Delta Wing


8/79

02/25/038

UAV Concepts

Folding Wing


9/79

02/25/039

UAV Concepts

Scissor Wing


10/79

02/25/0310

Selection of Preferred Concept

5.244.214.217.29Power Required (hp)

0.06190.04980.04980.0861Cd at Loiter

5.7476Manufacturing Costs

189187187193Weight (lbs)

AverageScissorFoldingDeltaFOMs

ScissorFoldingDeltaFOMs

11.50814.15516.338Total

0.8040.8041.392(3) Power Required (hp)

0.8040.8041.392(2) Cd at Loiter0.7061.2351.059(5) Manufacturing Costs

0.9890.9891.021(4) Weight (lbs)

Normalized Selection Matrix

Detailed analysis of the 3 concepts yielded the following data

Conclusion: Scissor wing concept is preferred design


11/79

02/25/0311

Deployment

Parachute Assisted Drop Launch

Aircraft Ejection

Nose Down Attitude

Chute ReleaseFlight Surface Deployment

Self-sustained Flight

Pullout Region

Controlled Descent Region

Chute Stabilization Region


12/79

02/25/0312

Deployment

Boom Storage

Boom Extension

UAV Release

Freefall Region

Flight SurfaceDeployment

Flight Entrance Region


Boom Launch


13/79

02/25/0313

Deployment

Tow Line Launch

UAV Release

Descent Region



14/79

02/25/0314

Final 3-view


15/79

02/25/0315

Final Inboard Dimensions


16/79


17/79

02/25/0317

Full Configuration

Structure

Flight Control

Payload

Electrical Power Communication

Propulsion

Fuel

Wing Pivot


18/79

02/25/0318

Aerodynamics

Mission:

Airfoil Design and Selection Wing Optimization

Drag / Climb estimation


19/79

02/25/0319

Aerodynamics

Airfoil:

Desired Characteristics Flat Bottom ClCR 0.8 Low Cd at ClCR

Team designed Airfoil Xfoil MDES used to shape pressure distribution

Compared Drag Polars

Xfoil OPER viscous polar accumulation used (Re = 8.8e5,M = 0.1231)

Considered Structural Acceptability


20/79

02/25/0320

Aerodynamics

Airfoil Drag Comparison:


21/79

02/25/0321

Aerodynamics

Airfoil Profile Comparison:


22/79

02/25/0322

Aerodynamics

Airfoil Selection Conclusion:

Midnight CLL/Dmax

= 0.889

CLmax = 1.58

Highest L/D = 155.4

Best structural characteristics


23/79

02/25/0323

Aerodynamics

Wing Optimization:

CLL/Dmax= 0.889; V = 135 fps

Sreq. = W / (__V

2

CL) = 11.27ft

2

Sactual = b * c = 10ft * 14in = 11.67ft2

Conclusion

Wing size kept same, to accommodate weight

growth during design


24/79

02/25/0324

Aerodynamics

Trimmed CUAV Lift Estimation:

Used Midnight Airfoil Polar to produce Cl forboth wing and tail

Clcuav = Clwing+Cltail

+=

cS

lSe tt

c

h

ClCCMwblcuav


25/79

02/25/0325

Aerodynamics

Trimmed CUAV Drag Estimation:

Program Friction used to find Cdo ofAirframe (wing not included)

Cdoairframe = 0.0156

Used Midnight Airfoil Polar to produce Cdoand Cl for both wing and tail

Cd

= Cdoairframe

+ Cdoairfoil

+ KCl2


26/79

02/25/0326

Aerodynamics

Trimmed CUAV Polars:


27/79

02/25/0327

Stability and Control

Mission:

Size Surfaces Calculate Aileron Hinge Moments

Validate Tornado Code

Verify Stability of Aircraft


28/79

02/25/0328


Surface Sizing:

