Heavy Lift Cargo PlaneHeavy Lift Cargo Plane ProposalProposal

Matthew Chin, Aaron Dickerson, Matthew Chin, Aaron Dickerson, Brett J. Ulrich, Tzvee WoodBrett J. Ulrich, Tzvee Wood

October 5October 5thth, 2004, 2004Group #1 – Project #3Group #1 – Project #3

Project IntroductionProject Introduction The The apexapex of design courses, work will focus on of design courses, work will focus on

applying course knowledge to an industrial applying course knowledge to an industrial projectproject

Project will encompass planning, design, Project will encompass planning, design, construction and testing of a complete construction and testing of a complete engineering endeavorengineering endeavor

Teamwork and leadership skills will be an Teamwork and leadership skills will be an important factor in the synthesis of a complete important factor in the synthesis of a complete designdesign

Learn / Experience design process first hand Learn / Experience design process first hand from design to construction to testingfrom design to construction to testing

BackgroundBackground Need for heavy lift cargo Need for heavy lift cargo

planes to serve planes to serve energy/mining/military sectorsenergy/mining/military sectors

Short takeoff and landing Short takeoff and landing (STOL)(STOL)

Fuel efficiency for long range Fuel efficiency for long range transporttransport

Current market limited - Current market limited - Ukrainian-built Antonov only Ukrainian-built Antonov only real contender - Antonov An-real contender - Antonov An-225 capable of transporting 225 capable of transporting over 250 tons – only one builtover 250 tons – only one built

An-124 – 150 ton payload An-124 – 150 ton payload capacitycapacity

Project ImpactProject Impact Change air transport optionsChange air transport options Enhance ability to distribute natural Enhance ability to distribute natural

resourcesresources Reduce shipping costs, time, and energy Reduce shipping costs, time, and energy

consumptionconsumption Broader military transport optionsBroader military transport options

Project ObjectivesProject Objectives Compete in SAE Aero East Competition to Compete in SAE Aero East Competition to

design a heavy lift cargo planedesign a heavy lift cargo plane Apply areas of Mechanical Engineering Apply areas of Mechanical Engineering

education to a real life problem:education to a real life problem:– DynamicsDynamics– Fluid MechanicsFluid Mechanics– Modeling & SimulationModeling & Simulation– Analysis of StressesAnalysis of Stresses

Competition SelectionCompetition Selection Regular Class:Regular Class:

– Maximum wing spanMaximum wing span– One type of engine, no modifications allowedOne type of engine, no modifications allowed

Open Class:Open Class:– No wing span restrictionNo wing span restriction– Any reciprocating internal combustion engine allowedAny reciprocating internal combustion engine allowed– Maximum empty weightMaximum empty weight

Micro Class:Micro Class:– No wing span restriction or weight limitNo wing span restriction or weight limit– Internal combustion or electrical engines allowedInternal combustion or electrical engines allowed– Winner determined by highest lift/weight ratioWinner determined by highest lift/weight ratio

Competition SelectionCompetition Selection Open and Micro Class require more in-depth Open and Micro Class require more in-depth

designdesign– Selection of engine & fuelSelection of engine & fuel– Gearbox ratios different from 1:1Gearbox ratios different from 1:1– Gyroscopic assist allowedGyroscopic assist allowed

Regular Class requires less design decisionsRegular Class requires less design decisions– Concentrate on Airfoil & Body DesignConcentrate on Airfoil & Body Design– Able to compete better with schools that focus on Able to compete better with schools that focus on

aerospace engineeringaerospace engineering– Stevens has previously entered Regular ClassStevens has previously entered Regular Class

2005 Regular Class 2005 Regular Class RequirementsRequirements

No lighter-than-air or rotary wing aircraftNo lighter-than-air or rotary wing aircraft Maximum wing span of 60 inchesMaximum wing span of 60 inches Take off zone of 200 feetTake off zone of 200 feet Landing zone of 400 feetLanding zone of 400 feet Single, unmodified O.S. .61FX Engine with Single, unmodified O.S. .61FX Engine with

E-4010 Muffler E-4010 Muffler Payload bay must enclose a block measuring Payload bay must enclose a block measuring

5 in. x 6 in. x 8 in.5 in. x 6 in. x 8 in. Plane that lifts the most winsPlane that lifts the most wins

