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P09123 – 2009 RIT MAV Platform System Level Design Review

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2009 MAV Team Members

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Basic Project Information

• Project Number and Name– P09123 Micro Aerial Vehicle (MAV) Platform

• Project Family – Micro Aerial Vehicle

• Track – Aerospace Systems and Technology

• Start Term – 2009-1

• End Term – 2009-3

• Faculty Guide – Dr. Jeffery Kozak (Mechanical Engineering)

• Faculty Consultants– Dr. Agamemnon Crassidis (Mechanical Engineering)– Dr. Hany Ghoneim (Mechanical Engineering)

• Primary Customer – Dr. Jeffery Kozak, RIT MAV Team

• Secondary Customer – Impact Technologies

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Product Description /Project Overview

Mission Statement:

The MAV Family of Projects:

• To build a semi-autonomous, tending towards full autonomy, air vehicle that will be used in the future for Multidisciplinary Senior Design and for graduate studies in the college of engineering and the college of imaging science.

• To have a hands on aeronautical project for undergraduate students that is of low cost and simplicity as to be able to be made by hand.

• To provide an incentive for students as well as exposure of engineering at RIT by competing in the more aggressive United States/Europe MAV competition

The P09123 Project will:

• Develop the Platform for an expandable and re-useable Micro Aerial Vehicle (MAV) that is intended to be used as a basis for current and future MAV design.

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Concept Generation - Propulsion

Poor

Satisfactory

Good

Excellent

Gas

Batteries

Solar Cells

Jet TurbineRocket

Super Capacitor

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Basic Subsystem Layout – “The Diagram”

Nose Cone Assembly: -Propulsion -Motor/Controller -Propeller

Equipment Cage: -R/F Electronics -GPS -Microcontroller -Batteries

Fuselage

Tail Assembly: -Vertical Stabilizer -Horizontal Stabilizers -Control Servos

Wing Assembly (2): -Airfoil -Control Surfaces -Control Servos

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MAV Subsystem Breakdown

• Fuselage– Material/Construction

– Structure

– Integration

• Wings/Airfoil– Airfoil Shape

– Tail Design

– Flight Dynamics

– Aerodynamics

– Material/Construction

• Propulsion– Thrust Requirements– Propeller – Motor and Controller – Nose Cone Design

• Control Surfaces– Servo Actuation– Size, Shape, Function– Material– Location

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MAV Subsystem Breakdown

• Equipment Cage– Structural Integrity

– Hardware Mounting

– Protection

– Vibration Damping

• Electronics– Batteries

– R/C Elements

– Motor Controller

– Power Requirements

– Servo Control

• Process Development– Manufacturing Process

– Final Assembly

– Documentation

– Procurement

– Bill of Materials/Cost Analysis

• Analysis/Testing– Flight Testing

– Wind Tunnel Testing

– CFD/FEA

– Material Testing

– Simulation

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SPECIFICATIONS

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AIRFOIL ANALYSIS

Aaron Nash

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2009 MAV Airfoil & Wing

Design Assumptions• Velocities

• VCruise = 20 mi/hr, Ma = 0.026• VMax = 35 mi/hr, Ma = 0.046• VMin = 10 mi/hr, Ma = 0.013

• Chord = 6 inches

Reynolds Number Calculations• ReCruise = 10312• ReMax = 180482• ReMin = 51581.55

Look for Low Reynolds Number Airfoils!

vlvl

Re

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Coefficient Calculations

• Minimum Coefficient of Lift Calculation– Assuming a span of three feet

and a weight of 3.31 lbs (1.5 kg)

– Clmin = 2.1564 (v = 25 mph)

– Clmin = 0.7041 (v = 35 mph)

– Clmin = 8.62 (v = 10 mph)Sv

Lift

Sq

LiftCl

25.0min

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Airfoils

• UIUC Database

• Selected a number of low Reynolds Number Data Airfoils– Benchmarked from

P08121

• Results can be seen in handout

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Airfoil Selection

• Selig s1210– 2nd highest Lift Coeff

– Highest operating envalope

• Between 2 and 9 degrees AoA

• Selig s1223– Highest Lift Coeff

– Operating Point at 2 degrees AoA

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Wing position

• Wing will be positioned on the top of the fuselage– Creates a pendulum

effect

– Uses the weight of the fuselage to provide natural lateral stability

– Keel Effect

• Tapered wing tips to add “virtual span”