Tail Surfaces sized in Preliminary bactual = 2.21ft

C = 0.5ft

Aileron Sizing using Raymers traditionalaileron vs percent chord

caileron = 25% baileron = 2ft (per aileron)


29/79

02/25/0329


Hinge Moment Calculations:

Used Xfoil OPER menu, and FMOM command

Maximum Speed and S.L. used for analysis

6.7001-4.39730.3326Bottom

6.70011.73760.2375Top

Y-Force (lb)X-Force (lb)Hinge Moment(ft-lb)


30/79

02/25/0330


Tornado Verification:

Used 2D viscous lift curve and pitch moment of

airfoil and Raymer 3D conversion Enter wing dimension and estimated camber line

slope of Midnight airfoil into Tornado

Analysis

Central Difference Analysis used

V = 45.156 m/s = 135 fps


31/79

02/25/0331




32/79

02/25/0332


Tornado Validation:

0.03354.43Xfoil Results4.64%8.47%Error

0.03504.80Tornado Results

Cm_CL_

Conclusion:

Tornado provides good approximation of stabilityparameters

Only Use Tornado for all derivatives


33/79

02/25/0333



Conclusion:

Tornado provides good approximation of stabilityparameters

Aircraft is statically stable, and stable w.r.t. controldeflections

0.2168Cn_r0.0398Cl_r23.31%Static Margin

-0.0193Cn_a

0.3145Cl_a

-2.7082Cm_e

Control

Deflection

0.0130Cn_-0.0349Cl_-1.4376Cm_5.1404CL_Static

Lateral-DirectionalLongitudinal


34/79

02/25/0334

Performance

Performance was not defined in RFP

Team Defined Performance Parameters:

Cruise altitude of 5,000 feet

Minimum ceiling of 10,000 feetSpeed range of 65 -140 knots

30-minute positioning time (launch to station)

5-hour loiter time

200 fpm ROC at 5,000feet

100 fpm ROC at 10,000 feet

The CUAV easily exceeds all performance requirements


35/79

02/25/0335

Rate of Climb

Maximum rate of climb occurs at Vmp

=

CV

Do

mp

k

S

W

3

2

r

W

DV

W

pbhpROC -=

h550

Altitude Max Rate of Climb

Sea Level 2211 fpm

5,000 ft 1684 fpm

10,000 ft 1277 fpm


36/79

02/25/0336

Flight Envelope

For stall boundary: Clmax = 1.57 SClWV r5.0maxmin=

For Vmax boundary: Pa = Pr SVSV

WkCPdor

2

2

2 5.05.0

rr

+=


37/79

02/25/0337

Loiter Performance

Altitude Min Power Vel Drag Power Req'd Est. Fuel Cons. Endurance RangeSea Level 111 fps 9.05 lbs 1.83 Hp 0.28 gal/hr 11.7 hr 880 mile

5,000 ft 120 fps 9.09 lbs 1.98 Hp 0.37 gal/hr 8.6 hr 705 mile

10,000 ft 129 fps 9.029 lbs 2.12 Hp 0.48 gal/hr 6.7 hr 590 mile

0 100 200 300 400 500 600 700 800 900 10000

5

10

15

Sea Level

5k Feet10k Feet


38/79

02/25/0338

Engine Selection

Yes

No

No

Yes

No

ElectricStarter

$742.50962Honda GX270QAE2

CostPower

(hp)Weight(lbs.)

Engine

$1100.0014.815Radne Raket 120

Aero ES

$799.997.56.2Fuji BT-86 Twin

$1069.9576.5Saito FA-450R3-D

$495.991055Tecumseh Power

Sport


39/79

02/25/0339

Propeller Sizing

Raymers Method

Assume: Activity Factor = 100 (typical for light-aircraft)

Blade design CL = 0.5

Extract propeller efficiency _p from figure 13.12 in Raymer

using equations: J = V/nd

cP = (550 bhp)/(_n3D5)

Other parameters and coefficients:

