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Heavy Lift Cargo PlaneHeavy Lift Cargo Plane ProposalProposal
Matthew Chin, Aaron Dickerson, Matthew Chin, Aaron Dickerson, Brett J. Ulrich, Tzvee WoodBrett J. Ulrich, Tzvee Wood
October 5October 5thth, 2004, 2004Group #1 – Project #3Group #1 – Project #3
Project IntroductionProject Introduction The The apexapex of design courses, work will focus on of design courses, work will focus on
applying course knowledge to an industrial applying course knowledge to an industrial projectproject
Project will encompass planning, design, Project will encompass planning, design, construction and testing of a complete construction and testing of a complete engineering endeavorengineering endeavor
Teamwork and leadership skills will be an Teamwork and leadership skills will be an important factor in the synthesis of a complete important factor in the synthesis of a complete designdesign
Learn / Experience design process first hand Learn / Experience design process first hand from design to construction to testingfrom design to construction to testing
BackgroundBackground Need for heavy lift cargo Need for heavy lift cargo
planes to serve planes to serve energy/mining/military sectorsenergy/mining/military sectors
Short takeoff and landing Short takeoff and landing (STOL)(STOL)
Fuel efficiency for long range Fuel efficiency for long range transporttransport
Current market limited - Current market limited - Ukrainian-built Antonov only Ukrainian-built Antonov only real contender - Antonov An-real contender - Antonov An-225 capable of transporting 225 capable of transporting over 250 tons – only one builtover 250 tons – only one built
An-124 – 150 ton payload An-124 – 150 ton payload capacitycapacity
Project ImpactProject Impact
Change air transport optionsChange air transport options Enhance ability to distribute natural Enhance ability to distribute natural
resourcesresources Reduce shipping costs, time, and energy Reduce shipping costs, time, and energy
consumptionconsumption Broader military transport optionsBroader military transport options
Project ObjectivesProject Objectives
Compete in SAE Aero East Competition to Compete in SAE Aero East Competition to design a heavy lift cargo planedesign a heavy lift cargo plane
Apply areas of Mechanical Engineering Apply areas of Mechanical Engineering education to a real life problem:education to a real life problem:– DynamicsDynamics– Fluid MechanicsFluid Mechanics– Modeling & SimulationModeling & Simulation– Analysis of StressesAnalysis of Stresses
Competition SelectionCompetition Selection Regular Class:Regular Class:
– Maximum wing spanMaximum wing span– One type of engine, no modifications allowedOne type of engine, no modifications allowed
Open Class:Open Class:– No wing span restrictionNo wing span restriction– Any reciprocating internal combustion engine allowedAny reciprocating internal combustion engine allowed– Maximum empty weightMaximum empty weight
Micro Class:Micro Class:– No wing span restriction or weight limitNo wing span restriction or weight limit– Internal combustion or electrical engines allowedInternal combustion or electrical engines allowed– Winner determined by highest lift/weight ratioWinner determined by highest lift/weight ratio
Competition SelectionCompetition Selection
Open and Micro Class require more in-depth Open and Micro Class require more in-depth designdesign– Selection of engine & fuelSelection of engine & fuel– Gearbox ratios different from 1:1Gearbox ratios different from 1:1– Gyroscopic assist allowedGyroscopic assist allowed
Regular Class requires less design decisionsRegular Class requires less design decisions– Concentrate on Airfoil & Body DesignConcentrate on Airfoil & Body Design– Able to compete better with schools that focus on Able to compete better with schools that focus on
aerospace engineeringaerospace engineering– Stevens has previously entered Regular ClassStevens has previously entered Regular Class
2005 Regular Class 2005 Regular Class RequirementsRequirements
