rd ii daniel p. schrage georgia tech rotorcraft design ii: preliminary design dr. daniel p. schrage...

Daniel P. SchrageGeorgia Tech

RD II

Rotorcraft Design II:Preliminary Design

Dr. Daniel P. SchrageProfessor and Director, CERT & CASA

School of Aerospace EngineeringGeorgia Tech, Atlanta, GA


RD II

Course Outline• Review of Conceptual Design Solutions• Conceptual Design Issues for Resolution• Structural Design• Dynamics• Stability and Control• Drive System Design• Life Cycle Cost• Power Plant Selection and Installation• Secondary Power Systems• Weight and Balance• Maintainability• Reliability and Availability• Configuration and Arrangement


RD II

PRODUCT DEVELOPMENTPRODUCT DEVELOPMENT PROCESS DEVELOPMENTPROCESS DEVELOPMENTRequirements

Analysis(RFP)

Baseline VehicleModel Selection

(GT-IPPD)

Baseline UpgradeTargets

Vehicle Sizing &Performance(RF Method)

(GTPDP)

FAA Certification

ManufacturingProcesses(DELMIA)

Linear StaticStructural Analysis

(CATIA-ELFINI)

Multi-Body, Non-LinearDynamic Analysis

(DYMORE)

Linear & Non-LinearStructural Analysis

(NASTRAN/ABAQUS)

Stability and ControlAnalysis

(MATLAB/LMS/CATIA)

Cost Analysis(PC Based Cost

Model)

Reliability Modeling(PRISM)

Light Helicopter-GTX

Final Proposal

Revised PreliminaryConceptual Design

(CATIA)

Overall EvaluationCriterion Function

Georgia Tech Evolving Rotorcraft Preliminary Design Methodology

Support Processes(DELMIA)

Vehicle OperationSafety Processes

(DELMIA)

AerodynamicPerformance

Analysis (BEMT)

PropulsionPerformance

Analysis

Noise/VibrationCharacteristicsAnalysis (LMS)

Preliminary VehicleConfiguration Geometry

(CATIA)

Vehicle EngineeringAnalysis(CATIA)

Vehicle AssemblyProcesses(DELMIA)

Virtual Product DataManagement

(ENOVIA)

New Design Upgraded/Derivative. Design


RD II

Process DevelopmentProcess DevelopmentProduct DevelopmentProduct DevelopmentRequirements Analysis

(RFP)

Baseline Model Selection (IPPD)

Baseline PDS Targets

Vehicle Sizing & Performance(RF Method)

(GTPDP)

FAA Certification/Mil Qualification

Manufacturing Processes

Geometry/Static Analysis(CATIA)

Dynamic Analysis (DYMORE)

Structural Analysis (NASTRAN)

Stability and Control Analysis (MATLAB)

Cost Analysis(PC Based Cost Model)

Reliability Modeling(PRISM, etc.)

ITU LCHFinal Design

PreliminaryDesign

Overall Evaluation Criterion Function

Present Conceptual and Preliminary Design Approach

Operations & Support Processes

Safety Processes

CBEM Engine Model


RD II2003 AHS Student Design Competition: VTOL

Urban Disaster Response Vehicle (VUDRV) (Sponsored by Sikorsky Aircraft and NASA)

• Critical Milestones

• Response Requirements

• Competition Judging Criteria

• Conceptual Exploration Status

• Conceptual Design Issues for Resolutions

• Recommended Conceptual and Preliminary Design Approach


RD II

VUDRV Critical Milestones

• Release of RFP: October 21, 2002• Notice of intent to Compete: October 28, 2002• Teleconference w/Sikorsky: Oct 30,2002

on Problem Statement• Additional teleconferences: As Required• 2 page emerg results sumry: Feb. 15, 2003• Final report due: June 15, 2003• Winners announced: August 1, 2003


RD II

VUDRV Response Requirements

• A written report limited to100 pages shall provide the following:– Executive Summary (5 page summary of entire report & key findings)– Description of operational environment and mission requirements (add

critical requirements identified during concept exploration)• Detailed mission profiles shall be recommended for the following

missions:

– High rise Firefighter deployment– Roof Occupant extraction– Building face penetration and occupant recovery– Ground pump water cannon fire fighting– Self contained tank water cannon fire fighting– Disaster command and control