T = P_p/V

cT = T/_n2D4

cS = V(_/Pn2)1/5


40/79

02/25/0340

Altitude Power Adjustments

Power = PowerSL _ (_/_0 (1 _/_0)/7.55)

11.067000

10.678000

10.299000

13.17200012.733000

12.304000

11.875000

11.466000

9.9110000

13.621000

14.80Sea Level

Adjusted Power (hp)Height (ft)


41/79

02/25/0341

Propeller Sizing

0.155250.051.14930.830.12610.782675.002.3

0.196550.051.20480.830.17950.880466.672.3

0.231945.221.27090.750.26791.006258.332.3

0.178748.241.14930.800.15740.818275.002.2

0.206444.021.20480.730.22420.920566.672.2

0.232737.991.27090.630.33461.051958.332.2

0.170047.031.10190.780.14480.771483.332.1

0.209947.031.14930.780.19870.857175.002.1

0.221439.191.20480.650.28290.964366.672.1

0.213528.941.27090.480.42221.102058.332.1

0.198745.221.10190.750.18480.810083.332.0

0.222441.001.14930.680.25360.900075.002.0

0.219431.961.20480.530.36101.012566.672.0

ThrustCoef.

Thrust(lbs)

Speed-PowerCoef.

PropEff.

PowerCoef.

Advance RatioRotation Speed(rev/s)

Diameter(ft)


42/79

02/25/0342

Propeller Selection

To avoid losing thrust at high speeds or RPMs, the helical tipspeed of the propeller should not get too close to the speed ofsound

Mtip = (V2 + (nD)2)1/2/a

At sea level, the calculated tip Mach is 0.4675, well below thespeed of sound.

Materials: Metal, Carbon Fiber, Glass Fiber, Plastic, Wood

Wood is the ideal material for our design.

Zinger Propellers: 25 8 wood propeller costing $31.39.


43/79

02/25/0343

Engine Installation

Mount engine upside-down.5.1" _ 6.1" _ 0.25" Flat plateto mount to firewall, 1.5"from top of fuselage.

Connect fuel feed to

carburetor inlet.

Connect throttle servo tothrottle shaft.

Run exhaust to outside offuselage.

Extension for engine shaft.


