EDGE™

Final Project PlanP09123 – MAV Platform Structure

Joe Hozdic (Mechanical Engineering)

EDGE™

Basic Project Information

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

• 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) – Confirmed

• Faculty Consultant– Dr. Agamemnon Crassidis (Mechanical Engineering) –Confirmed– Dr. Amitabha Ghosh (Mechanical Engineering) – Not Confirmed

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

• Secondary Customer – MAV09 Flight Competition

EDGE™

Planning: Project Mission Statement

Product Description /Project Overview

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 Structure 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.

Key Business Goals/Project Deliverables• Materials Research, Testing, and Manufacturability• Evaluate Structural Integrity of Airframe and Components• Determine Crash Worthiness and Failure Modes• Equipment Protection, Packaging, and Mounting

EDGE™

Planning: Project Mission StatementPrimary Market /Project Opportunities

The primary market for this project is the RIT MAV team, their future vehicle development, and the push toward a fully autonomous vehicle

Secondary Market /Project Opportunities–US/European MAV 2009 Competition –DARPA –CIA –Military –Coast Guard –HAZMAT Teams –National Weather Service

Stakeholders

- RIT MAV Team- Dr. Jeffery Kozak- 2008 MAV Competition – Rules and Regulations- Erik Bellandi – P09122- Micro Air Vehicle (MAV) Control System- Aaron Nash – P09121 - Micro Air Vehicle (MAV) Airframe and Propulsion System- Future Sponsors

EDGE™

Planning: Staffing Requirements

Name Discipline Role

Dr. Jeffery Kozak Mechanical Engineering Faculty Guide

TBD Mechanical Engineering Faculty Consultant

Joseph Hozdic Mechanical Engineering Project Manager/Chief Engineer

TBD ME Student Mechanical Engineering Design Engineer

TBD ME Student Mechanical Engineering Materials Engineer

TBD ME Student Mechanical Engineering Structural/Fluid Analyst

TBD IE Student Industrial Engineering Manufacturing Engineer

TBD ME/MET Student Mechanical Engineering/Tech Test Engineer

EDGE™

Project Manager/Chief Engineer (ME)

– Oversee all project activities and assign appropriate tasks to all group members

– Actively participate in procuring project endorsement and facilitating customer communication.

– Responsible for ensuring that the project is delivered successfully, on time, and under budget.

– Work with the Project Managers of concurrent MAV projects toward a successful integration scheme.

– Oversee all technical aspects of the design and assist team members wherever possible.

Design Engineer (ME)

– Responsible for the overall mechanical design of the MAV Platform.– Will work closely with the materials and manufacturing engineers to

develop a successful product.– Must be able to perform fundamental engineering analysis, in a variety of

disciplines, in order to ensure that product will meet all design goals.

Planning: Staffing Requirements

EDGE™

Planning: Staffing Requirements

Materials Engineer (ME)

– Responsible for all material selection and testing. – During the early stages of the project, the Materials Engineer will conduct

tests and collect data on a variety of possible materials. – Will work closely with Design Engineer and Structural Analyst to select

proper materials for a successful design. – Will work with Manufacturing Engineer to assess the manufacturability of all

components.

Structural/Fluid Analyst (ME)

– Responsible for the detailed structural and fluid analysis of the design. – Must be able to perform complex engineering calculations, analysis, and

simulations for all aspects of the design. – Must have experience and knowledge in the areas of Finite Element

Analysis (FEA) and Computational Fluid Dynamics (CFD) and their application.

EDGE™

Planning: Staffing Requirements

Manufacturing Engineer (IE)

– Responsible for all manufacturing actions and decisions. – Must ensure that the product can be produced cheaply and efficiently with

the materials and methods available. – Will work closely with the designer and material expert to develop a

production process that meets and/or exceeds the project goals for manufacturability.

Test Engineer (ME/MET)

– Responsible for developing a detailed test plan throughout the design process.

– Will conduct all testing and verification of the product during the final stages of the project.

– Will work with the Materials Engineer to develop standard testing procedures for all materials.

EDGE™

All Team Members

– All team members should be capable of working well with others in a structured team environment.

– All team members will be responsible for procuring components and materials, documenting the detailed design, as well as all other administrative work.

– All team members should keep the schedule, time constraints, cost, and project goals in mind while performing their duties.

– All team members should make an effort to secure outside funding for the project and attract new sponsors.

– All team members are encouraged to work outside of their specific role in order to assist other team members when necessary.

