22 April 2003

Final Design Presentation Low-cost Expendable UAV Project

1 02/25/03

Team Members

Atalla Buretta......... Materials Ryan Fowler... Propulsion Matt Germroth.... Weights, Materials Brian Hayes. Structures Timothy Miller. Aerodynamics, Stability & Control Evan Neblett Configuration Design Matt Statzer. Leader, Systems, Mission analysis

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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 time on station Not returning to base provides greater time over target
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Request for Proposal (RFP)

To create a cheap UAV with the following characteristics:
Launch or drop via air vehicle Carry 50 pound payload Fly for 5 hours on a circuit (pre-determined or directed) Crash

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Design Team Requirements

Navy aircraft Launch capability (primary or secondary) 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 5,000 feet

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Project Drivers Cost (UAV must be expendable) Aerial Launch Capability Endurance Requirements Payload Requirements

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UAV Concepts
Delta Wing

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UAV Concepts
Folding Wing

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UAV Concepts
Scissor Wing

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Selection of Preferred Concept

Detailed analysis of the 3 concepts yielded the following data
FOMs
Weight (lbs) Manufacturing Costs Cd at Loiter Power Required (hp)

Delta
193 6 0.0861 7.29

Folding
187 7 0.0498 4.21

Scissor
187 4 0.0498 4.21

Average
189 5.7 0.0619 5.24

Normalized Selection Matrix

FOMs (4) Weight (lbs) (5) Manufacturing Costs (2) Cd at Loiter (3) Power Required (hp) Total Delta 1.021 1.059 1.392 1.392 16.338 Folding 0.989 1.235 0.804 0.804 14.155 Scissor 0.989 0.706 0.804 0.804 11.508

Conclusion: Scissor wing concept is preferred design

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Deployment
Parachute Assisted Drop Launch
Aircraft Ejection Chute Stabilization Region Nose Down Attitude Controlled Descent Region

Chute Release Flight Surface Deployment Pullout Region Self-sustained Flight

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Deployment
Boom Launch

Boom Storage Boom Extension

UAV Release Freefall Region Flight Surface Deployment Flight Entrance Region Self-sustained Flight

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Deployment
Tow Line Launch

UAV Release Descent Region Self-sustained Flight

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Final 3-view

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Final Inboard Dimensions

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Final Inboard Profile

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Full Configuration

Structure Flight Control Payload Electrical Power 17

Propulsion Fuel Wing Pivot Communication 02/25/03

Aerodynamics
Mission:
Airfoil Design and Selection Wing Optimization Drag / Climb estimation

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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

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Aerodynamics
Airfoil Drag Comparison:

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Aerodynamics
Airfoil Profile Comparison:

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Aerodynamics
Airfoil Selection Conclusion:
Midnight
CLL/D = 0.889 max CLmax = 1.58 Highest L/D = 155.4 Best structural characteristics

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Aerodynamics
Wing Optimization:
CLL/D = 0.889; V = 135 fps max Sreq. = W / (__V2CL) = 11.27ft2 Sactual = b * c = 10ft * 14in = 11.67ft2 Conclusion
Wing size kept same, to accommodate weight growth during design

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Aerodynamics
Trimmed CUAV Lift Estimation:
Used Midnight Airfoil Polar to produce Cl for both wing and tail h c Clcuav = C Mwb + Cl St lt e S c Clcuav = Clwing + Cltail

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Aerodynamics
Trimmed CUAV Drag Estimation:
Program Friction used to find Cdo of Airframe (wing not included)
Cdoairframe = 0.0156

Used Midnight Airfoil Polar to produce Cdo and Cl for both wing and tail
Cd = Cdoairframe + Cdoairfoil + KCl2

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Aerodynamics
Trimmed CUAV Polars:

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Stability and Control

Mission:
Size Surfaces Calculate Aileron Hinge Moments Validate Tornado Code Verify Stability of Aircraft

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Stability and Control

Surface Sizing:
Tail Surfaces sized in Preliminary
bactual = 2.21ft C = 0.5ft

Aileron Sizing using Raymers traditional aileron vs percent chord

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

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Stability and Control

Hinge Moment Calculations:
Used Xfoil OPER menu, and FMOM command Maximum Speed and S.L. used for analysis Hinge Moment (ft-lb) X-Force (lb) Y-Force (lb) Top Bottom 0.2375 0.3326 1.7376 -4.3973 6.7001 6.7001

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Stability and Control

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

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Stability and Control

Tornado Verification:

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Stability and Control

Tornado Validation:
CL_ Cm_

Tornado Results Xfoil Results Error

4.80 4.43 8.47%

0.0350 0.0335 4.64%

Conclusion:
Tornado provides good approximation of stability parameters Only Use Tornado for all derivatives
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Stability and Control