44/79

02/25/0344

COMPOSITES

Bi-directional Kevlar

ALUMINIUM

6061T6

Materials


45/79

02/25/0345

Skin material is Bi-directional Kevlar

Good resistance to corrosion and fatigue

Elimination of part interface

High damping characteristics

Low coeff of Thermal Expansion

Materials


46/79

02/25/0346

Stress analysis using FEPC suggests reinforcementfor composite frame

Failure at 90 degree joints may occur

Materials


47/79

02/25/0347

Aluminum 6061T6 Airframe

Abundant and Low Cost

Versatile Good formability

Resistance to corrosion

Ductile

Materials


48/79

02/25/0348

Material Designation

Complete skin construction

of Composites

Aluminum beams forreinforcement

Fuselage and wings 0.03

Materials


49/79

02/25/0349

Structures


50/79

02/25/0350

Structures Overview

Wing loading Shearing force

Bending moment

V-n diagram Maneuver loading Gust conditions

Spar designs Shearing stress

Compressive stress

Deflection

Aileron integration

Rear wing sparattachment

Tail integration Offset bearing

system


51/79

02/25/0351

Wing loading

Max shear force

Level flight: 84.5 lbs 3g turn: 277.5 lbs

Max bending moment

Level flight: 174.8 ft-lbs 3g turn: 584.3 ft-lbs


52/79

02/25/0352

V-n Diagram

Max structural loading 3

Min structural loading -1.2

Gust conditions 66 ft/sec stall

50 ft/sec cruise

25 ft/sec max velocity


53/79

02/25/0353

0 50 100 150 200 250-2

-1

0

1

2

3

4

5

V-n Diagram


54/79

02/25/0354

Wing Spar Design

Designed to withstand 3g maneuver

Constructed from 6061T6 aluminum Yield strength of 35,000 psi in compression

Yield strength of 20,000 psi in shear Designed with 2 C - beams

Height of 1.54 in

Width of 0.6 in

Thickness of 0.1 in

Combined weight of 6.03 lbs

Tip deflection of 0.024 in


55/79

02/25/0355

0 2 4 6 8 10 12 14

-4

-2

0

2

4

6

Spar Design


56/79

02/25/0356

Tail Spar Design

Designed for 3g turn requirement: 67 lbs

Constructed from 6061T6 aluminum Yield strength of 35,000 psi in compression

Yield strength of 20,000 psi in shear

Designed with C beam at quarter chord Height of 0.51 in

Width of 0.40 in

Thickness of 0.10 in

Weight of 0.27 lbs each Tip deflection of 0.50 in


57/79

02/25/0357

Tail Spar Design

1 2 3 4 5 6

-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

Spar Location

inches

inches


58/79

02/25/0358

Aileron Integration


59/79

02/25/0359

TailIntegration


60/79

02/25/0360

UAV Systems

Systems to be incorporated into UAV:

Navigation

AutopilotControl

Communication

Electrical

Deployment


61/79

02/25/0361

Navigation and Autopilot Systems

Micropilot MP1000SYS Micropilot MP1000SYS autopilot Originally designed for model airplanes

Combines navigation and stability functions

Integrated GPS and GPS antenna

Designed to interface with standard RC servos

Operates with RC transmitter or other data linkwww.uavflight.com

Micropilot MP1000SYS SpecificationsGPS Accuracy 25 ft

Altitude Accuracy 5 ft

Speed Limit 255 fps

Altitude Limit 25,000 ftDimensions 6" x 3.2" x 1.5

Weight 0.33 lbs

Antenna Length 48 in

Current Draw 0.30 Amps @ 8 V

Unit Cost $1,500


62/79

02/25/0362

Control System

_ Scale RC Servo

www.towerhobbies.com

_ Scale Radio Control Model Airplane Servos

Inexpensive, readily available, variety of choices

Off-the-shelf integration with autopilot system

Number and type of servos determined by hingemoment calculations

1/4 Scale RC Servo SpecificationsDimensions 2.33" x 1.13" x 1.96"

Torque 0.66 ft-lb -- 1.52 ft-lbAvg Current 97 mA -- 495 mA

Unit Cost $27.99 -- $94.99


63/79

02/25/0363

Communication System

In 1991 the DOD made the Tactical Common Data Link (TCDL)

the standard for military imaging and signals intelligence

UAV was initially designed to use a TCDL

Use of standard link would facilitate use of existing control stations

Cost of TCDL is prohibitively expensive

TCDL from L3 Comm.

www.l-3.com

L-3 Communications TCDL Specifications

Range 120 nm

Data Rate up to 45 Mbps

Dimensions 3" x 6.75" x 10"

3" x 12" x 10"

Current Draw 5.89 Amps at 28 V

Unit Cost 200,000 +


64/79

02/25/0364

Communication System

CUAV will use data link built by AACOM communication systems. Range will be 50 miles

Cost will be 7.5 % of TCDL cost

Range 50 miles Range 50 miles

Voltage Input 28 V DC Voltage Input 28 V DC

Current Draw 6.0 Amps Current Draw 0.20 Amps

Dimensions 7" x 4.5" x 2.34" Dimensions 3" x 4" x 1.95"

Weight 4.375 lbs Weight 1.31 lbs

Power Output 20 WattAntenna

Total Unit Cost $15,000

AACOM AT6420 Transmitter

Data Link SpecificationsAACOM 3000 Receiver

20" Omni-directional colinear array


65/79

02/25/0365

Electrical System

2 Choices for the electrical system: (generator, batteries) Use of go-kart engine makes incorporation of generator infeasible