RD II

VUDRV Response Requirements• A written report limited to100 pages shall provide the

following (continued):– Concept evaluation and down-selection process and rationale– Selected Concept Preliminary Design

• Overview including concepts sketches in each mission role• Day in the life of the system description

– Timeline from 911 call to end of day• Vehicle Subsystem descriptions

– (airframe, rotors, drive, controls, avionics, landing gear…)– Include rationale for recommended subsystem technical

approach• Avionics system description including proposed operator interface• Mission kit descriptions as required for each mission• Weight empty derivations for primary vehicles• Mission gross weight derivations for each mission• Performance estimates and plots for each mission

– Such as time on station vs number of occupants recovered for building face extraction


RD II

VUDRV Response Requirements

• A written report limited to100 pages shall provide the following (continued):– Compliance matrix showing compliance with all

technical/mission requirements– Non-recurring and recurring unit cost estimates– Development schedule– Risk identification and Risk Reduction plan– Recommendation of how many systems would be required per

100,000 person city population– Concept sketch of future urban fire station with mix of ground

vehicles and proposed system(s)


RD II

VUDRV Competition Judging Criteria

• Innovation: 40%– Study shows ability to depart from conventional thinking and

paradigms to explore potentially high value solutions

• Understanding of the Problem: 10%– Study clearly demonstrates understanding of the real world

mission problem and the associated technical challenges

• Technical Content: 30%– Analysis and data is accurate and all methods used are well

understood. Underlying principles are well understood.

• Clarity: 20%– Report is clear, concise, and develops compelling case for

proposed solution. Emphasis is on clear graphics and diagrams to illustrate points and concepts


RD II

Review of VUDRV Conceptual Exploration Status

• Conceptual Design Selection still incomplete; however, not a problem based on RFP Requirements which places more emphasis on requirements, mission and operational analysis

• Initial Requirements Analysis well done and resulted in initial functional and resulting performance requirements

• More detailed mission and operational analysis required to further verify the performance requirements for concept selection


RD II

VUDRV Modes of Operation

• High-rise Firefighter Deployment– 15 Fire Fighters to Rooftop– 2 minute Cycle

• Rooftop Occupant Extraction– 1200 People/Hour

• Building Face Penetration / Occupant Recovery– 800 People/Hour

• Ground Pump Water Cannon Fire Fighting– Lift 5” Diameter Hose 1000

feet

• Onboard Tank Water Cannon Fire Fighting– 500 Gallon Tank; Refill in

60 seconds

• Disaster Command and Control– Occupant Locator– Information Gathering /

Transmitting

Define the Problem Requirements Analysis


RD II

VUDRV Operational Scenarios



RD II

VUDRV High-rise Firefighter Deployment

Land to Load Firementime = 0 sec

Land to Load Firementime = 120 sec

1500Feet

Radius of Action

20 naut. Mile

System Endurance > 1Hour

15 Firemen X 300 lbs.

4500 lbs.

Off Load Firemen

REPEAT

REPEAT

Define the Problem Requirements Analysis Operational Scenarios


RD II

VUDRV Rooftop Occupant Extraction

Unload Occupants1200 rescues/hour

REPEAT

UnloadLocation

Rooftop


Land to OffloadMission Supplies

time = 0 sec

1500Feet

Radius of Action

20 naut. Mile


Extract Occupants

REPEAT

REPEAT



RD II

VUDRV Building Face PenetrationOccupant Extraction


REPEAT

UnloadLocation

Rooftop



time = 0 sec

1500Feet

Radius of Action

20 naut. Mile


ExtractOccupantsFrom BuildingFace

REPEAT

REPEAT



RD II

VUDRV Water Cannon Fire FightingGround Pump

Land to UnloadMission Supplies

Hook up to GroundWater Pump Station

1000 ft.min

Radius of Action

20 naut. MileFight Fire Using

Water Cannon

5" DiameterWater House1500 gpm



RD II

VUDRV Water Cannon Fire FightingOnboard Tank

Land to UnloadMission Supplies

Hook up to GroundWater Pump Station

AnyFloor

Radius of Action

20 naut. MileFight Fire Using

Water Cannon

500 gallonOn-board Tank

Refill Tank60 seconds



RD II

VUDRV Disaster Command & Control


time = 0 sec

Radius of Action

20 naut. Mile

System Endurance > 2 hours1 hour at hover

1 hour at 60 knot cruise

Minimum of 4 personnel toOperate Command Center

MultiplexedCommunication

Develop Horizontal and VerticalTactical Displays with Overlay of

Information, Schematics, Maps, Etc.