2005 Regular Class 2005 Regular Class RequirementsRequirements

Cannot simply refine the 2004 entryCannot simply refine the 2004 entry Requirements vastly different in 2004:Requirements vastly different in 2004:

– 10 ft. wing span 10 ft. wing span minimumminimum– 6 in. x 5 in. x 4 in. payload bay6 in. x 5 in. x 4 in. payload bay

Some components can be re-used to Some components can be re-used to reduce cost:reduce cost:– Engine requirement is the same from 2004Engine requirement is the same from 2004– Functioning servos can be reusedFunctioning servos can be reused

Anticipated HurdlesAnticipated Hurdles No group members have any previous No group members have any previous

aerospace engineering experienceaerospace engineering experience Rule changes have forced the team to Rule changes have forced the team to

conceive a totally different design from conceive a totally different design from previous teamsprevious teams

Construction irregularities must be Construction irregularities must be minimized to produce results expected minimized to produce results expected from theoretical designfrom theoretical design

Overcoming the HurdlesOvercoming the Hurdles Consultation with project advisor and past Consultation with project advisor and past

competition participants will give insight into competition participants will give insight into aerospace design processaerospace design process– Existing research linksExisting research links– Techniques for design and buildingTechniques for design and building

WINFOIL software will be employed in aircraft WINFOIL software will be employed in aircraft designdesign– Enables trial and error approach to augment Enables trial and error approach to augment

theoretical calculationstheoretical calculations– Design can be exported to CADDesign can be exported to CAD– CAD drawings can be used with CNC machineryCAD drawings can be used with CNC machinery

Preliminary ConceptsPreliminary Concepts Flying wingFlying wing

– Fuselage is built into wing, cuts down on air Fuselage is built into wing, cuts down on air resistanceresistance

– Reduces material required for fuselageReduces material required for fuselage– May be difficult to support/brace payload bay properlyMay be difficult to support/brace payload bay properly

BiplaneBiplane– Larger wing surface areaLarger wing surface area– Increase in liftIncrease in lift– Not enough engine power suppliedNot enough engine power supplied

Preliminary ConceptsPreliminary Concepts MonoplaneMonoplane

– Clear and distinct partsClear and distinct parts– Easy to buildEasy to build– High lift when right wing is chosenHigh lift when right wing is chosen– Large quantity of known dataLarge quantity of known data– Rather “simple” calculationsRather “simple” calculations

Team selected Monoplane for designTeam selected Monoplane for design

Preliminary ConceptsPreliminary Concepts

Conceptual DesignsConceptual Designs Limited conceptual designs available at Limited conceptual designs available at

this time:this time:– No group member has previous aeronautical No group member has previous aeronautical

engineering or RC plane design experienceengineering or RC plane design experience– Competition requirements have only been Competition requirements have only been

available since the end of Septemberavailable since the end of September WINFOIL Software will be used in WINFOIL Software will be used in

developing wing and fuselage designdeveloping wing and fuselage design

Project Needs/MetricsProject Needs/Metrics

Project Needs/MetricsProject Needs/Metrics

Project Needs/MetricsProject Needs/Metrics

Heavy Lift ConsiderationsHeavy Lift Considerations High lift versus Wing weight/StabilityHigh lift versus Wing weight/Stability

MaterialMaterial Number of RibbingNumber of Ribbing Thickness of WingThickness of Wing Lesson Learned from last yearLesson Learned from last year FlapsFlaps

Max lift for areaMax lift for area Angle of wingAngle of wing Aspect RatioAspect Ratio Actual Type of Wing (ex. NACA 6409)Actual Type of Wing (ex. NACA 6409) Type of Plane (ex. Monoplane)Type of Plane (ex. Monoplane)

Preliminary WINFOIL TrialPreliminary WINFOIL Trial

3D Airfoil3D Airfoil

Future Planes:Future Planes:The TechnologyThe Technology

Entire planes tested and designed on the Entire planes tested and designed on the computercomputer

WingsWings Tail FinsTail Fins FuselageFuselage

No tedious calculationsNo tedious calculations No human errorsNo human errors Easy inputsEasy inputs Pretty graphs and easily interpretable resultsPretty graphs and easily interpretable results All plane data incorporated into programAll plane data incorporated into program