Tornado Verification:
Longitudinal Static Control Deflection CL_ 5.1404 Cm_ Cm_e Static Margin Lateral-Directional -1.4376 Cl_ -2.7082 Cl_a 23.31% Cl_r -0.0349 Cn_ 0.0130

0.3145 Cn_a -0.0193 0.0398 Cn_r 0.2168

Conclusion:
Tornado provides good approximation of stability parameters Aircraft is statically stable, and stable w.r.t. control deflections
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Performance
Performance was not defined in RFP Team Defined Performance Parameters:
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 5,000 feet 100 fpm ROC at 10,000 feet

The CUAV easily exceeds all performance requirements

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Rate of Climb
Maximum rate of climb occurs at Vmp
2W V mp = rS 3 C Do k

ROC =

550bhphp DV W W
Max Rate of Climb 2211 fpm 1684 fpm 1277 fpm

Altitude Sea Level 5,000 ft 10,000 ft

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Flight Envelope
For stall boundary: Clmax = 1.57

Vmin = W Cl max 0.5 rS

2 W 0.5 rV 2 S Pr = C do + k 2 0.5 rV S

For Vmax boundary: Pa = Pr

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Loiter Performance
Altitude Sea Level 5,000 ft 10,000 ft Min Power Vel 111 fps 120 fps 129 fps Drag 9.05 lbs 9.09 lbs 9.029 lbs Power Req'd 1.83 Hp 1.98 Hp 2.12 Hp Est. Fuel Cons. 0.28 gal/hr 0.37 gal/hr 0.48 gal/hr Endurance 11.7 hr 8.6 hr 6.7 hr Range 880 mile 705 mile 590 mile

Mission Profile for Cheap UAV t f 0 0 0 1 , 10 e d u t i i t l A 5 15 Sea Level 5k Feet 10k Feet

100

200

300

400 500 600 Distance, miles

700

800

900

1000

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Engine Selection
Engine Tecumseh Power Sport Honda GX270 QAE2 Saito FA-450R3-D Fuji BT-86 Twin Radne Raket 120 Aero ES Weight (lbs.) 55 62 6.5 6.2 15 Power (hp) 10 9 7 7.5 14.8 Electric Starter No Yes No No Yes Cost $495.99 $742.50 $1069.95 $799.99 $1100.00

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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
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Altitude Power Adjustments

Power = PowerSL _ (_/_0 (1 _/_0)/7.55) Height (ft) Sea Level 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
40

Adjusted Power (hp) 14.80 13.62 13.17 12.73 12.30 11.87 11.46 11.06 10.67 10.29 9.91
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Propeller Sizing
Diameter (ft) 2.0 2.0 2.0 2.1 2.1 2.1 2.1 2.2 2.2 2.2 2.3 2.3 2.3 Rotation Speed (rev/s) 66.67 75.00 83.33 58.33 66.67 75.00 83.33 58.33 66.67 75.00 58.33 66.67 75.00 Advance Ratio 1.0125 0.9000 0.8100 1.1020 0.9643 0.8571 0.7714 1.0519 0.9205 0.8182 1.0062 0.8804 0.7826 Power Coef. 0.3610 0.2536 0.1848 0.4222 0.2829 0.1987 0.1448 0.3346 0.2242 0.1574 0.2679 0.1795 0.1261 Prop Eff. 0.53 0.68 0.75 0.48 0.65 0.78 0.78 0.63 0.73 0.80 0.75 0.83 0.83 Speed-Power Coef. 1.2048 1.1493 1.1019 1.2709 1.2048 1.1493 1.1019 1.2709 1.2048 1.1493 1.2709 1.2048 1.1493 Thrust (lbs) 31.96 41.00 45.22 28.94 39.19 47.03 47.03 37.99 44.02 48.24 45.22 50.05 50.05 Thrust Coef. 0.2194 0.2224 0.1987 0.2135 0.2214 0.2099 0.1700 0.2327 0.2064 0.1787 0.2319 0.1965 0.1552

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Propeller Selection
To avoid losing thrust at high speeds or RPMs, the helical tip speed of the propeller should not get too close to the speed of sound Mtip = (V2 + ( nD)2)1/2/a At sea level, the calculated tip Mach is 0.4675, well below the speed 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.

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Engine Installation
Mount engine upside-down. 5.1" _ 6.1" _ 0.25" Flat plate to mount to firewall, 1.5" from top of fuselage. Connect fuel feed to carburetor inlet. Connect throttle servo to throttle shaft. Run exhaust to outside of fuselage. Extension for engine shaft.

