October 30, 2001 A&AE 451 - Fall, 2001 1

Critical Design Review

Brian Barnett
Rob Benner
Alex Fleck
Ryan Srogi
John Keune
October 30, 2001 A&AE 451 - Fall, 2001 2
Preliminary Design
Initial Weight Estimation (Historical Data)
Payload = approx 1.18 lb
3 Battery Cells
Rate Gyro
Weight = approx 5 lb.
October 30, 2001 A&AE 451 - Fall, 2001 3
Preliminary Design
Equations of Constraint (Roskam)
Loiter Velocity



Turn Radius



Climb Angle
cruise
p
V q Cd
S
W
P
W
* *
* * 550 q =
(
(
(
(

+ =
S
W
V Cd q
S
W K
r g
V
V P
W
cruise o cruise
cruise
p
* *
*
* 2
*
) * * (
* * 550
2
3
t
q
19 *
* *
*
9 .
2 / 3
2
Cl
e AR
Cl
Cd
S
W
RCP
P
W
|
|
.
|

\
|
+
+
=
t
October 30, 2001 A&AE 451 - Fall, 2001 4
Preliminary Design
Cl V
S
W
stall
* * *
2
1
2
=
2
max
) ( * 0148 . 0 * 13 . 8 /
* 87 . 0 *
TOP TOP Roll O T
S
W
C TOP
P
W
L
+ =
|
.
|

\
|
=
Equations of Constraint (Roskam)
Ground Roll





Stall
October 30, 2001 A&AE 451 - Fall, 2001 5
Preliminary Design
Constraint Diagram
W/P = 23 lb/hp

W/S = 0.55 lb/ft
2


With AR=6,
S = 9.1 ft
2

b = 7.4 ft
c = 1.2 ft
October 30, 2001 A&AE 451 - Fall, 2001 6
Aerodynamics
Airfoil Selection
Best endurance when C
L
3/2
/C
D
is maximized
Selig airfoils for low Re flight
2-D Data readily available online (www.nasg.com)
Compared 13 Selig airfoils
Roskam method used to generate C
L
and C
D
values
e AR
C
C C
d
d
S
S
C C C
C C C
L
D D
ht
L L L
L
Lo L
h wf
t
o
c
q
o
q
o o o
o
2
0
1
+ =
|
.
|

\
|

|
.
|

\
|
=
+ =
+
October 30, 2001 A&AE 451 - Fall, 2001 7
Aerodynamics
C
L
(3/2)
/C
D
0
2
4
6
8
10
12
14
0 2 4 6 8 10 12
Alpha (deg)
C
L
(
3
/
2
)
/
C
D
S1210
S2048
S2048
S2055
S2091
s3010
S3016
s3014
Selig S1210 Airfoil
October 30, 2001 A&AE 451 - Fall, 2001 8
Aerodynamics
Twist for elliptical loading
2
2
1
4 ) ( ) (
|
.
|

\
|
=
b
y
C C
y C y C
L
l
t
. , ), ( const C C y C
L
=
Elliptical Lift Distribution
-10
-8
-6
-4
-2
0
2
4
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
2y/b
C
l

,

o

(
d
e
g
)
Cl
Alpha (deg)
Elliptical Loading
12 total twist
Very high do/dy near wing tips
Twist for elliptical loading very
difficult to manufacture
Linear Twist
3 twist is sufficient to ensure initial
stall at root
Angle of incidence
C
L
3/2
/C
D
peaks at 3
October 30, 2001 A&AE 451 - Fall, 2001 9
Aerodynamics
Vertical Tail Sizing
v
v
v
x
Sb V
S =
2
92 . 0 ft S
v
=
(Roskam)
Aerodynamics
October 30, 2001 A&AE 451 - Fall, 2001 10
Longitudinal Xplot
SM = 15%
Horizontal Tail
Area = 1.7 ft
2

Xcg = 0.37c
Xac = 0.52c
Aerodynamics
October 30, 2001 A&AE 451 - Fall, 2001 11
Propulsion
Power Analysis