Communicate Data andDecisions to Network on

Ground and in Air



RD II

VUDRV Utilization Environments

• Urban Canyon

• Low to Zero Visibility

• Turbulent Air

• High Temperature Exposure

• Extreme Weather Conditions

• Road Transport



RD II

VUDRV Functional Requirements

Mission300 lb Person

200 lb Person

Internal(assumed)

Module(assumed)

Persons Water External Total

FFD 15 0 612 1,000 4,500 0 5,500 6,112

RTOE 0 70 612 1,000 14,000 0 15,000 15,612

BFPOE 2 70 612 1,250 14,600 0 15,850 16,462

DWCFFgp 0 0 612 750 0 8,500 9,250 9,862

DWCFFip 0 0 612 750 0 4,164 4,914 5,526

CAC 0 4 612 2,000 800 0 2,800 3,412


Payload Capacity


RD II

VUDRV Performance Requirements

Useful Load: 16,500 lbs.

Forward Speed: 60+ knots

VROC5500 lbs.: 2500 ft/min

Hover Ceiling: 7,000+ ft ASL

OEIHOVER: 6000 ft ASL / 16,500 lb.

Endurance: 1 hr. hover / 1 hr. cruise



RD II

VUDRV Conceptual Design Issues for Resolution

• Is a new or derivative aircraft the preferred solution? (depends on the time frame when the system must be operational)

• The system is more than the vehicle; emphasis is on addressing the ‘system of systems’

• Strong emphasis must be placed on reconfigurability of the system for the different missions

• Strong emphasis must be placed on automatic flight control and sensor sub-systems


RD II

Recommended Conceptual and Preliminary Design Approach

• Should spend substantial more effort on completing the Conceptual Exploration and Design Effort

• Need to reach a decision on new or derivative system for the air vehicle (suggest telecon with Andy Keith, Sikorsky)

• Explore the use of the ASDL Mission and Unified Tradeoff Environment (UTE) for evaluating combinations of requirements, concepts and technologies (See Dr. Dan DeLaurentis, ASDL, A. Baker Ph.D Thesis)


RD II

Requirements (Mission) Space• Concept Space - vehicles attributes used as factors in DoE, built

around baseline vehicle

• Technology Space - technology metric dials used as factors in DoE, built around baseline vehicle

• Mission Space

• Compatibility with Concept Space and Technology Space

• Mission requirements used as factors in DoE, built around baseline vehicle

• Based on a Master Mission Structure which captures primary missions and provides reference point for understanding mission parameter effects on system sizing.

• Allows capture of multiple missions and provides continuous mission space

• Secondary missions flown after sizing to determine performance


RD II

Master Mission Structure

Taxi / Warm-up

Hover 1 (OGE)

Cruise 1

Mid Hover (OGE)

Drop Payload

Cruise 2

Cruise 3

Hover 2 (OGE)

Fuel ReserveVelocity Best EnduranceTime 30 min

Payload

Altitude Temperature

Hover 1 Time

Cruise 1 Combat Radius

Payload Dropped

Cruise 3 Altitude

Cruise 3 TemperatureCruise 3 Combat Radius

Hover 2 TimeVertical ROC

Common Requirements

Cruise 1 Flat Plate Drag Area


RD II

Functionally Relating Responses and Inputs

Response = fcn (Requirements, Concepts, Technologies)

Technology Dials (related to product

and/or process)

Top-Level requirements related to the

mission

Vehicle Attribute Variables

Potentially large number of inputs;

To cope, evaluate response in “snapshots”, where most inputs are held constant while a subset of the inputs varies

Each “snapshot” computes “deltas” in responses with respect to a baseline

This approach allows the additive combination of the effects of concepts, technologies, and requirements on the decision-making space

Objective (O) or System Level

Attribute (SLA)


RD II

Unified Tradeoff Environment• What is needed is a design environment that allows the designer to

assess the simultaneous impact of changes in mission requirements, vehicle attributes and technologies while being amenable to probabilistic techniques.