No lighter-than-air or rotary wing aircraftNo lighter-than-air or rotary wing aircraft Maximum wing span of 60 inchesMaximum wing span of 60 inches Take off zone of 200 feetTake off zone of 200 feet Landing zone of 400 feetLanding zone of 400 feet Single, unmodified O.S. .61FX Engine with Single, unmodified O.S. .61FX Engine with
E-4010 Muffler E-4010 Muffler Payload bay must enclose a block measuring Payload bay must enclose a block measuring
5 in. x 6 in. x 8 in.5 in. x 6 in. x 8 in. Plane that lifts the most winsPlane that lifts the most wins
2005 Regular Class 2005 Regular Class RequirementsRequirements
Cannot simply refine the 2004 entryCannot simply refine the 2004 entry Requirements vastly different in 2004:Requirements vastly different in 2004:
– 10 ft. wing span 10 ft. wing span minimumminimum– 6 in. x 5 in. x 4 in. payload bay6 in. x 5 in. x 4 in. payload bay
Some components can be re-used to Some components can be re-used to reduce cost:reduce cost:– Engine requirement is the same from 2004Engine requirement is the same from 2004– Functioning servos can be reusedFunctioning servos can be reused
Anticipated HurdlesAnticipated Hurdles
No group members have any previous No group members have any previous aerospace engineering experienceaerospace engineering experience
Rule changes have forced the team to Rule changes have forced the team to conceive a totally different design from conceive a totally different design from previous teamsprevious teams
Construction irregularities must be Construction irregularities must be minimized to produce results expected minimized to produce results expected from theoretical designfrom theoretical design
Overcoming the HurdlesOvercoming the Hurdles
Consultation with project advisor and past Consultation with project advisor and past competition participants will give insight into competition participants will give insight into aerospace design processaerospace design process– Existing research linksExisting research links– Techniques for design and buildingTechniques for design and building
WINFOIL software will be employed in aircraft WINFOIL software will be employed in aircraft designdesign– Enables trial and error approach to augment Enables trial and error approach to augment
theoretical calculationstheoretical calculations– Design can be exported to CADDesign can be exported to CAD– CAD drawings can be used with CNC machineryCAD drawings can be used with CNC machinery
Preliminary ConceptsPreliminary Concepts
Flying wingFlying wing– Fuselage is built into wing, cuts down on air Fuselage is built into wing, cuts down on air
resistanceresistance– Reduces material required for fuselageReduces material required for fuselage– May be difficult to support/brace payload bay properlyMay be difficult to support/brace payload bay properly
BiplaneBiplane– Larger wing surface areaLarger wing surface area– Increase in liftIncrease in lift– Not enough engine power suppliedNot enough engine power supplied
Preliminary ConceptsPreliminary Concepts
MonoplaneMonoplane– Clear and distinct partsClear and distinct parts– Easy to buildEasy to build– High lift when right wing is chosenHigh lift when right wing is chosen– Large quantity of known dataLarge quantity of known data– Rather “simple” calculationsRather “simple” calculations
Team selected Monoplane for designTeam selected Monoplane for design
Preliminary ConceptsPreliminary Concepts
Conceptual DesignsConceptual Designs
Limited conceptual designs available at Limited conceptual designs available at this time:this time:– No group member has previous aeronautical No group member has previous aeronautical
engineering or RC plane design experienceengineering or RC plane design experience– Competition requirements have only been Competition requirements have only been
available since the end of Septemberavailable since the end of September WINFOIL Software will be used in WINFOIL Software will be used in
developing wing and fuselage designdeveloping wing and fuselage design
Project Needs/MetricsProject Needs/Metrics