P
req
= P
pout
= P
pin
* q
p
P
pin
= P
gout

P
gout
= P
gin
* q
g
P
gin
= P
mout
P
mout
= P
min
* q
m

P
min
= P
bout
Battery
Speed
Controller
Motor Gearbox Propeller
q
p
q
g q
m
P
pout
P
gout
= P
pin
P
mout
= P
gin
P
bout
= P
min

October 30, 2001 A&AE 451 - Fall, 2001 12
Propeller Selection
Power required from aerodynamics
8.6 ft*lb
f
/sec

Gold matlab code
15 x 10 propeller was chosen


4 2
* * * D n C P
p pout
=
n = RPM/60 = Hz
D = propeller diameter
q
p
= .766

Propulsion
October 30, 2001 A&AE 451 - Fall, 2001 13
Propulsion
Effect of Differing Prop Diameter with Pitch = 10
P
r
o
p

E
t
a

Power Out (ft*lb
f
/sec)
RPM =1910
Eta =.766
Ground Clearance
Constraint (15)
D=8
D=18
D=16
D=14
D=12
D=10
Power Required=8.6
October 30, 2001 A&AE 451 - Fall, 2001 14
Gearbox Selection
P
pin
= P
gout
= 11.23 ft*lb
f
/sec

P
gin
= P
gout
/ .95 = 11.82 ft*lb
f
/sec
Gear ratio = 3:1

q
g
= .95

Propulsion
October 30, 2001 A&AE 451 - Fall, 2001 15
Propeller Selection
Power required from aerodynamics
8.6 ft*lb
f
/sec


Gold matlab code
15 x 10 propeller was chosen


Propulsion
4 2
* * * D n C P
p pout
=
n = RPM/60 = Hz
D = propeller diameter
J = V/(n*D)
q
p
= Ct*J/Cp = .766

October 30, 2001 A&AE 451 - Fall, 2001 16
Motor Selection
P
gin
= P
mout
= 11.82 ft*lb
f
/sec
RPM = 1910
Matlab script was run for 615 motors
Motor was chosen for highest efficiency using three
battery cells
Propulsion
Efficiencies
q
m =
.519 q
g
= .95 q
p
= .766 q
tot
= .378

October 30, 2001 A&AE 451 - Fall, 2001 17
Motor Performance
Motor Current (amperes)
Propulsion
October 30, 2001 A&AE 451 - Fall, 2001 18
Battery Selection
3 x Panasonic NiMH batteries
3000 mAh
1.2 V/cell
57.4 g/cell
Propulsion
October 30, 2001 A&AE 451 - Fall, 2001 19
Propulsion
Maxx Products Cobalt 400 14T
Kv = 2290 RPM/V
Io = 2.5 A
Imax = 20 A
Rm = .108 Ohm
$70.00

Maxx Products Ball
Bearing Gearbox
Ratio 3:1
$22.50
October 30, 2001 A&AE 451 - Fall, 2001 20
Finite Element Methods Modeling
Moment of Inertia: I = 2(A
flange
x d
2
) + 1/12 (b
web
x h
3
web
)
3/8
1/8
3/8
All Spars
Structures
October 30, 2001 A&AE 451 - Fall, 2001 21
Bending Load Carried in Spars
Huge percentage of bending moment transmitted to all spars
Max stress:
o
max
= M
max
y
I
Uniform Pressure Load:
2.5 lbs x 2.5 gs = 6.25 lbs
6.25 lbs x 1.5 safety factor =
Applied Load = 9.38 lbs
Divided by Wing Area:
9.38 lbs / 648 in
2
= Distributed Pressure Load = .0145 psi
Structures
October 30, 2001 A&AE 451 - Fall, 2001 22
FEM Calculated Weight:
.56 lbs for wing
Exaggerated Wing Deflection

FEM Results:
o
max
= 273.3 psi
o
max
= .34
Balsa Properties:
o
yield
= 1725 psi
(WT team, Spring 99)

Structures
October 30, 2001 A&AE 451 - Fall, 2001 23
Buckling Load:
FEM calculates Eigenvalue of stability problem
This value is a load multiplier for buckling to occur
Wing Spar Buckling Point
E
value
= 5.443
Applied Load = .0145 psi
Buckling Load = .0789 psi
Structures
October 30, 2001 A&AE 451 - Fall, 2001 24
Fuselage Structure
Employing bulkheads/stringers for ease of manufacturing
Tail-boom to be captured through reinforced bulkheads
Terminates at wing bolt-down block
Pinned to prevent rotation
Removable at fuselage
junction