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FUSELAGE

Joe Hozdic

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2009 MAV Fuselage• Material: Carbon/Kevlar Biaxial Sleeve

Woven Carbon Cloth

Wings Attach To Protrusion

Cage Structure Contained in Body

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Wing Attachment Concepts

•Adhesive

•Strong Connection

•Permanent

•No Affect on Aerodynamics

•Pinned Joint

•Relatively Weaker

•Removable

•May Affect Aerodynamics

Adhesive Thru Pin

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Cage Location•Cage may be adjusted front to back:

•Shifts center of gravity

•Compensates for various configurations

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Equipment Cage AssemblyFoam Isolators: Secure Cage Inside Fuselage

Protective Cage: Carbon or Aluminum Rods

Components will attach either directly to cage or the voids may be filled with a thin sheet of plastic/composite to mount equipment on

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WING STRUCTURE

Corey Kulcu-Roca

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Skin Materials

• Monokote

• Fiberglass

• Carbon /Kevlar

• Carbon fine weave

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Wing Core Materials

• Foam

• Balsa Wood

• Carbon Ribs

• Honeycomb

• Carbon Rod

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Wing Materials Comparison

Skin Material Benefits Disadvantages     Monokote weight strength

  costadhesion to honeycomb

Fiberglass strength fabrication

   adhesion to honeycomb

Carbon/Kevlar sock extra strength weight

  no wing coreadhesion to honeycomb

  fabrication  Carbon (fine weave) strength fabrication  weight cost

   adhesion to honeycomb

Core Material Benefits Disadvantages     Foam cost strength  weight    fabrication  Balsa Wood cost strength

  weight fabrication

Carbon rods weight assembly  strength  Carbon ribs weight assembly  strength  Honeycomb extra strength fabrication  weight cost    assembly

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PROPULSION

Brian David

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Propulsion Components

• Motor– 7.8 V– 32000 RPM – 5.7 W– .8 oz

• Battery – 7.4 V– 600 mAh– 1.3 oz

• Propeller – 5.1x4.5 APC E– Hub ID = .25”– .00125 oz

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Propulsion Calculations

• Thrust– 7.40*.60=4.44 W– 4.44/4.70=.947– .947*32000=30230 RPM– Max RPM = 190000/D = 37255 RPM– 30230 < 37255 OK– From thrust calc:

• Thrust at 30230 RPM = 1.66 Kg

• Power to weight ratio– Max Thrust / Max Weight– 1.66 / 1.5 = 1.1

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Flight Time

• Full Throttle– P / V = current draw– 4.7 W / 7.8 V = .603 A– 600 mAh / .603 A = 59.7 min– 4.8 V cutoff voltage– 7.4 / 4.8 = 1.54– 59.7 min / 1.54 = 38.8 min

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MANUFACTURABILITY

Joe Chow

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Concept Development- Structure Diagram

MAV

Propeller

Nose Cone

Fuselage + Tail Stock

Wings (2)

Motor

Cage

L. Horizontal Stabilizers

R. Horizontal Stabilizers

Vertical Stabilizers

Servos

Aileron

Elevator

Elevator

Rudder

Electronics

SA-1

SA-2-1

SA-2-2

SA-2-3

SA-2-4

SA-2

SA-3

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RISK ASSESSMENT

Concept Development

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Materials are too heavy once built

The motor does not support the weight, therefore the plane 

cannot fly.

M H M

Review and design based on past MAV projects, since it was quite successful 

before.

Vehicle does not survive crash test

Microcontrollers and other components may be damaged during actual flight

L H M

Microcontroller will not be flown in plane until it survives the crash test. All 

electronics will be placed in a cage, that is reinforced by 

durable materials. 