Planning: Staffing Requirements

EDGE™

Intellectual Property Considerations

All work to be completed by students in this track is expected to be released to the public domain. Students, Faculty, Staff, and other participants in the project will be expected to release rights to their designs, documents, drawings, etc., to the public domain, so that others may freely build upon the results and findings without constraint.

Students, Faculty, and Staff associated with the project are encouraged to publish findings, data, and results openly.

To be reviewed when adding any future sponsors

EDGE™

Preliminary Work Breakdown Structure Overview

MAV Structural

MaterialsAnd

Manufacturing

Structural Design

Develop Packaging

and Protection

Evaluate Crash

Worthiness

Research TestingAirframe Design

Airframe Analysis

Component Protection

Mounting Points

Analysis Testing

EDGE™

Preliminary Work Breakdown Structure Details

MAV Structural

Materialsand Manufacturing

Structural Design

Research Testing

Types of Material

Historical Uses

Impact Testing

Strength Testing

Vibration Testing

Airframe Design Airframe Analysis

Fuselage Structure

Flight Surfaces

Flight Environment

Vibrations

Input from Aero Design

Control Surfaces

Manufacturability

Methods

Tooling

Resources

EDGE™

Preliminary Work Breakdown Structure Details

MAV Structural

Develop Packaging and Protection

Evaluate Crash Worthiness

Component Protection

Mounting Points

Analysis Testing

Impact Testing

Failure Modes

Survivability

Simulation

Input from materials research

Input from Controls Group

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Preliminary Schedule - MSD 1

EDGE™

Preliminary Schedule MSD 2

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Team Values and NormsPunctual

Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict comes up, the absent team member will notify at least one team-mate prior to the expected absence. An absent team-member should confirm that a team-mate has received their message (in person, voice mail, email, etc).

ThoroughEach team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person.

AccurateEach team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow.

Professional and EthicalEach team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers.

Committed Each team member will contribute an equal share to the success of the project.

Demonstrates the core RIT values of SPIRIT.

EDGE™

Team Values and Norms

CompetentEach team member will perform his/her duties to the best of their ability. It is every team members job to posses any skills that are necessary for the completion of the project. If a team member does not possess a particular skill, it is that person's responsibility to learn it, even if it means going outside of his/her discipline. During the project it may be necessary to perform skills and techniques that you have not been trained for.

Adaptable22 weeks is a very tight schedule for a project of this magnitude. Each team member must be able to adapt to a rapidly changing schedule, as well as scope creep, changing requirements, and a shrinking budget. Each team member must be ready to assist other team members with their tasks in addition to performing their own role.

EDGE™

Grading Assessment SchemeGRADE MSD I MSD I I

A

-follows proper engineering process -meets or exceeds all design criteria -documents reasons for failure (if any) -all work is properly documented -performs assigned function and helps others when possible

-complete and working prototype -detailed design documentation -proof of concept -extra effort and well organized

B

-basic effort toward completeing tasks -mediocre documentation -unexplained shortcomings -missing small details

-working prototype -semi documented design package -meets project goals with little effort

C

-minimal effort when performing tasks - little documentation -poor performance -some tasks missing/ incomplete

-semi developed prototype -minimal effort towards design package -some project goals are met

D

-no attempt to follow process -project is missing important aspects -no clear path or direction -not enough input to the team

-no working prototype - incomplete/missing design - little effort toward project -no explaination for failure

EDGE™

Required Resources - Environment

Item Source Description Available

Computer Labs KGCOE PC Based Tools and Analysis Yes

Machine Shop ME 09-2360 Fabrication Yes

Brinkman Lab ME Dept CNC Machining Yes

Materials Science Lab KGCOE Material Testing Yes

Mechanics Lab KGCOE 09- Material Testing Yes

Aeromechanics Lab KGCOE 09- Aerodynamic Testing Yes

General Workspace MSD Center/Aero Club Room General Workspace Yes

EDGE™

Required Resources - Equipment/Software

Item Source Description Available

Desktop PC Computer LabsWorkstation with high end computing power for FEA/CFD

Yes

ANSYS ME PC LabSoftware for performing Finite Element Analysis

Yes

Fluent/ ANSYS CFX CFD LabSoftware for performing CFD analysis

Yes

CAD Software ME PC Lab3-D Modeling Software (ProE, Solidworks, NX 5.0)

Yes

MS Office Any PC LabDocumentation, Presentations, General Word Processing

Yes

Strength Testing Equipment

Mechanics Lab, Material Science Lab

Material Testing Equipment (tensile, torsion, impact, etc)