Structures
October 30, 2001 A&AE 451 - Fall, 2001 25
Tail Structure
Built on a box design
Hole drilled into box to allow tight fit of tail-boom
Pinned design prevents rotation
Stabilizer assembly removable
from boom
Stabilizers manufactured from
sheet balsa with lightening holes
Structures
October 30, 2001 A&AE 451 - Fall, 2001 26
Landing Gear Structure
Steerable nose-wheel mounted to internal firewall
Main gear mounted to internal/external
sandwich plate
Bolt holes run vertically
between stringers
Minimize damage if
shear-off occurs
Easily replaceable
Structures
October 30, 2001 A&AE 451 - Fall, 2001 27
Control Surface Sizing
41 . =
h
e
S
S
081 . =
S
S
a
38 . =
v
r
S
S
Class I sizing based on historical data
2
35 . 2 ft S
h
=
2
92 . ft S
r
=
2
09 . 9 ft S
a
=
2
74 . ft S
a
=
2
35 . ft S
r
=
2
96 . ft S
e
=
Dynamics & Control
October 30, 2001 A&AE 451 - Fall, 2001 28
Dihedral and Static Margin
2 dihedral recommended for high-wing model aircraft
with ailerons and no sweep.
The Basics of R/C Model Aircraft Design

15% Static Margin
Mark Peters recommends 18%
Previous 451 designs have gone as low as 10%
Adjustable by moving internal components
Dynamics & Control
October 30, 2001 A&AE 451 - Fall, 2001 29
Loop Closure
K
H
g
(s)
Rate Gyro
Transfer Function Feedback Gain
H
e
(s)

q(s)/o
e
(s)

E
Servo
Transfer Function
Aircraft
Transfer Function
+
-
o
e
(s) q(s)
Pilot
Input
Dynamics & Control
October 30, 2001 A&AE 451 - Fall, 2001 30
Transfer Functions
( ) ( ) | |
98 . 43 2 . 15
95 . 63 75 . 6
) (
) (
2
1 1
2
1
1
+ +

=
(

|
|
.
|

\
|
+
|
|
.
|

\
|
+ +
+ +
=
s s
s
M
U
M Z
s M
U
Z
M s U
M Z Z M s M Z M U
s
s q
q
q
e
e e e e
o
o
o
o
o o o o o o o
o

Aircraft Transfer Function (Short Period Approximation)

Natural Frequency and Damping Ratio
9991 . 0
2
/ 25 . 7
1
1
=
|
|
.
|

\
|
+ +
~
= ~
sp
sp
n
q
q
n
M
U
Z
M
s rad M
U
M Z
e

e
o
o
o
o

sp
sp
n
q
sp
q
n
M
U
Z
M
M
U
M Z
e
,
e
o
o
o
o
2
1
1
|
|
.
|

\
|
+ +
~
~

= 6.63 rad/s
= 1.146
Dynamics & Control
October 30, 2001 A&AE 451 - Fall, 2001 31
Transfer Functions
Futaba S-148 Servo Transfer Function (2
nd
Order Approximation)
2 2
2
2
) (
servo servo
servo
n n servo
n
e
s
S H
e e ,
e
+ +
=
2 1
2 1
1
) (
G G
G G
S H
e
+
=
40
950
1
+
=
s
G
s
G
1
2
=
Airtronics SG-1 Gyro System
Gain K (abs value) < 1.3 deg/(deg/sec)
Dynamics & Control
October 30, 2001 A&AE 451 - Fall, 2001 32
Root Locus
Dynamics & Control
October 30, 2001 A&AE 451 - Fall, 2001 33
Bode Plot
Dynamics & Control
October 30, 2001 A&AE 451 - Fall, 2001 34
Nyquist Plot
Dynamics & Control
October 30, 2001 A&AE 451 - Fall, 2001 35
30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21-25 26-29 30 1 2 3 4 5
Construction
Wing
Tail
Fuselage
Assembly
Changes
Component Testing
Wing Strength
Boom Strength
Landing Gear
Motor
Control Surface
Flight Testing
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Phase 6
First Flight
Final Presentation
Thikol Final Report
November October December
Flight Testing
Schedule of Events
October 30, 2001 A&AE 451 - Fall, 2001 36
Component Testing
Test boom for structural strength with point load at end of
boom
Test wing with uniform load distribution
Landing gear test for impact load carrying
Provides time to add strength if needed before flight
Engine test on stand, check operation
Control Surface test, check operation
Flight Testing
October 30, 2001 A&AE 451 - Fall, 2001 37
Ground Testing
Phase 1 (AR 106)
Ground Stability Check
Phase 2 (Black IM Fields)
Running takeoff, feedback off, turns, climbs, descents, approaches to landing

