WWeesstteerrnn MMiicchhiiggaann UUnniivveerrssiittyy SScchhoollaarrWWoorrkkss aatt WWMMUU Honors Theses Lee Honors College 12-9-2014 DDeevveellooppmmeenntt ooff LLoonngg EEnndduurraannccee SSmmaallll UUnnmmaannnneedd AAeerriiaall SSyysstteemm Andreas Quainoo Western Michigan University, [email protected] Follow this and additional works at: https://scholarworks.wmich.edu/honors_theses Part of the Aeronautical Vehicles Commons, and the Systems Engineering and Multidisciplinary Design Optimization Commons RReeccoommmmeennddeedd CCiittaattiioonn Quainoo, Andreas, "Development of Long Endurance Small Unmanned Aerial System" (2014). Honors Theses. 2499. https://scholarworks.wmich.edu/honors_theses/2499 This Honors Thesis-Open Access is brought to you for free and open access by the Lee Honors College at ScholarWorks at WMU. It has been accepted for inclusion in Honors Theses by an authorized administrator of ScholarWorks at WMU. For more information, please contact [email protected]. MAE Senior Design Project Final Report Development of Long Endurance Small Unmanned Aerial System Western Michigan University Department of Mechanical and Aerospace Engineering Andreas Quainoo Shane Russell Cameron Segard Advisor : Dr. K. Ro Abstract The purpose of this Senior Design Project is to design, build, and test an Unmanned Aerial System (UAS). The purpose of this system is to be used as a test platform for airborne electronics. The intended capabilities of this project include a 12-hour flight time, the ability to carry 5lbs of payload, and the ability to recharge the batteries of electronics while in the air. With these parameters in mind, the focus of the design was on endurance, and, by extension, efficiency and durability. After design was completed, the aircraft and its onboard systems was constructed and evaluated. DISCLAIMER This project report was written by students at Western Michigan University to fulfill an engineering curriculum requirement. Western Michigan University makes no representation that the material contained in this report is error-free or complete in all respects. Persons or organizations that choose to use this material do so at their own risk. Table of Contents Introduction ..................................................................................................................................... 1 Background ................................................................................................................................. 1 Goals and Objectives .................................................................................................................. 1 Design Overview and Development Process .............................................................................. 1 Benchmarking and Decisions ......................................................................................................... 1 Decision Matrix .......................................................................................................................... 3 Engine Testing and Propeller Selection .......................................................................................... 4 Load Cell Calibration .................................................................................................................. 4 LabVIEW Development ............................................................................................................. 6 Engine Test Stand Development ................................................................................................. 7 Wind Tunnel Testing .................................................................................................................. 9 Summary of Data ...................................................................................................................... 10 Charging System Design............................................................................................................... 13 Overview ................................................................................................................................... 13 Alternator Selection and Testing .............................................................................................. 13 Charging Circuit Design and System Integration ..................................................................... 21 Alternator Mount Design .......................................................................................................... 24 Design 1: Pulley Connection .................................................................................................... 24 Design 2: Steel Gear on Plastic Gear Connection .................................................................... 26 Design 3: Steel Gear on Steel Gear Connection ....................................................................... 30 Final Testing on Aircraft ........................................................................................................... 30 Charging System Conclusions and Recommendations............................................................. 32 Aircraft Design.............................................................................................................................. 33 Configuration ............................................................................................................................ 33 Considerations....................................................................................................................... 33 Final Aircraft Configuration ................................................................................................. 33 Performance .............................................................................................................................. 36 Stability and Control ................................................................................................................. 39 Progress Photo Documentation & Captions ............................................................................. 41 Flight Testing ............................................................................................................................ 47 Recoverable Flight Test Data................................................................................................ 50 Recommendations ..................................................................................................................... 51 Conclusion .................................................................................................................................... 54 Expenses ................................................................................................................................... 54 Weight Analysis ........................................................................................................................ 55 Rebuild ...................................................................................................................................... 55 Closing Remarks ....................................................................................................................... 56 Works Cited .................................................................................................................................. 57 Appendices .................................................................................................................................... 58 Appendix I: Raw Alternator Testing Data ................................................................................ 58 Appendix II: Graphed Alternator Testing Data with Best Fit Curves ...................................... 60 Appendix III: Corrected Alternator Testing Data ..................................................................... 63 Appendix IV: Performance MATLAB Code ............................................................................ 63 Appendix V: Stability & Control MATLAB Code................................................................... 66 Appendix VI: Assessment Program Outcomes......................................................................... 68 Appendix VII: Gantt chart ........................................................................................................ 76 Appendix VIII: Resumes .......................................................................................................... 77 Page 2 of 80 Table of Figures Figure 1: ESP-6 Beam Type Load Cell and MLP Series Load Cell ............................................... 4 Figure 2: Load cell calibration curves ............................................................................................ 5 Figure 3: Control panel of LabVIEW VI ........................................................................................ 6 Figure 4: Block diagram of LabVIEW VI ...................................................................................... 7 Figure 5: Engine stand development phases ................................................................................... 8 Figure 6: LabVIEW Control panel in operation ............................................................................. 9 Figure 7: Engine test stand in wind tunnel.................................................................................... 