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Materials

COMPOSITES Bi-directional Kevlar ALUMINIUM 6061T6

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Materials
Skin material is Bi-directional Kevlar
Good resistance to corrosion and fatigue Elimination of part interface High damping characteristics Low coeff of Thermal Expansion

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Materials
Stress analysis using FEPC suggests reinforcement for composite frame Failure at 90 degree joints may occur

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Materials Aluminum 6061T6 Airframe

Abundant and Low Cost Versatile Good formability Resistance to corrosion Ductile

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Materials
Material Designation
Complete skin construction of Composites Aluminum beams for reinforcement Fuselage and wings 0.03

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Structures

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Structures Overview
Wing loading
Shearing force Bending moment

Aileron integration
Rear wing spar attachment

V-n diagram
Maneuver loading Gust conditions

Tail integration
Offset bearing system

Spar designs
Shearing stress Compressive stress Deflection

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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

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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

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V-n Diagram
V-n Diagram 5

4 r o t c a F d a o L

-1

-2

50

100 150 Velocity (ft/sec)

200

250

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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

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Spar Design
Spar Location 6

s e h c n i

-2

-4 0 2 4 6 inches 8 10 12 14

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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

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Tail Spar Design

Spar Location

2 1.5 1 s e h c n i 0.5 0 -0.5 -1 -1.5 -2 1 2 3 inches 4 5 6

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Aileron Integration

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Tail Integration

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UAV Systems
Systems to be incorporated into UAV: Navigation Autopilot Control Communication Electrical Deployment

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Navigation and Autopilot Systems

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 link
Micropilot MP1000SYS Specifications
GPS Accuracy Altitude Accuracy Speed Limit Altitude Limit Dimensions Weight Antenna Length Current Draw Unit Cost
61
www.uavflight.com

Micropilot MP1000SYS

25 ft 5 ft 255 fps 25,000 ft 6" x 3.2" x 1.5 0.33 lbs 48 in 0.30 Amps @ 8 V $1,500
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Control System
_ 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 hinge moment calculations
1/4 Scale RC Servo Specifications
Dimensions Torque Avg Current Unit Cost 2.33" x 1.13" x 1.96" 0.66 ft-lb -- 1.52 ft-lb 97 mA -- 495 mA $27.99 -- $94.99
www.towerhobbies.com

_ Scale RC Servo

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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

L-3 Communications TCDL Specifications

Range Data Rate Dimensions Current Draw Unit Cost 120 nm up to 45 Mbps 3" x 6.75" x 10" 3" x 12" x 10" 5.89 Amps at 28 V 200,000 +

TCDL from L3 Comm.

www.l-3.com

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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
Data Link Specifications
AACOM AT6420 Transmitter AACOM 3000 Receiver 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 Watt Antenna 20" Omni-directional colinear array Total Unit Cost $15,000

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Electrical System
2 Choices for the electrical system: (generator, batteries) Use of go-kart engine makes incorporation of generator infeasible
UAV Electrical Requirements
System Autopilot Servos (times 5) Reciever Transmitter Payload Miscellaneous Total Amps 0.30 0.50 0.20 6.00 10.00 1.00 20.00
Electric Fuel Zinc-Air BA-8180/U

www.electricfuel.com

20 Amps x 5.5 hrs = 110 Ah

UAV Battery Selection

Type Lithium-Ion Zinc - Air Zinc - Air Manufacturer Ultra-Life Electric Fuel Electric Fuel Voltage 28 V 28 V 28 V Capacity 11 Ah 56 Ah 30 Ah Weight 2.9 lb 5.9 lb 3.1 lb Dimensions Cost 5"x4.4"x2.45" $125 12.2"x7.3"x2.4" $290 12.2"x3.7"x2.7" $210

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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
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Cost Analysis
Summary of Fly-Away Cost Engineering Costs Airframe Costs Assembly Costs Systems Costs

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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

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Airframe Cost
Study of composite kit-planes indicated that airframe materials could be acquired for $3,000. The group allowed $ 2,000 for airframe assembly Total airframe cost = $ 5,000

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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

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Systems Cost

Systems Cost System Cost per Unit Data Link $15,000 Autopilot / Navigation $2,000 Servos $ 70 x 6 Batteries $580 Total $18,000

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Cost Summary
UAV Cost Summary per Unit Product Engineering $1,500 Airframe $5,000 Systems $18,000 Assembly / Testing $640 Total Cost $25,140

Total production estimated at $ 25,140 With a profit margin, units could be sold for less than $ 30,000

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Weights and CG
= pt. load

CG?

4 3 6

5 1 2

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Weights and CG
Moment summation
S Mcg = 0; S Mcg = 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

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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

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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 in4

Sample Output

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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
LIMIT SPRING

LIMIT

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Conclusions
CUAV design meets or exceeds all RFP requirements Maximum Payload Endurance Autonomous Operation Expendability Cost Lowest of all UAVs of similar performance

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Questions?

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