Rolling Takeoff
Phase 3 (Smooth Surface Strip)
Stabilizing feedback on, turns, climbs, descents, approaches to landing
Phase 4 (Smooth Surface Strip)
Destabilizing feedback, turns, climbs, descents, approaches to landing
Phase 5 (Smooth Surface Strip)
Confined space practice, endurance test
Phase 6 (Mollenkopf)
Stabilizing and destabilizing feedback, indoor endurance test

Flight Testing
October 30, 2001 A&AE 451 - Fall, 2001 38
Approximate cost for boom $25
This is available at Hobby Time
Approximate cost for landing gear $20
This is available at Tower Hobbies
Item # Quantity Description Price Item # Quantity Description Price
GPMQ3900 1 NYLON CONTROL HORNS 0.85 $ TOWR1395 1 1/4x3x36 BALSA SHEET 7.99 $
GPMQ3702 1 FLEXIBLE CABLE PUSHRODS 2.99 $ TOWR1500 1 1/8x1/8 BALSA STICK 3.29 $
GPMQ3920 1 NYLON BELLCRANKS 1.05 $ TOWR1505 1 1/8x1/4 BALSA STICK 2.99 $
GPMQ3710 1 ACCU-GLIDE NYLON PUSHRODS 3.99 $ TOWR1520 1 1/4x1/4 BALSA STICK 3.79 $
GPMQ3750 1 THREADED PUSHRODS 2.79 $ TOWR1535 1 3/8x3/8 BALSA STICK 4.79 $
GPMQ3840 1 BALL LINKS 1.39 $ TOWR1650 1 1/4x1/4 BALSA STICK 2.59 $
GPMQ4260 1 STEERABLE NOSE GEAR 4.49 $ TOWR1760 1 1/4x1-1/2 AILERON STOCK 3.49 $
DAVQ5030-5530 2 LITE FLITE WHEELS 3" 9.98 $ TOWR1560 1 1/2x1 BALSA STICK 4.49 $
HAYQ1105 1 HINGES (20) 1.80 $ TOWR1850 1 1x2 BALSA BLOCK 1.89 $
TOWR3800 1 BUILD-IT CA THIN GLUE 7.99 $ TOWR1920 1 1/4x6x12 PLYWOOD 1.79 $
TOWR3807 1 6-MINUTE EPOXY 5.99 $ TOWR1905 3 1/16x6x12 PLYWOOD 4.47 $
GPMR8070 1 SILVER SOLDER 6.99 $ TOWR1910 3 1/8x6x12 PLYWOOD 5.37 $
GPMR1054 1 FIBERGLASS TAPE 3.99 $ NHPR2211 1 BALSA MICRO-FILL 4.09 $
TOWR1305 1 1/16x3x30 BALSA SHEET 4.49 $ XACR4317 1 XACTO KNIFE W/ 5 BLADES 4.29 $
TOWR1355 2 1/8x3x36 BALSA SHEET 10.98 $ TOPQ0304 1 MONOKOTE TRANS. BLUE 12.99 $
TOWR1360 1 1/8x4x36 BALSA SHEET 7.98 $ TOWQ1008 1 TOWERKOTE CUB YELLOW 6.99 $
TOTAL (MINUS LANDING GEAR AND BOOM: 153.04 $
Brings total cost to
approximately $198
Cost & Economics
October 30, 2001 A&AE 451 - Fall, 2001 39
Man-hours devoted
0
20
40
60
80
100
120
140
160
180
200
T
e
a
m