Project Needs/MetricsProject Needs/Metrics
Project Needs/MetricsProject Needs/Metrics
Heavy Lift ConsiderationsHeavy Lift Considerations
High lift versus Wing weight/StabilityHigh lift versus Wing weight/Stability MaterialMaterial Number of RibbingNumber of Ribbing Thickness of WingThickness of Wing Lesson Learned from last yearLesson Learned from last year FlapsFlaps
Max lift for areaMax lift for area Angle of wingAngle of wing Aspect RatioAspect Ratio Actual Type of Wing (ex. NACA 6409)Actual Type of Wing (ex. NACA 6409) Type of Plane (ex. Monoplane)Type of Plane (ex. Monoplane)
Preliminary WINFOIL TrialPreliminary WINFOIL Trial
3D Airfoil3D Airfoil
Future Planes:Future Planes:The TechnologyThe Technology
Entire planes tested and designed on the Entire planes tested and designed on the computercomputer
WingsWings Tail FinsTail Fins FuselageFuselage
No tedious calculationsNo tedious calculations No human errorsNo human errors Easy inputsEasy inputs Pretty graphs and easily interpretable resultsPretty graphs and easily interpretable results All plane data incorporated into programAll plane data incorporated into program
Sample CalculationsSample Calculations
Gantt ChartGantt ChartTask Name
1 Initial Project Review
1.1 Review General Air Foil Theory
1.2 Preliminary Senior Design Coordinator Meetings
1.3 Examine Existing RC Planes
1.4 Review Competition Requirements
1.4.1 Select Competition Class
1.4.2 Review Selected Class Requirements
1.5 Establish Requirements Matrix
2 Research & Development
2.1 Wings
2.1.1 Review Existing Wing Designs
2.1.2 Select Basic Wing Layout
2.1.3 Theoretical Design of Wing
2.1.4 Computer Aided Wing Analysis
2.1.5 Physical Modeling
Stereo-Lithography Session
2.2 Propeller
2.2.1 Existing Technology Review
2.2.2 Theoretical Propeller Design
2.2.3 Computer Aided Propeller Analysis
2.2.4 Physical Modeling
2.3 Fuselage
2.3.1 Aerodynamic Review
2.3.2 Theoretical Fuselage Design
2.3.3 Computer Aided Fuselage Design
2.3.4 Physical Modeling
3 Testing
3.1 Combine Wing, Propeller, Fuselage Models
3.2 Wind Tunnel Testing
3.3 Analyze Results
4 Reporting
4.1 Written
4.1.1 Project Proposal
Written Project Proposal Due
4.1.2 Semester Report
Written Semester Report
4.2 Oral
4.2.1 Project Proposal
Oral Project Proposal
4.2.2 Semester Report
Oral Final Report
F T S W S T M F T S W S T M F T S W S T M F T S W S T MAug 15, '04 Aug 29, '04 Sep 12, '04 Sep 26, '04 Oct 10, '04 Oct 24, '04 Nov 7, '04 Nov 21, '04 Dec 5, '04
Aaron 145 hrs
1.1 Review General Air Foil Theory 6 hrs
1.2 Preliminary Senior Design Coordinator Meetings 2 hrs
1.3 Examine Existing RC Planes 12 hrs
1.4.1 Select Competition Class 10 hrs
1.4.2 Review Selected Class Requirements 10 hrs
2.1.1 Review Existing Wing Designs 8 hrs
2.1.2 Select Basic Wing Layout 9 hrs
2.1.3 Theoretical Design of Wing 18 hrs
2.1.4 Computer Aided Wing Analysis 14 hrs
2.1.5 Physical Modeling 10 hrs
3.1 Combine Wing, Propeller, Fuselage Models 2 hrs
3.2 Wind Tunnel Testing 2 hrs
3.3 Analyze Results 1 hr
4.1.1 Project Proposal 4 hrs
4.1.2 Semester Report 14 hrs
4.2.1 Project Proposal 4 hrs
4.2.2 Semester Report 19 hrs
Brett 148 hrs
1.1 Review General Air Foil Theory 6 hrs
1.2 Preliminary Senior Design Coordinator Meetings 2 hrs
1.3 Examine Existing RC Planes 12 hrs
1.4.1 Select Competition Class 10 hrs
1.4.2 Review Selected Class Requirements 10 hrs
2.2.1 Existing Technology Review 9 hrs
2.2.2 Theoretical Propeller Design 9 hrs
2.2.3 Computer Aided Propeller Analysis 9 hrs
2.2.4 Physical Modeling 9 hrs
2.3.1 Aerodynamic Review 6 hrs
2.3.2 Theoretical Fuselage Design 8 hrs
2.3.3 Computer Aided Fuselage Design 6 hrs
2.3.4 Physical Modeling 4 hrs
3.1 Combine Wing, Propeller, Fuselage Models 2 hrs
3.2 Wind Tunnel Testing 2 hrs
3.3 Analyze Results 1 hr
4.1.1 Project Proposal 4 hrs
4.1.2 Semester Report 14 hrs
4.2.1 Project Proposal 6 hrs
4.2.2 Semester Report 19 hrs
Matt 148 hrs
1.1 Review General Air Foil Theory 6 hrs
1.2 Preliminary Senior Design Coordinator Meetings 2 hrs
1.3 Examine Existing RC Planes 12 hrs
1.4.1 Select Competition Class 10 hrs
