hale uav preliminary design aersp 402b spring 2014 team: nsfw nisherag gandhithomas gempp doug...
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HALE UAV Preliminary Design
AERSP 402BSpring 2014
Team: NSFW
Nisherag Gandhi Thomas Gempp
Doug Rohrbaugh Gregory Snyder
Steve Stanek Victor Thomas
SAURON
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Mission Statement
To design a High Altitude / Long Endurance (HALE) UAV using alternative fuel sources to support homeland security efforts with a concentration in long term border security.
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Design Changesv1
v3
v2
v4
v5
v6
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Sauron v7
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Design Changes – Wing and Tail
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Design Changes – Landing Gear
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DimensionsParameter Wing Tail
Airfoil SM701 Jouk0015
Span (ft.) 128.6 18.0
Reference Chord (ft.) 4.0 2.5
Area (ft.2) 557.5 45.0
Cruise CL 0.66 0.09
Span Efficiency 1.01
Max CL 1.4
Power Generated (kW) 16.93
Aspect Ratio 29.6
Neutral Point Location (ft.) 13.4
C.G. Location (ft.) 13.2
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Wing/Tail Lift Distribution
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Structures – Materials
• HexPly M91 - Epoxy Matrix for primary aerospace structure
• High residual compression strength after impact (CAI)
• Supports automated manufacturing• HexTow IM10 - Carbon Fiber 12k
tow• Suitable for weaving, pre-pregging,
filament winding, braiding, and pultrusion
• Enhanced tensile properties• Highest commercially available
tensile strength
* Avg. cost: $45/lb.
M91/IM10
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Structures – Materials
Epoxy-Fiber (Prepreg) Combination (M91/IM10)Theoretical Values
Cured Ply Thickness (in) ~ 0.0072
Fiber Volume (%) ~ 58.9
Laminate Density (g/cm3) ~ 1.4
Laminate Modulus (GPa) ~ 200
Tensile Strength (MPa) ~ 3620
HexTow IM10 Carbon Fiber
# of Filaments 12000
Filament Diameter (microns) 4.4
Tensile Strength (MPa) 6964
Tensile Modulus (GPa) 310
Strain (%) 2.0
Density (g/cm3) 1.79
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Wing – Spar Design
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Wing – Weight and Lift Distribution
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Wing – Moment and Stress
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Wing – Deflection
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Wing Deflection Analysis
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H &V Stabilizer Spar Design
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Horizontal Stabilizer – Lift Distribution
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H. Stabilizer – Moment and Stress
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H. Stabilizer – Wing Deflection
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Vertical Stabilizer – Weight and Lift Distribution
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V. Stabilizer – Moment and Stress
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V. Stabilizer - Deflection
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Weight BreakdownAircraft Part Empty Weight (lbs)
Wing 126.89
Fuselage 32.77
Horizontal Stabilizer 10.24
Vertical Stabilizer 3.98
Solar Cell 87.53
Wing Spar 70.38
Vertical Stab Spar 0.71
Horizontal Stab Spar 1.87
4 Motors 16.00
Fuselage Formers 15.00
Gear System 40.00
Total Empty Weight 404.44
Parameter Empty Weight (lbs)
Total Empty Weight 404.44
Battery 180.00
Payload 250.00
Total 834.44
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Control Surfaces
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Aileron
Control Surface Area: 3%
Pcruise|61k ft = 13.8 deg/sec
Pstall|61k ft= 11.5 deg/sec
Required Aileron Deflection =10°
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Elevator
Control Surface Area: 46.7%
Pitch Rate= 9 deg/sec
Required Elevator Deflection= -2.6°
Lift Coefficient, CL Elevator Deflection (°)
0.1 1.55
0.4 0.90
0.66 0.25
1.0 -0.74
1.4 -2.14
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Rudder
Control Surface Area: 42.9%
Rudder Deflection: 20°
Maximum Sidewash: 10°
Max Crosswind: 12.5 ft/s
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Control Surface Demo
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Airfoil Selection
Wing Airfoil H&V Stabilizer Airfoil
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Updated Drag Analysis
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Updated Drag AnalysisSea Level 45,000 feet 61,000 feet 79,000 feet
Stall Speed (ft/s) 37.0 83.9 122.3 188.7
Cruise Speed (ft/s) 44.4 100.7 146.8 226.5
Max Speed (ft/s) 113.0 191.5 245.3 294.0
Total Drag (lbs) 18.4 20.3 22.5 26.9
Power Required (kW) 1.05 2.7 4.3 8.1
Reynolds’ Number 1,129,663.40 626,856.80 429,692.6 274,504.6
CDo 0.0087 0.01 0.0105 0.0125
Oswald’s Efficiency 0.76 0.73 0.69 0.63
Max L/D 46.7 42.4 38.2 31.9
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Updated Power Analysis
0 5 10 15 20 25 30 35 40 45 500
2
4
6
8
10
12
14
1648 hour UAV Power Plan
Time (hours)
Pow
er (
Kilo
wa
tts)
Previous Power CalculationCurrent Power Calculation
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TakeoffParameter Sea Level Denver Afghanistan
Ground Roll [ft]
Vtakeoff [ft/s]
dab|35ft [ft]
dab|50ft [ft]
Dtotal|35ft [ft]
Dtotal|50ft [ft]
Thrust [lbs]
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LandingParameter Sea Level Denver AfghanistanVa [ft/s]
γa [deg]
Radius [ft]
Flare Height [ft]
Flare Speed [ft/s]
da35ft [ft]
da50ft [ft]
df [ft]
VTD [ft/s]
Thrust [lbs]
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Constraint Diagram
Original
Current
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Cost AnalysisFixed Costs for 5 Developmental Aircraft:
– Engineering Costs: $29,869,717.35
– Flight Test Ops: $17,638,487.67
– Tooling: $4,567,827.99
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Pricing
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Pricing Summary1 10 100 500 1000
Design Aircraft 5
Engineering Costs $ 29,869,717.35
Flight Test Ops $ 17,638,487.67
Tooling Costs $ 4,567,827.99
Manufacturing Costs $ 3,411,149.77 $ 14,924,534.27 $ 65,298,136.52 $ 183,206,365.99 $ 285,693,781.52
Quality Control Costs $ 490,688.06 $ 2,146,868.71 $ 9,393,025.19 $ 26,353,922.21 $ 41,096,561.54
Total Materials Costs $ 889,569.58 $ 2,223,923.96 $ 15,567,467.69 $ 74,872,106.51 $ 149,002,905.04
Design Materials Costs $ 741,307.99 $ 741,307.99 $ 741,307.99 $ 741,307.99 $ 741,307.99
Production Materials Costs $ 148,261.60 $ 1,482,615.97 $ 14,826,159.71 $ 74,130,798.53 $ 148,261,597.05
Total Frame Costs $ 60,725,386.10 $ 75,229,305.63 $ 146,192,608.09 $ 340,366,373.41 $ 531,727,226.80
Minimum Price Per UAV $ 60,725,386.10 $ 7,522,930.56 $ 1,461,926.08 $ 680,732.75 $ 531,727.23
* +$2M per for custom sensory packages
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Comparison to Competitors
• RQ-1/MQ-1 Predator– Unit Cost: $4.03M– 360 Built
• MQ-9 Reaper– Unit Cost: $16.9M– 104 Built
• RQ-4 Global Hawk– Unit Cost: $131.4M– 42 Built
• Solara 50/60– Unit Cost: $1-2M– N/A Built
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Questions?
14 Days ‘Til Graduation
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Double Camera
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Summary