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SAE Aero Team

Design Review

Presented by:

Parker Chenoweth

Andy Eash

Nathaniel Ritzman

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Presentation Program

Project Overview

Electrical Systems

Mechanical Design

Budget

Schedule

Testing

Future

Conclusion

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Project Overview

SAE Aero Design East Competition: March 9th-11th in Lakeland, Florida

Our Mission Statement:

  • To design and build a remote controlled model airplane in accordance with SAE Aero Design competition rules which will carry a maximum number of passengers (tennis balls) with their respective luggage (weights) propelled by a power-limited motor.

21 Tennis Balls, 11-15 lbs of extra weight

To fly 3+ times at competition

​

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Electrical Overview

Battery

Motor

Servos

ESC

Transmitter

Receiver

Power Limiter

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Battery

Requirements

  • 22.2 V (6 cell) Lithium Polymer
  • 3000 mAh capacity (min)
  • 25 C discharge rate (min)
  • Commercially available
  • Only form of stored energy

Basher

  • 22.2 V (6 cell LiPo)
  • 4000 mAh
  • 65 C
  • $47.66
  • 795 g

Factors

Weight

Turnigy

Turnigy

Turnigy

Basher

Turnigy Heavy D

Capacity

0.1

3

0

0

10

10

Discharge Rate

0.3

2

2

4

9

8

Weight

0.2

7.86

7.86

7.14

5.00

3.57

XT60 connector

0.1

10

10

10

0

0

Price

0.3

8.97

9.48

8.10

6.21

6.72

​

Totals:

6.16

6.02

6.06

6.56

6.13

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Motor

Requirements

  • 1000 W max power draw
  • Only one motor allowed
  • Multiple props allowed
  • No further restriction

Tacon Big Foot 60

  • 1200 W
  • $49.95
  • 400 KV
  • .023 ohms

Factors

Weight

Tacon BF 60

Propdrive V2

Turnigy AeroDrive

Turnigy AeroDrive

Turnigy L5055A

Turnigy G60

Power (1176 W goal)

0.3

9

5

3

8

2

4

KV (400 goal)

0.3

10

4

4

7

10

10

Price

0.2

3

8

10

5

7

1

Internal Resistance

0.2

10

8

10

9

0

3

​

Totals:

8.3

5.9

6.1

7.3

5.0

5.0

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Servos

Requirements

  • Prove servo can handle load
  • Calculations show 1.14 kg*cm minimum
  • Control ailerons, elevator, and rudder
  • Direction control wheel

TowerPro MG996R

  • 12 kg*cm torque
  • .17 sec/60 degree turn
  • $6.45
  • 61 g
  • Digital

Factors

Weight

Turnigy TGY-225

TowerPro MG995

TowerPro MG996R

TowerPro MG946

Hextronic D-MG

HiTec HS-5055

Torque

0.3

3

7

10

9

2.5

1

Rotation Speed

0.3

6

1

3

1

10

3

Digital/Analog

0.1

2

10

10

10

10

10

Price

0.3

10

8

9

3

5

1

​

Totals:

5.9

5.8

7.6

4.9

6.25

2.5

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Electronic Speed Controller (ESC)

Requirements

  • No specific requirements
  • Simply needs to perform task
  • Rated for at least 50A
  • Should have BEC

AeroStar 80A

  • 80A + 10A burst
  • 5.5V / 5A BEC
  • $31.65
  • 82g

Factors

Weight

AeroStar 80A

AeroStar 50A

YEP 60A

HobbyKing

Turnigy dlux

Turnigy SB

Turnigy Plush

Turnigy AE

Current

0.3

10

1

3

10

3

3

3

4

BEC V and A

0.3

7

7

10

4

10

4

1

4

Weight

0.15

2.55

10.00

6.27

0.00

2.94

8.82

6.86

4.31

XT60 connector

0.05

0

10

0

0

0

0

0

0

Price

0.2

0.87

2.32

1.74

2.32

0.00

10.00

0.43

1.59

​

Totals:

5.66

4.86

5.19

4.66

4.34

5.42

2.32

3.37

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Transmitter

Requirements

  • 2.4 GHz frequency
  • Needs 5+ channels
  • Programable is prefered

Spektrum DX6i

  • 2.4 GHz
  • 6 channels
  • Multiple modes
  • Free, already have it

Factors

Weight

Spektrum DX6i

FrSky Taranis

Turnigy 9X

Futaba T8FG

Orange T-SIX

Quality

0.4

8

10

5

10

1

Range

0.1

9

10

3

10

7

Price

0.3

10

3

8

0

9

Modes Available

0.15

10

10

7

10

10

Channels

0.05

3

10

5

5

3

​

Totals:

