Detailed Design Review

Tethered GliderP14462

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Outline• Engineering Requirements• Glider Status• Tether Design• Base Station Design• DAQ System• Bill of Materials• DOE ANOVA Analysis• Test Plan• MSD II Plan• Work Breakdown• Risk Assessment

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Engineering Requirements

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Glider Status

• Art’s Planeo Suffered Multiple

Crasheso Totalled

• 1st Bixlero Few flights on first

dayo Missing in swamp

• 2nd Bixlero On order

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1st Bixler

• Learned how to glue glider and set up receiver

• Needed to be modified due to poor manufacturingo Drilled out interfering

plastic/wood

• Bixler was tail heavy

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Tether Design

• DynaGlide Throw Lineo Material: Dyneema with Vinyl Coatingo Vendor: WesSpuro Diameter: 1.8mmo Tensile Strength: 1000 lbo Highly Visibleo Price: $39.00 for 200 feet

http://www.wesspur.com/throw-line/zing-it-throw-line.html12/10/2013 14462

Tether Drag

• Numerical Approximation

• Calculates:o Tether Drago Tension Changeo Tether Angle

Change

Rajani, Ashok, Rajkumar Pant, and K. Sudhakar. "Dynamic Stability Analysis of a Tethered Aerostat." Journal of Aircraft 47.5 (2010): 1531-538. American Institute of Aeronautics and Astronautics. Web. 7 Dec. 2013. <http://arc.aiaa.org/doi/pdf/10.2514/1.47010>.

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Tether Drag

Total tether drag of DynaGlide tether: 27.063 NNegligible force compared to the lift and drag

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Tether-Wing Attachment Setup

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Tether-Wing Attachment

• Tether may rip EPO foam if attached directly

• Design plate to rest on top of wingo Distributes loado Foam is minimally

damaged

• Tethered over carbon fiber spars

• Material: Polycarbonate12/10/2013 14462

Tether-Wing Attachment Setup

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Tether-Wing Attachment Stress Analysis

Plate material: PolycarbonateMax stress: 38.4 GPaMax allowable: 55 GPa

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Tether-Wing Attachment Displacement Analysis

Plate material: PolycarbonateMax deflection: 0.002 in

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Bridle Setup

• 3 point bridle with extra support line• Use crimps for permanent attachments• Adjustable fuselage tether to change bridle angle

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Bridle Setup

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Base Station - Week 6 Concept

● Concept from week 6, selected by week 9

● Consists of 2 potentiometers and 1 load cell

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Base Station - Detailed Design

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Base Station - Detailed Design

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Exploded View of Upper Portion

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Design Focus - Upper Portion

• Wanted minimal flexing on the shaft in order to prevent bearing seizure

• Wanted to prevent screw pullout

• Wanted minimal plywood flexing

• Ensure top bolt did not tear through plywood due to loading

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Shaft Selection

T=1200 lbf

RR=600 lbfRL=600 lbf

x

y

● Wanted to minimize deflection, bending stress, and moment of inertia of shaft

● Utilized Excel and varied L and R and calculated corresponding deflections and max stress

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Shaft Selection Continued

¾” x 7’’ AISI 1566 Steel shaft

● Only 4” of the shaft will be between the bearings, which is the length used for deflection and stress calculations.

● With these values the shaft will deflect 0.0036” under the max loading of 1200 lbs

● The thicker shaft allows for tapping in order to connect the load cell

Selection:

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Pillow Block Screw Pullout T=300 lbf

x

y

Selection:

4 #12-10 machine screws¾” C-D grade plywood

http://www.grabberman.eu/Media/TechnicalData/452.pdf

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Plywood Flexing

● Modeled as an isotropic material, although wood is anisotropic

● Showed max deflection of 0.503E-05 inches

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Bolt Tear Through

● Wanted to prevent the bolt from tearing through the plywood

● A 3 inch washer was added to distribute the loading on the face of the plywood

1200 lbf

170 psi

Without Washer: Compressive stress on the plywood of 8692 psi. The maximum allowable compressive stress for loading perpendicular to the face grain is between ~ 900 – 1500 psi

With Washer: Compressive stress on plywood of 170 psi, within the allowable stress

1200 lbf

8692 psi

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Source: www.buildgp.com/DocumentViewer.aspx?repository=bp&elementid

Pillow Block Bearings

Selection:

● Shaft will insert and then be screwed down with set screws

● Do not need to be thrust bearings, as platform will rotate

¾” Stamped-Steel Mounted Ball Bearings—ABEC-1

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Exploded View of Lower Portion

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Design Focus - Lower Portion

• Wanted to ensure sleeve bearing did not deform under worst-case scenario loading

• Wanted to prevent screw pullout

• Ensure sheet metal flexed minimally under applied load

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Sleeve Bearing

T=1200 lbf

hsb

H

RL

RR

Selection:

0.752” x 1” Ultra Tough Oil Lubricated Bronze Flanged Sleeve Bearing

● Utilized Excel to calculate various reaction forces for different hsb, and compared versus the max allowable force on the inner walls of the bearing

● For worst case scenario chosen bearing will see 5100 lbs and it is capable of handling 6016 lbs.