Sample CalculationsSample Calculations

Gantt ChartGantt ChartTask Name

1 Initial Project Review1.1 Review General Air Foil Theory1.2 Preliminary Senior Design Coordinator Meetings1.3 Examine Existing RC Planes1.4 Review Competition Requirements

1.4.1 Select Competition Class1.4.2 Review Selected Class Requirements

1.5 Establish Requirements Matrix2 Research & Development

2.1 Wings2.1.1 Review Existing Wing Designs2.1.2 Select Basic Wing Layout2.1.3 Theoretical Design of Wing2.1.4 Computer Aided Wing Analysis2.1.5 Physical ModelingStereo-Lithography Session

2.2 Propeller2.2.1 Existing Technology Review2.2.2 Theoretical Propeller Design2.2.3 Computer Aided Propeller Analysis2.2.4 Physical Modeling

2.3 Fuselage2.3.1 Aerodynamic Review2.3.2 Theoretical Fuselage Design2.3.3 Computer Aided Fuselage Design2.3.4 Physical Modeling

3 Testing3.1 Combine Wing, Propeller, Fuselage Models3.2 Wind Tunnel Testing3.3 Analyze Results

4 Reporting4.1 Written

4.1.1 Project ProposalWritten Project Proposal Due4.1.2 Semester ReportWritten Semester Report

4.2 Oral4.2.1 Project ProposalOral Project Proposal4.2.2 Semester ReportOral Final Report

F T S W S T M F T S W S T M F T S W S T M F T S W S T MAug 15, '04 Aug 29, '04 Sep 12, '04 Sep 26, '04 Oct 10, '04 Oct 24, '04 Nov 7, '04 Nov 21, '04 Dec 5, '04

Aaron 145 hrs1.1 Review General Air Foil Theory 6 hrs1.2 Preliminary Senior Design Coordinator Meetings 2 hrs1.3 Examine Existing RC Planes 12 hrs1.4.1 Select Competition Class 10 hrs1.4.2 Review Selected Class Requirements 10 hrs2.1.1 Review Existing Wing Designs 8 hrs2.1.2 Select Basic Wing Layout 9 hrs2.1.3 Theoretical Design of Wing 18 hrs2.1.4 Computer Aided Wing Analysis 14 hrs2.1.5 Physical Modeling 10 hrs3.1 Combine Wing, Propeller, Fuselage Models 2 hrs3.2 Wind Tunnel Testing 2 hrs3.3 Analyze Results 1 hr4.1.1 Project Proposal 4 hrs4.1.2 Semester Report 14 hrs4.2.1 Project Proposal 4 hrs4.2.2 Semester Report 19 hrsBrett 148 hrs1.1 Review General Air Foil Theory 6 hrs1.2 Preliminary Senior Design Coordinator Meetings 2 hrs1.3 Examine Existing RC Planes 12 hrs1.4.1 Select Competition Class 10 hrs1.4.2 Review Selected Class Requirements 10 hrs2.2.1 Existing Technology Review 9 hrs2.2.2 Theoretical Propeller Design 9 hrs2.2.3 Computer Aided Propeller Analysis 9 hrs2.2.4 Physical Modeling 9 hrs2.3.1 Aerodynamic Review 6 hrs2.3.2 Theoretical Fuselage Design 8 hrs2.3.3 Computer Aided Fuselage Design 6 hrs2.3.4 Physical Modeling 4 hrs3.1 Combine Wing, Propeller, Fuselage Models 2 hrs3.2 Wind Tunnel Testing 2 hrs3.3 Analyze Results 1 hr4.1.1 Project Proposal 4 hrs4.1.2 Semester Report 14 hrs4.2.1 Project Proposal 6 hrs4.2.2 Semester Report 19 hrs