T
o
t
a
l

H
o
u
r
s
1 2 3 4 5 6 7 8 9 10 11
Week Number
Team Time Spent
Includes time spent in classroom.
Total hours
spent: 985 hrs
Man hours per
person per
week: 17.9 hrs
Project 600
man hours for
construction
Cost & Economics
October 30, 2001 A&AE 451 - Fall, 2001 40
Prototype Cost: $119,073
985 design hours + 600 construction hours
1585 prototype development hours

Further Production Cost: $257.54
Sell 2000 aircraft kits
Prototype costs/2000 kits + kit price
$75.00 per hour labor cost
Kit Price = $198.00
Cost & Economics
October 30, 2001 A&AE 451 - Fall, 2001 41
Questions?
October 30, 2001 A&AE 451 - Fall, 2001 42
Appendix
3-View Drawing
October 30, 2001 A&AE 451 - Fall, 2001 43
Appendix
Roskam Method:
{ }
e AR
C
C C
K K K
d
d
C K C
d
d
S
S
C C C
C C C
L
D D
c h A
L wf L
ht
L L L
L
Lo L
w wf
h wf
t
o
c
o
c
q
o

o o
q
o o o
o
2
0
19 . 1
4 /
) (cos 44 . 4
1
+ =
(

A =
=
|
.
|

\
|

|
.
|

\
|
=
+ =
+
October 30, 2001 A&AE 451 - Fall, 2001 44
Appendix
Cdo AR e Lift/(Weight) (lb) Rho(slug/ft^3) d (ft) b (ft) Kwf K= Beta etaH de/da i (deg) Power Req'd
0.018 6 0.85 5 0.002378 0.5 8.7 1.000611 0.875065708 0.9999 0.97 0.544138 2.5 8.630929352
K (1/piARe) Sht (ft^2) W/P (lb/hp) W/S (lb/ft2) i (rad)
0.062414 2.03 23 0.55 0.043633231
S (ft2) b c
Vh: 0.63 xh: 3 Sh: 2.349928464 1.7??? 9.0909091 7.385489 1.23091491
Vv: 0.041 xv: 3 Sv: 0.917591115
S1210
ALPHA AlphRAD Cl Cd ClAlpha CLAlphaW CLAlphaWF CLAlphaH CLAlpha AlphaZL (Rad) CL0 CL CD CL^(3/2)/D Velocity (ft/s)
-5.1 -0.08901 0.294 0.0203 5.4982 0.266086039 0.266248629 4.1238602 4.12386 -0.1646 0.055408 -0.434 0.029756 #NUM! #NUM!
-4.1 -0.07156 0.447 0.0148 -0.33803 0.025132 #NUM! #NUM!
-3.05 -0.05323 0.586 0.0116 AlphaZL (Deg) -0.23728 0.021514 #NUM! #NUM!
-2.03 -0.03543 0.698 0.0116 -9.430885308 -0.13939 0.019213 #NUM! #NUM!
-1.03 -0.01798 0.796 0.0126 -0.04343 0.018118 #NUM! #NUM!
0.02 0.000349 0.904 0.0135 0.057327 0.018205 0.753958612 89.82766114
1.01 0.017628 1.005 0.0138 0.152329 0.019448 3.056991716 55.10598167
2.09 0.036477 1.116 0.0146 0.255968 0.022089 5.862676418 42.5106426
3.1 0.054105 1.217 0.0151 0.352889 0.025772 8.133963637 36.2052234
4.13 0.072082 1.316 0.0157 0.45173 0.030736 9.877997552 32.00008059
5.15 0.089884 1.409 0.0158 0.549611 0.036853 11.05617431 29.01100928
6.17 0.107687 1.493 0.0163 0.647492 0.044167 11.79659549 26.72842374
7.13 0.124442 1.571 0.0172 0.739615 0.052142 12.19886093 25.00849825
8.23 0.143641 1.66 0.0183 0.845173 0.062583 12.4153991 23.3947113
9.14 0.159523 1.721 0.0195 0.932498 0.072272 12.45953497 22.27237359
10.23 0.178547 1.778 0.0224 1.037096 0.08513 12.40637314 21.11936822
11.27 0.196699 1.812 0.0273 1.136896 0.098672 12.28537184 20.17111955
12.27 0.214152 1.835 0.0339 1.232858 0.112865 12.12858842 19.37019092
S1223
ALPHA AlphRAD Cl Cd ClAlpha CLAlphaW CLAlphaWF CLAlphaH CLAlpha AlphaZL (Rad) CL0 CL CD CL^(3/2)/D Velocity (ft/s)
-2.68 -0.04677 0.642 0.04 5.0126 0.264844364 0.265006196 4.1238602 4.12386 -0.2519 0.07827 -0.15619 0.019523 #NUM! #NUM!
-1.02 -0.0178 0.961 0.0168 -0.01097 0.018008 #NUM! #NUM!
0.48 0.008378 1.131 0.0164 AlphaZL (Deg) 0.120264 0.018903 2.206368695 62.01875021
2.05 0.035779 1.282 0.0187 -14.43280686 0.257617 0.022142 5.905302011 42.37432957
3.6 0.062832 1.429 0.02 0.393221 0.027651 8.917663024 34.29824701
5.1 0.089012 1.548 0.0212 0.524451 0.035167 10.80001185 29.69874064
6.61 0.115366 1.671 0.0232 0.656555 0.044904 11.84727582 26.54329174
8.21 0.143292 1.8 0.0257 0.796533 0.057599 12.34208384 24.09841119
9.7 0.169297 1.91 0.0281 0.926888 0.071621 12.4595064 22.33967008
11.22 0.195826 2.016 0.0307 1.059867 0.08811 12.38367855 20.89126051
12.84 0.2241 2.116 0.0336 1.201595 0.108115 12.18293575 19.62055542
14.74 0.257262 2.175 0.0371 1.367819 0.134772 11.8698312 18.38975857
16.38 0.285885 2.217 0.0454 1.511297 0.160554 11.57186685 17.49506218
October 30, 2001 A&AE 451 - Fall, 2001 45
Effect of Differing Prop Diameter with Pitch = 6
Power Out (ft*lb
f
/sec)
P
r
o
p