Yes

Wind Tunnel Aeromechanics Lab Aerodynamic Testing and Validation Yes

EDGE™

Concept Development- Identify Customer Needs

– Provide undergraduate students with a hands on aero project– Allow for addition of various sensors and other equipment– Integrate various control devices and inputs into the structure– Provide a stable platform from which to base future MAV projects

and designs– Provide opportunities for graduate level research projects– Stay within guidelines of MAV09 Competition rules with goal of

entering the competition within the next few years– The Micro Air Vehicle needs to be:

1. Cost effective2. Easy to manufacture 3. Made from readily available materials4. Less than 1 kg in weight, and 80 cm in any dimension5. Made from lightweight materials6. Able to survive a crash with minimal damage to critical

components7. Capable of withstanding sustained flight loads8. Self-sustainable

EDGE™

Identify Customer Needs - Objective Tree

Develop Structural Portion of Future

MAV Platform

Light Weight and Strong Structure

Integrate Control Devices and Hardware

Reusable PlatformMAV09 FlightCompetition

Undergrad Aero Projects

Graduate Level Research

Future designs use same airframe

Provide Protection for critical devices

Room for addition of new hardware

Light MaterialsKeep within weight

and size requirements

Allow for ExpansionEasy to manufacture

Heavy use of composites

Readily available materials and parts

Readily available materials

Allow for Expansion

EDGE™

Identify Customer Needs - Needs Hierarchy

•Provide a stable platform for future MAV projects•Hands on aero project for undergraduate students•Base model for future senior design projects•Support for graduate level research projects

•Allow for future development and easy integration•Allow for addition of various sensors and other equipment•Integrate various control devices and inputs into the structure

•Design within guide lines of MAV09 Competition rules•Less than 1 kg in weight, and 80 cm in any dimension•Made from lightweight materials•Capable of withstanding sustained flight loads

•MAV projects must be self-sustainable•Cost effective•Easy to manufacture •Made from readily available materials•Able to survive a crash with minimal damage to critical components

EDGE™

Establishing Target Specifications List of Metrics

No. Metric Importance Units1 # of Sponsors 3 num2 Overall Mass 4 lbs (g)3 Time to Build 3 hours4 Overall Cost 3 USD5 Payload Margin 2 lbs (g)6 Mounting Surfaces 2 num.7 Interior Volume 2 cu.in. (cc)8 Interior Dimensions 2 in. (mm)9 Useability 1 subj.10 Life Cycle 2 cycles11 Consistancy 3 subj.12 Exterior Dimensions 4 in. (mm)13 Energy Absorption 3 ft-lbs (J )14 Material Strength 4 psi (kpa)15 Flight Time 4 s16 Natural Frequency 3 Hz17 Stiffness 3 lbs/ in (N/m)18 Budget 3 USD

EDGE™

Establishing Target Specifications

Needs-Metrics Matrix

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NeedsHands-on Undergrad Project x x x

Integration of additional Hardware x x x x

Ability to integrate components x x x x

Stable Developmental Platform x x x x

Graduate Research x x x

Follow Competition Rules x x

Cost Effective x x x

Easy to Build x x

Readily Available Materials x x

Less than 1 kg x

Light Weight Materials x x

80cm Max Lateral Dimension x

Crash Survivability x x x

Withstand Sustained Flight Loads x x x x xSelf-Sustainable Program x x

EDGE™

Issues and RisksRisk Possible Consequences

Probability of Risk (H/M/L)

Severity of Risk (H/M/L)

Overall Risk

(H/M/L)Contingency Plan

Materials are too heavy once built

Vehicle over weight limit, does not qualify for competition, vehicle may not fly

M H MReview design, look to past MAV design for support since it is under the limit

Vehicle does not survive crash test

Microcontroller and other components may be damaged during actual flight

L H MMicro controller will not be flown in plane until crash surviveability is achieved

Vehicle dimensions outside envelope

Vehicle not qualified for competition L M L

MAV team will not attend competion. Next senior design project will be used to reduce size of vehicle

Components do not fit inside plane

Vital functions (flight control) may be lost

L M MRevise 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 overall performance for design simplicity

Aero and Structural project overlap

repeat tasks, both projects completing same work, information is lost, some design details may be over looked

M M M

The two projects may be combined into one project. This would reduce the risk of design overlap

Budget runs outUnable to procure necessary materials and resources

L L LAlternate sources of funding - Pizza Sale?

EDGE™

Outstanding Items:– Coordinate with aero design project and controls

design projects

– Update remaining sections on EDGE

– Pursue external funding over the summer

– Start recruiting team members

– Additional Risks (Early Stages of MSD1)

Recommendation:Merge the Structural (P09123) and Aero

(P09121) into one PRP