• Whether constructed as an integrated environment or built from individual spaces this design environment is called the Unified Tradeoff Environment (UTE).

• Integrated UTE

• Multi-Space UTE

• Most logical breakdown considers design spaces already created.

• Concerns with multiple spaces.


RD IIMulti-Space Unified Tradeoff Environment

Technology Space Mission Space

R

esp

on

ses

Mission Requirements

Snapshot 1

R

esp

on

ses

Technology Dials

Snapshot 3

Vehicle Attributes

Snapshot 2

Concept Space

(Vehicle Attributes)

Baseline +

Fixed Geometry, Technology SetFixed Requirements, Geometry

Fixed Requirements, Technology Set

R

esp

on

ses

R

esp

on

ses

(Technology Dials)(Mission Requirements)


RD II

Concerns with Multi-Space UTE

Mission Space

Mission Requirements

R

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po

ns

es

Vehicle Attributes

Concept Space

R

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po

ns

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Technology Space

Technology Dials

R

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Engineering Knowledge/Analysis Codes

Modified Screening Test

Sizing Variables

• Independence - Correlation

• Across-Design-Space Interactions

• Sizing Effects


RD II

ITU LCH Conceptual and Preliminary Design Effort

• Baseline Istanbul Technical University (ITU) Light Commercial Helicopter (LCH) Prototype Requirements

• Status of ITU LCH Conceptual Design effort

• Proposed approach for conducting the ITU LCH Preliminary Design effort


RD II

Baseline ITU Light LCH Prototype Requirements

• A Challenging set of requirements were provided to GIT and ITU Student Design Teams

• Results from GIT and ITU individual and team design efforts appear to substantiate the feasibility of meeting the requirements

• A baseline ITU LCH Conceptual Design has been established

• Some refinements to the ITU LCH Conceptual Design will be made and an ITU LCH Product Design Specification (PDS) established


RD II

ITU LCH Specification SummaryITU LCH Specification SummarySeating 2 crew, 4 pax (6 high density)

Anti-torque NOTARHub Hanson EA

Engine GAP Turboshaft 500 Hp MCPTransmission 650 shp COTS TOPLanding Gear Metal SkidFlight Controls Mech push-pull

SCAS Electric Yaw SASAirfoil VR-7

Drag polar Cd = .0081 + .4494*2

WG 3950 lbWE 1660 lbWU 1500 lbWF 790 lb

Fuel cap. 116.2 galEW/GW 0.42Height 9 ft

Width (max) 6 ftLength 31.25 ft

Tip Speed 650 fpsDisk Loading 5.48 lb/sqft

Solidity 0.07# Blades 4Disk Area 721 sqftMR Radius 15.15 ft

MR blade chord 0.83 ftMR blade twist -12 deg

42.9MR blade AR 18.26Lock number 6.45

Max Lift curve slope 6.45 per radBlade loading 78.6 lb/sqft

Blade lift 988.36 lbCF (each blade) 20486.8 lbBlade tip weight 6 lb

Rotor Polar Moment 604 slug-ft2

Flare Factor 51.3flat plate drag area 10 sqft

Ixx 421.015 slug-ft2

Iyy 1015 slug-ft2

Izz 853.485 slug-ft2


RD IIITU LCH Conceptual Design ITU LCH Conceptual Design

SummarySummaryRFP ActualPerformance Gross Weight < 4500 lbs 3950

OGE Hover Ceiling 10,000 ft ISA +20 deg NoCruise Speed > 120 kts 123Range >350 (w/20 min reserve 381

Stability & ControlCooper/Harper Rating <3.5 YesTraining Time <10 hrs ???Very Safe Auto K factor > 1.35 sec 1.43

Useful Load Cockpit seating 2 (1 pilot) 2Cabin seating 4 (standard config) 4

6 (high density) 5Cost Acquisition (2002 $) < 400 k Yes

DOC < $100 YesAirframe < $50 Yes

Maintainability Maint. Man hr/flt hr 0.8 ??Reliability Total System MTBF > 20 hrs 20.5Weights EW/GW fraction < .45 0.42