UAV Battery Selection

Type Manufacturer Voltage Capacity Weight Dimensions CostLithium-Ion Ultra-Life 28 V 11 Ah 2.9 lb 5"x4.4"x2.45" $125

Zinc - Air Electric Fuel 28 V 56 Ah 5.9 lb 12.2"x7.3"x2.4" $290

Zinc - Air Electric Fuel 28 V 30 Ah 3.1 lb 12.2"x3.7"x2.7" $210

Electric Fuel Zinc-Air BA-8180/U

www.electricfuel.com

UAV Electrical Requirements

System Amps

Autopilot 0.30

Servos (times 5) 0.50

Reciever 0.20Transmitter 6.00

Payload 10.00

Miscellaneous 1.00

Total 20.00

20 Amps x 5.5 hrs = 110 Ah


66/79

02/25/0366

Deployment System

UAV will be designed for 3 deployment options:

Parachute Deploy

Design of chute packaging, opening, and release systems

Sizing of parachute Boom Deploy

Design of boom and related systems

Integration of boom attachment points into UAV design

Tow-line

Placement of tow-line attachment point

Design of tow-line release mechanism


67/79

02/25/0367

Cost Analysis

Summary of Fly-Away Cost

Engineering Costs

Airframe Costs

Assembly Costs

Systems Costs


68/79

02/25/0368

Cost Analysis

Engineering Cost

7 member team

3 months concept evaluation

3 months detailed design

3 months of flight test evaluation & redesign

Total cost = $ 300,000

Cost per unit for 200 units = $ 1,500


69/79

02/25/0369

Airframe Cost

Study of composite kit-planes indicated thatairframe materials could be acquired for $3,000.

The group allowed $ 2,000 for airframe assembly

Total airframe cost = $ 5,000


70/79

02/25/0370

Assembly Costs

Assembly Includes:

Joining airframe components

Mounting and integration of UAV systems

Final testing and quality assurance

32 man-hours at $20 per hour

Assembly Cost = $ 640


71/79

02/25/0371

Systems Cost

System Cost per Unit

Data Link $15,000

Autopilot / Navigation $2,000Servos $ 70 x 6

Batteries $580

Total $18,000

Systems Cost


72/79

02/25/0372

Cost Summary

Product Engineering $1,500

Airframe $5,000

Systems $18,000

Assembly / Testing $640

Total Cost $25,140

UAV Cost Summary per Unit

Total production estimated at $ 25,140

With a profit margin, units could be sold

for less than $ 30,000


73/79


74/79

02/25/0374

Weights and CG

Moment summation SMcg = 0;

SMcg = 0 = S[weighti*(localcgi-cg)]

Features of MATLAB code Amount of fuel (input function)

Reads data file with over 80 specifications, explanation

Individual weights and cgs displayed

Weight of skin (Kevlar), airframe (Al), and UAV displayed

UAV CG displayed Ixx, Iyy displayed

Accepts airfoil geometry


75/79

02/25/0375

Weights and CG

Key Contributing Factors

Skin thickness = 0.06, Bi-directional Kevlar

Aluminum tail boom

Full fuel tank of 15 lb Payload of 50 lb

Forward engine of 15 lb

Most internal components behind spring


76/79

02/25/0376

Weights

Results Skin (Kevlar) weight = 10.61 lb

Airframe (Aluminum) weight = 36.07 lb

Total UAV weight = 159.39 lb

Ixx = 216129 in4; Iyy = 759934 in

4

Sample

Output


77/79

02/25/0377

CG

Results

For full fuel and payload, cg is 0.57 in front of shaft

Acceptable cg is from 17.9 % chord to 49.4 % chord

SPRING

LIMIT

LIMIT


78/79

02/25/0378

Conclusions

CUAV design meets or exceeds all RFP requirements

Maximum Payload

Endurance

Autonomous Operation

Expendability

Cost

Lowest of all UAVs of similar performance


79/79

Questions?

c uav final pres

Documents