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Components do not fit inside plane

Vital Functions ( Flight Control) may be lost L M L

Revise design of vehicle. Search for 

smaller components or components that multi 

task

Design is too complex

Undergrads may not be able to benefit 

from project. Vehicle may not be possible to build with current 

resources

L M LMay have to sacrifice performance for design simplicity

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Budget runs outUnable to procure necessary materials and resources

L M LFind alternate source 

of funding or fundraser

Power Source Calculation Error

Power source does not support the actual power needed, 

therefore, the plane cannot fly.

L M L

In addition to the experts on the team, 

previous years calculations were also 

reviewed.

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Concept Development- Risk Assessment

Risk

Possible Consequence

Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Wings are not symmetrical

Plane will either not fly or the maneuverability of the plane will be affected. This is so 

because of unbalanced moment and improper 

flight dynamics

M H M

Detailed Drawings of the wings will be completed. Also a mold of the wings will be made.

Poor wing construction/  tolerances

The plane will either not get much lift or will fail 

to take off.L M M

Calculations for wing structure will be calculated and 

simulated through simulations 

program. Then the actual structure will be tested at the Wind Tunnels Facility.

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Wing to Fuselage Joint Fails or misaligned

Wings will be crooked, therefore flight will be unstable or fail during flight. It might not even fly 

also.

L H M Design one piece wing

Power Requirements too high

Will need to spend a lot of money on a bigger battery or alternate power 

source, which might increase the weight 

of the plane.

M M M

The minimum amount of 

electronics will be used in the plane. Also, EE's will be assigned for the P09122 project.

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Platform is unstable

Maneuverability of the plane will be affected or it could fail during flight. 

Controls group may fail.

M H M

Platform specifications will be 

simulated for verification. Also, the platform will be tested in the Wind Tunnels Facility. 

Poor communication w/ P09122

P09122 will buy a premade RC Plane platform and not use our current platform. 

L H M

Talks between the current team 

members and the members of P09122 are always taking 

place. 

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Poor electronics design 

Sensors, accelerometers and cameras will not function properly, 

therefore information cannot be obtained.

H H HEE's will be assigned to the electronics part of 

the project.

Too much drag

Plane will either not fly or  it will not sustain in flight for the required amount of time.

L H L

Calculations, simulations and the professor's guidance will be utilized in designing and 

manufacturing of the platform.

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Fuselage Crooked and stabilizers are placed in the incorrect location

Aerodynamics of plane will be affected, therefore, more calibrations will be needed to be done. 

L M L

Careful calculation will be made and the 

fuselage will be placed with part of the sides 

overlapping with the tail stock. Therefore, it will be aligned with the tail 

stock.

Cage Assy. Too Heavy

More motor power will be needed to start and sustain the plane in flight. The plane might 

not fly either.

L M L

We will use a more powerful motor to cover for the extra weight. 

Also electrical equipment could be 

taken out.

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Low thrust

The plane will not be able to fly or sustain in flight for the required amount of time. Plane might also crash.

L H L

Calculations will be monitored by 

experienced engineers and the mentor.

Low Flight time

More calculations and modifications to the specification of the plane will be needed. Also larger batteries will be needed, 

therefore increase in weight.

L M L

Analyze plane structure, power issues and weight 

issues. 

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Servo Fail

Maneuverability of the plane will be affected and also defective servo motor. Could 

lead to crash

L M L

Servo  will be returned and replaced. 

Placement of the servo will be re-calculated

Control Surface Missaligned

The aerodynamics of the surface will be affected, therefore 

affecting the performance of the plane. It also prompts for improper flight control response.

M M MSimulation and tests 

will be done before any real tests takes place.

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Concept Development- Risk Assessment

Risk

Possible Consequence Probability Of Risk Severity Of Risk Overall Risk Contingency Plan

(H/M/L) (H/M/L) (H/M/L)  

Cage moves inside plane

There will be a shift in center of gravity. M H M

Composites will be used to reinforce the placement of 

the cage and a mold will be placed to make sure that it doesn't move.

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SCHEDULE

Concept Development

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Concept Development- Project Schedule

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Concept Development- Project Schedule

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THANK YOU