E
t
a

RPM =2430
Eta =.757
Ground Clearance
Constraint (15)
D=8
D=18
D=16
D=12 D=10
D=14
Power Required =8.6
October 30, 2001 A&AE 451 - Fall, 2001 46
Effect of Differing Prop Diameter with Pitch = 8
D =
8
D=1
2
D=1
0
D=1
8
D=1
6
D=1
4
Power Out
(ft*lb
f
/sec)
P
r
o
p

E
t
a

RPM
=2140
Eta =.765
Ground
Clearance
Constraint
(15)
Power
Required=8.6
October 30, 2001 A&AE 451 - Fall, 2001 47
Effect of Differing Prop Diameter with
Pitch = 12
Power Out
(ft*lb
f
/sec)
P
r
o
p

E
t
a

Ground
Clearance
Constraint (15)
D=8
D=10

D=12

D=14

D=16

D=18

RPM
=1750
Eta =.760
Power
Required=8.6
October 30, 2001 A&AE 451 - Fall, 2001 48
Dimensional Derivatives
490 . 4
2
1
2
= =
U F
C qSc
q
M
yy
mq
( )
9 . 181
1
=
+
=
m
C C qS
Z
D lo
o
236 . 8 = =
yy
m
I
qScC
M
e
e
o
o
25 . 13 =

=
m
qSC
Z
e
e
L
o
o
443 . 2
2
1
2
= =
U I
C qSc
M
yy
m
o
o
866 . 6 = =
yy
m
I
qScC
M
o
o
October 30, 2001 A&AE 451 - Fall, 2001 49
Stabilizing Root Locus
October 30, 2001 A&AE 451 - Fall, 2001 50
Stabilizing Bode Plot
October 30, 2001 A&AE 451 - Fall, 2001 51
Stabilizing Nyquist Plot
October 30, 2001 A&AE 451 - Fall, 2001 52
Step Response