Noise External:MR Tip Speed < 650 fps 650TR Tip Speed < 600 fps N/A

InternalUtility Version < 75 dB 70Exec. Version < 70 dB 70

Avionics Both VFR & IFR certified YesEnglish/Metric Accommodates both Yes


RD IIITU LCH Conceptual Design ITU LCH Conceptual Design

SummarySummaryRFP ActualGross Weight < 4500 lbs 3950OGE Hover Ceiling 10,000 ft ISA +20 deg No at 3650 lbsCruise Speed > 120 kts 123 from GTPDPRange >350 (w/20 min reserve 381 422-reserve

Cooper/Harper Rating <3.5 Yes verify with JeffTraining Time <10 hrs ???Very Safe Auto K factor > 1.35 sec 1.43 from JeffCockpit seating 2 (1 pilot) 2Cabin seating 4 (standard config) 4

6 (high density) 5 assuming 175 lbs ea (total of 8)Acquisition (2002 $) < 400 k Yes get from RichDOC < $100 Yes get from RichAirframe < $50 Yes get from RichMaint. Man hr/flt hr 0.8 ?? get from RichTotal System MTBF > 20 hrs 20.5 get from RichEW/GW fraction < .45 0.42External:

MR Tip Speed < 650 fps 650TR Tip Speed < 600 fps N/A

InternalUtility Version < 75 dB 70Exec. Version < 70 dB 70

Both VFR & IFR certified Yes verify with JeffAccommodates both Yes


RD II

GTX-Pegasus Three View Depiction (MD-500E Derivative – Not ITU LCH Baseline)


RD II

GTX- Pegasus Isometric Depiction


RD II

ITU LCH Conceptual Design Status

• The ITU LCH Conceptual Design is nearly complete and will be by the end of January 2003

• A Product Design Specification (PDS) will be prepared to document the ITU LCH Conceptual Design

• The ITU LCH Preliminary Design Effort will be initiated based on the PDS


RD II

Proposed approach for conducting the ITU LCH Preliminary Design effort

• The PD Approach is illustrated in the following figure and will emphasize the Product Development (Left Side) process

• Will be conducted jointly by ITU and GIT Faculty, Research Engineers, Post Docs, and Students over the next four months

• Will include Monthly In Process Reviews (IPRs) to review and approve the status and configuration for the ITU LCH


RD II

Process DevelopmentProcess DevelopmentProduct DevelopmentProduct DevelopmentRequirements Analysis

(RFP)

Baseline Model Selection (IPPD)

Baseline PDS Targets

Vehicle Sizing & Performance(RF Method)

(GTPDP)

FAA Certification/Mil Qualification

Manufacturing Processes

Geometry/Static Analysis(CATIA)

Dynamic Analysis (DYMORE)

Structural Analysis (NASTRAN)

Stability and Control Analysis (MATLAB)

Cost Analysis(PC Based Cost Model)

Reliability Modeling(PRISM, etc.)

ITU LCHFinal Design

PreliminaryDesign

Overall Evaluation Criterion Function

ITU LCH Preliminary Design Approach

Operations & Support Processes

Safety Processes

CBEM Engine Model


RD II

Planned ASD ITU LCH PD Support• The following design support activities are planned in conjunction with the ITU

LCH Design Team:– Development of the Initial Product Design Specification (PDS) – completed by

end of January 2003– Conceptual Designs for the ITU LCH – Baseline Conceptual Design

completed in GTPDP by end of January 2003, to include airfoil, blade planform, and baseline engines (turboshaft and piston/rotary)

– Rotor Airfoil & Blade Planform Trade Study – Complete by 15 February 2003– Develop DYMORE Dynamic Model of ITU LCH Rotor by 15 February 2003– Develop a CATIA Model of the ITU LCH by 15 February 2003– Conduct Stability & Control Analysis for the ITU LCH by 15 March 2003– Conduct Structures & Dynamics Analysis for the ITU LCH by 15 April 2003– Finalize the Preliminary Design and Complete & Deliver the ITU LCH Final

Report by 15 May 2003

rd ii daniel p. schrage georgia tech rotorcraft design ii: preliminary design dr. daniel p. schrage...

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