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Angle Iron Pullout and Shear

F=300 lbf

F=300 lbf

F=200 lbf Selection:

1”x1”x1/8” angle iron with #12 screws

6 vertical screws, and 4 horizontal

¾” C-D grade plywood

http://www.grabberman.eu/Media/TechnicalData/452.pdf

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Sheet Metal Plate• Max deflection of ~ 0.003 inches

Base Station – Cross Section View

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Base Station AnimationBase Station Animation

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NI USB-6210

16 bit Resolution = 10/(2^16) = 0.000153

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3140_0 S Type Load Cell (100-500kg)

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1046_0 PhidgetBridge 4-Input

Resolution = 5/(2^24) = 0.000000298

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Potentiometers

• 2 pots required.• 1 turn ~ 270 degrees• Between 1K-10K Resistance• Linear• Bourns brand• Potentiometers from Gomes still need to be spec out

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DAQ Operational Flowchart

DAQ Programming Flowchart

Wiring Schematic for DAQ

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Bill of Materials - Full

Bill of Materials – Already Have

Bill of Materials – Need to Buy

Bill of Materials - Possible Savings

Glider Configuration for Experiments

Total configurations: 2590

Range: Beta = 90-98 [deg] Wind Speed = 4-10 [m/s] Tether Length = 20-30 [m] Flight Radius = 10-18 [m]

Force [lbs] Wind Speed [m/s]

Radius [m]

Beta [deg]

Tether Length [m]

334.3693 7 15 92 30

309.5235 7 16 92 30

349.0444 7 18 93 30

Filtered: Force = 300-350 [lbs] Wind Speed = 7 [m/s] Tether Length = 30 [m]

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Regression Analysis including Wind

Force = -1523.83 + 44.6977 WindSpeed - 22.0839 Radius + 16.3528 Beta +11.4661 TethLen

Analysis of VarianceSource DF Seq SS F PRegression 4 14445969 580.40 0WindSpeed 1 6413421 2006.60 0Radius 1 2623543 887.44 0Beta 1 2732563 524.19 0TethLen 1 2676441 430.13 0Error 2583 16072377Total 2587 30518346

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Why the high error ?

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2000-200-400

99.99

9990

50

101

0.01

Residual

Perc

ent

500400300200100

200

0

-200

Fitted Value

Resi

dual

140700-70-140-210-280

160

120

80

40

0

Residual

Freq

uenc

y

2400

2200

2000

1800

1600

1400

1200

10008006004002001

200

0

-200

Observation Order

Resi

dual

Normal Probability Plot Versus Fits

Histogram Versus Order

Residual Plots for Force

DOE ANOVA Analysis

Analysis is based off of above equationExperiment was run using the following

Factor Type Levels ValuesRadius fixed 9 10, 11, 12, 13, 14, 15, 16, 17, 18Beta fixed 8 91, 92, 93, 94, 95, 96, 97, 98TethLen fixed 11 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 Analysis of Variance for Force for TestsSource Seq SSRadius 1074979Beta 1039829TethLen 772033Radius*Beta 383755Radius*TethLen 263954Beta*TethLen 312236Radius*Beta*TethLen 818325Error 25853236Total 30518346

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Interaction plots for Tension

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Main effects on tension

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Graphical Sensitivity (contour plots) of each factor

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Graphical Surface plots

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Test Plan

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Test Plan

• Varied wind speed: Dependent on environment• Varied glider mass would be an additional test if time

allows

Component/System Tested Specification Tested

Responsibility Completion Date

Experimental Proof of Theoretical Model

Tension Team 02/28/2014

Varied Tether Length Model Sensitivity Team 03/14/2014

Varied Wind Speed Model Sensitivity Team 03/28/2014

Varied Beta Angle Model Sensitivity Team 04/04/2014

Varied Flight Path Radius Model Sensitivity Team 04/11/2014

Varied Glider Mass Tension Team 04/18/2014

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Risk Assessment - Full

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Risk Assessment - High Priority/New

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Project Plan

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MSD II Plan

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MSD II Plan (Continued)

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Work Breakdown Matt – Building glider, attaching bridal, flying tethered

glider Paul - Building glider, attaching bridal, flying tethered

glider Jon – Machine parts, assemble base station Kyle - Machine parts, assemble base station Bill – Create LabVIEW code, test DAQ equipment, Saj- Update project timeline, develop more detailed test

plans from DOE, maintain transparency between team and customer/guides

All – Assist in base station build

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Summary• Engineering Requirements• Glider Status• Tether Design• Base Station Design• DAQ System• Bill of Materials• DOE ANOVA Analysis• Test Plan• MSD II Plan• Work Breakdown• Risk Assessment

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Questions?

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