Matt 148 hrs1.1 Review General Air Foil Theory 6 hrs1.2 Preliminary Senior Design Coordinator Meetings 2 hrs1.3 Examine Existing RC Planes 12 hrs1.4.1 Select Competition Class 10 hrs1.4.2 Review Selected Class Requirements 10 hrs2.2.1 Existing Technology Review 9 hrs2.2.2 Theoretical Propeller Design 9 hrs2.2.3 Computer Aided Propeller Analysis 9 hrs2.2.4 Physical Modeling 9 hrs2.3.1 Aerodynamic Review 6 hrs2.3.2 Theoretical Fuselage Design 8 hrs2.3.3 Computer Aided Fuselage Design 6 hrs2.3.4 Physical Modeling 4 hrs3.1 Combine Wing, Propeller, Fuselage Models 2 hrs3.2 Wind Tunnel Testing 2 hrs3.3 Analyze Results 1 hr4.1.1 Project Proposal 4 hrs4.1.2 Semester Report 14 hrs4.2.1 Project Proposal 6 hrs4.2.2 Semester Report 19 hrsTzvee 145 hrs1.1 Review General Air Foil Theory 6 hrs1.2 Preliminary Senior Design Coordinator Meetings 2 hrs1.3 Examine Existing RC Planes 12 hrs1.4.1 Select Competition Class 10 hrs1.4.2 Review Selected Class Requirements 10 hrs1.5 Establish Requirements Matrix 4 hrs2.1.1 Review Existing Wing Designs 8 hrs2.1.2 Select Basic Wing Layout 9 hrs2.1.3 Theoretical Design of Wing 18 hrs2.1.4 Computer Aided Wing Analysis 14 hrs2.1.5 Physical Modeling 10 hrs3.1 Combine Wing, Propeller, Fuselage Models 2 hrs3.2 Wind Tunnel Testing 2 hrs3.3 Analyze Results 1 hr4.1.1 Project Proposal 4 hrs4.1.2 Semester Report 14 hrs4.2.1 Project Proposal 0 hrs4.2.2 Semester Report 19 hrs

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Phase I: Design Phase I: Design BudgetBudget

Design budget does not include construction or Design budget does not include construction or competition costscompetition costs

Employee Cost:Employee Cost:– Wage: $30/hr (10 hrs per week, 14.5 weeks)Wage: $30/hr (10 hrs per week, 14.5 weeks)– Benefits estimated at 50% wages: $15/hrBenefits estimated at 50% wages: $15/hr– Total Phase I Employee Cost: $26,100Total Phase I Employee Cost: $26,100

Additional funds required to cover overhead Additional funds required to cover overhead estimated at approximately 50% of total labor estimated at approximately 50% of total labor cost: $13,050cost: $13,050

Total estimated Phase I Budget: $39,150Total estimated Phase I Budget: $39,150

Future DeliverablesFuture Deliverables Conceptual design sketchesConceptual design sketches Final calculationsFinal calculations Metrics used in airfoil selectionMetrics used in airfoil selection Final plane design selectionFinal plane design selection Model of final designModel of final design Phase II: Construction BudgetPhase II: Construction Budget

ConclusionsConclusions Design requirements dictate the Design requirements dictate the

concentration on airfoil and fuselage concentration on airfoil and fuselage designdesign

Utilization of WINFOIL will enable the Utilization of WINFOIL will enable the design team to overcome any theoretical design team to overcome any theoretical inadequacies among team membersinadequacies among team members

Large scope of project dictates strict Large scope of project dictates strict adherence to the proposed GANTT Chartadherence to the proposed GANTT Chart

Feedback is Feedback is AppreciatedAppreciated

Thank YouThank You

ReferencesReferences http://airfieldmodels.com/information_source/index.htmhttp://airfieldmodels.com/information_source/index.htm http://web.umr.edu/~aavg/http://web.umr.edu/~aavg/ http://airfieldmodels.com/information_source/http://airfieldmodels.com/information_source/

math_and_science_of_model_aircraft/math_and_science_of_model_aircraft/flaperons_on_model_aircraft.htmflaperons_on_model_aircraft.htm

http://www.winfoil.com/http://www.winfoil.com/ http://www.ctaz.com/~kelcomp/airfoils5.htmhttp://www.ctaz.com/~kelcomp/airfoils5.htm http://www.pdas.com/index.htmhttp://www.pdas.com/index.htm http://www.centennialofflight.gov/essay/Theories_of_Flight/http://www.centennialofflight.gov/essay/Theories_of_Flight/

airplane/TH2.htmairplane/TH2.htm http://www.towerhobbies.com/rcwairinfo.htmlhttp://www.towerhobbies.com/rcwairinfo.html http://www.easyrc.com/airplanes/airplanes3.htmlhttp://www.easyrc.com/airplanes/airplanes3.html http://students.sae.org/competitions/aerodesign/east/http://students.sae.org/competitions/aerodesign/east/