1.4.2 Review Selected Class Requirements 10 hrs
2.2.1 Existing Technology Review 9 hrs
2.2.2 Theoretical Propeller Design 9 hrs
2.2.3 Computer Aided Propeller Analysis 9 hrs
2.2.4 Physical Modeling 9 hrs
2.3.1 Aerodynamic Review 6 hrs
2.3.2 Theoretical Fuselage Design 8 hrs
2.3.3 Computer Aided Fuselage Design 6 hrs
2.3.4 Physical Modeling 4 hrs
3.1 Combine Wing, Propeller, Fuselage Models 2 hrs
3.2 Wind Tunnel Testing 2 hrs
3.3 Analyze Results 1 hr
4.1.1 Project Proposal 4 hrs
4.1.2 Semester Report 14 hrs
4.2.1 Project Proposal 6 hrs
4.2.2 Semester Report 19 hrs
Tzvee 145 hrs
1.1 Review General Air Foil Theory 6 hrs
1.2 Preliminary Senior Design Coordinator Meetings 2 hrs
1.3 Examine Existing RC Planes 12 hrs
1.4.1 Select Competition Class 10 hrs
1.4.2 Review Selected Class Requirements 10 hrs
1.5 Establish Requirements Matrix 4 hrs
2.1.1 Review Existing Wing Designs 8 hrs
2.1.2 Select Basic Wing Layout 9 hrs
2.1.3 Theoretical Design of Wing 18 hrs
2.1.4 Computer Aided Wing Analysis 14 hrs
2.1.5 Physical Modeling 10 hrs
3.1 Combine Wing, Propeller, Fuselage Models 2 hrs
3.2 Wind Tunnel Testing 2 hrs
3.3 Analyze Results 1 hr
4.1.1 Project Proposal 4 hrs
4.1.2 Semester Report 14 hrs
4.2.1 Project Proposal 0 hrs
4.2.2 Semester Report 19 hrs
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Phase I: Design Phase I: Design BudgetBudget
Design budget does not include construction or Design budget does not include construction or competition costscompetition costs
Employee Cost:Employee Cost:– Wage: $30/hr (10 hrs per week, 14.5 weeks)Wage: $30/hr (10 hrs per week, 14.5 weeks)– Benefits estimated at 50% wages: $15/hrBenefits estimated at 50% wages: $15/hr– Total Phase I Employee Cost: $26,100Total Phase I Employee Cost: $26,100
Additional funds required to cover overhead Additional funds required to cover overhead estimated at approximately 50% of total labor estimated at approximately 50% of total labor cost: $13,050cost: $13,050
Total estimated Phase I Budget: $39,150Total estimated Phase I Budget: $39,150
Future DeliverablesFuture Deliverables
Conceptual design sketchesConceptual design sketches Final calculationsFinal calculations Metrics used in airfoil selectionMetrics used in airfoil selection Final plane design selectionFinal plane design selection Model of final designModel of final design Phase II: Construction BudgetPhase II: Construction Budget
ConclusionsConclusions
Design requirements dictate the Design requirements dictate the concentration on airfoil and fuselage concentration on airfoil and fuselage designdesign
Utilization of WINFOIL will enable the Utilization of WINFOIL will enable the design team to overcome any theoretical design team to overcome any theoretical inadequacies among team membersinadequacies among team members
Large scope of project dictates strict Large scope of project dictates strict adherence to the proposed GANTT Chartadherence to the proposed GANTT Chart
Feedback is Feedback is AppreciatedAppreciated
Thank YouThank You
ReferencesReferences http://airfieldmodels.com/information_source/index.htmhttp://airfieldmodels.com/information_source/index.htm http://web.umr.edu/~aavg/http://web.umr.edu/~aavg/ http://airfieldmodels.com/information_source/http://airfieldmodels.com/information_source/
math_and_science_of_model_aircraft/math_and_science_of_model_aircraft/flaperons_on_model_aircraft.htmflaperons_on_model_aircraft.htm
http://www.winfoil.com/http://www.winfoil.com/ http://www.ctaz.com/~kelcomp/airfoils5.htmhttp://www.ctaz.com/~kelcomp/airfoils5.htm http://www.pdas.com/index.htmhttp://www.pdas.com/index.htm http://www.centennialofflight.gov/essay/Theories_of_Flight/http://www.centennialofflight.gov/essay/Theories_of_Flight/
airplane/TH2.htmairplane/TH2.htm http://www.towerhobbies.com/rcwairinfo.htmlhttp://www.towerhobbies.com/rcwairinfo.html http://www.easyrc.com/airplanes/airplanes3.htmlhttp://www.easyrc.com/airplanes/airplanes3.html http://students.sae.org/competitions/aerodesign/east/http://students.sae.org/competitions/aerodesign/east/