10 Figure 8. SFC vs. engine RPM for various props at 40 mph ........................................................ 11 Figure 9.SFC vs engine RPM for various props at 50 mph .......................................................... 12 Figure 10: “Paidiss MT28-30” (Paidiss MT28-30 Series 900KV High-Powered Brushless Outrunner Motor, 2014) ................................................................................................................ 14 Figure 11: 3-Pase Voltage vs time (Graph made using LTSPICE) .............................................. 15 Figure 12: Bridge Rectifier Circuit Schematic (Made using LT Spice) ....................................... 15 Figure 13: Raw DC Voltage from rectifier (Graph made using LT Spice) .................................. 16 Figure 14: Alternator Test Setup................................................................................................... 17 Figure 15: Alternator Test Setup (cont.) ....................................................................................... 18 Figure 16: Extrapolated Power vs Voltage at a Given Alternator RPM ....................................... 20 Figure 17: Wiring Diagram (Drawn using LT Spice) ................................................................... 21 Figure 18: "Antigravity Batteries Micro Start XP1: Micro Start Details" (Micro Start XP 1, 2014) ....................................................................................................................................................... 22 Figure 19: Charging System Pulleys and Belt from First Mount Design ..................................... 25 Figure 20: Alternator Mount First Design .................................................................................... 25 Figure 21: Pitch Line Velocity (Juvinall & Marshek, 2012) ........................................................ 27 Figure 22: Tangential Force Applied to Gear Tooth (Juvinall & Marshek, 2012) ....................... 27 Figure 23: Gear Surface Fatigue Stress (Juvinall & Marshek, 2012) ........................................... 27 Figure 24: Alternator Mount Second Design ................................................................................ 29 Figure 25: Alternator Mount Third Design ................................................................................... 30 Figure 26: Alternator Gear Wear .................................................................................................. 31 Figure 27: Concept Design ........................................................................................................... 34 Figure 28: Final Airframe ............................................................................................................. 34 Figure 29: Various Pictures .......................................................................................................... 35 Figure 30: Initial Performance Conditions ................................................................................... 36 Figure 31: Flight Testing Takeoff Distance Graph ....................................................................... 37 Figure 32: Flight Testing Performance Graph .............................................................................. 37 Figure 33: Endurance Takeoff Graph ........................................................................................... 38 Figure 34: Endurance Performance Graph ................................................................................... 38 Figure 35: Static Margin vs Aircraft Weight (No Payload only Fuel) ........................................ 40 Figure 36: Bare Engine Dyno Stand ............................................................................................. 41 Figure 37: Laminating Fuselage Profiles (2 x 1/8" Birch Plywood) ............................................ 41 Figure 38: Laminating Upper Wing Mount (2 x 3/16” Birch Plywood) ...................................... 41 Figure 39: Laminating Various Fuselage ...................................................................................... 41 Figure 40: Initial Wing Mounting ................................................................................................ 42 Figure 41: Installation of Nose Gear ............................................................................................ 42 Figure 42: Fuselage Mock Up....................................................................................................... 42 Figure 43: Engine Mounted ......................................................................................................... 42 Figure 44: Upper Wing Mounting and Alignment Structure ........................................................ 43 Figure 45: Top of Lower Wing Mount ......................................................................................... 43 Figure 46: Unfinished modification to fuselage ........................................................................... 43 Figure 47: Lower Wing Installation and Customization ............................................................... 43 Figure 48: Setting Lower Wing Incidence Angle ........................................................................ 44 Figure 49: Initial Wiring Harness Configuration ......................................................................... 44 Figure 50: Bottom of Lower Wing Mount .................................................................................... 44 Figure 51: Completed Modification to Fuselage (Post Crash) .................................................... 44 Figure 52: Having to Disassemble the Battery to Use the Drill .................................................. 45 Figure 53: 3-Phase AC to DC Rectifier ....................................................................................... 45 Figure 54: Excessive Upper Wing Deflection .............................................................................. 45 Figure 55: Wing Struts Installed ................................................................................................... 45 Figure 56: Trimmed Propellers .................................................................................................... 46 Figure 57: How to Install Windows with Monocoat .................................................................... 46 Figure 58: Aluminum Nose Wheel Mount ................................................................................... 46 Figure 59: Base Camp @ AMA HQ ............................................................................................ 47 Page 2 of 80 Figure 60: Final Alternator Testing .............................................................................................. 47 Figure 61: Takeoff ........................................................................................................................ 48 Figure 62: Flight ........................................................................................................................... 49 Figure 63: Loss of Control & Final Moments .............................................................................. 49 Figure 64: Taxi & Flight Path ...................................................................................................... 50 Figure 65: Flight Test Data Graph ................................................................................................ 50 Figure 66: Expense Distribution ................................................................................................... 54 Figure 67: Weight Analysis .......................................................................................................... 55 Page 3 of 80 Table of Tables Table 1: Equations used in VI ......................................................................................................... 7 Table 2: Summary of performance parameters at 40 mph ............................................................ 10 Table 3: Summary of performance parameters at 50 mph ............................................................ 11 Table 4: Gear Surface Fatigue Stress Values ................................................................................ 27 Table 5: Alternate Gear Surface Fatigue Stress (Juvinall & Marshek, 2012) .............................. 27 Table 6: Alternate Gear Surface Fatigue Stress Values ................................................................ 28 Table 7: LEUAS Specifications .................................................................................................... 35 Table 8: LEUAS Flight Performance ........................................................................................... 36 Table 9: Fifteen Required Stability and Control Inputs ................................................................ 39 Table 10: Static Margin Results .................................................................................................... 40 Table 11: Flight Data Table .......................................................................................................... 50 Table 12: Expense Breakdown ..................................................................................................... 54