8.75

7.9

6

6.75

5.45

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Receiver

Requirements

  • 2.4 GHz frequency
  • Needs 5+ channels
  • Functional failsafe for LOS

Spektrum AR610

  • 2.4 GHz
  • 6 channels
  • Failsafe for LOS
  • Free, already have it

Factors

Weight

Spektrum AR610

Spektrum AR636

OrangeRx R615X

Redcon CM703

Quality

0.3

10

10

5

7

Price

0.3

10

0

7

8

Channels

0.2

8

8

8

10

Failsafe

0.2

10

10

10

10

​

Totals:

9.6

6.6

7.2

8.5

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2017 Power Limiter

  • Only one approved device is allowed
  • Made by NeuMotors
  • $70.00
  • Soft cutoff at power limit
  • XT60 connectors for power
  • Smaller than current power limiter

Example SAE Power Limiter

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Electrical Components and Prices

Component

Device

Price

Battery

Basher

$47.66

Motor

Tacon Big Foot 60

$49.95

Servos

TowerPro MG996R

$6.45 * 7 = $45.15

ESC

AeroStar 80A

$31.65

Transmitter

Spektrum DX6i

$0

Receiver

Spektrum AR610

$0

Power Limiter

NeuMotors PL

$70

Miscellaneous

Wires/plugs/etc.

$20

​

Total:

$264.41

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Mechanical Overview

Goals/Constraints

Major Components

  • Airfoil
  • Wing
  • Airplane Shape
  • Materials

Analysis

  • FEA
  • CFD

​

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Mechanical Goals and Constraints

Goals

  • Carry 21 Tennis Balls and 11+ lbs of extra weight
  • Design and build a sound body capable of surviving 10+ flights
  • Plane can be picked up by wings without breaking
  • Plane weight under 10 lb

Constraints

  • Max - 12 foot wingspan
  • Total Weight under 55 lbs
  • No fiber-reinforced plastic
  • Tennis balls on single dimensional plane
  • Passengers and luggage separated

​

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Airfoil

Choice through Simulation

  • Tested airfoils of small, medium, and large camber
  • CFD Simulation using STAR-CCM+
  • NACA 63-412 performed at 225% of other airfoils

Airfoil Matrix

​

​

​

​

​

​

​

Option 1

Option 2

Option 3

Option 4

Factors

Weight

NACA 63-412

Clark V

NACA 6412

NACA 2414

Lift

0.5

5

3

2

1

Drag

0.2

5

3

1

2

Manufacturability

0.1

2

5

2

2

Lift/Drag

0.2

5

3

1

2

​

​

4.7

3.2

1.6

1.5

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Airfoil (cont.)

Concerns and Solutions

  • Complicated shape -> complicated manufacturing
  • Precision Cut with CNC machine
  • Obtained a sample with Liteply ⅛” thick

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Wing Design

Major Features

  • Airfoil
  • Taper
  • Length
  • Ailerons
  • Construction
    • Rods and Spars

Strength

  • Simulations

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Airplane Shape 1

Primary Concerns:

  • Manufacturability
  • Strength
  • Aerodynamics
  • Weight

Strengths

  • Semi-Aerodynamic
  • Space-saving
  • Strong

Weaknesses

  • Heavy
  • Not pretty

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Airplane Shape 2

Design Option 2:

Strengths:

  • Aerodynamic
  • Lightweight
  • More space for tennis balls and luggage
  • Larger wings

Weaknesses:

  • Hard to construct
  • Weaker
  • More empty space

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Material Choice

Wood

  • Balsa - 9 lb/ft^3
  • Liteply - 31.5 lb/ft^3
  • Basswood - 26 lb/ft^3

Aluminum

  • 6061-T6, 6063-T3, and 2024-T3

Other Materials

  • Film Covering
  • Carbon Fiber

​

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FEA

Analysis over structural integrity of weight-bearing components

​

Major Areas that needed FEA:

  • Wing
  • Body
  • Tail

​

Conclusion

  • Wing 🗸
  • Body
  • Tail ✓

0.1372 in. max Displacement

5.7 in. max displacement

24,000 psi max stress

​

0.217 in max displacement

520 psi max stress

15 lbf at very end of tail

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CFD

Attempted full airplane

  • Obtained divergent results

Attempted smaller wing with wake region

  • Obtained divergent results

Wing Simulation with wake region 5 deg

  • Simulation ran giving 25 N of lift

Wing simulation without wake region

  • Obtained results up to 10 deg

Max Shear Stress of ~19 Pa

Max Velocity of 15.443 m/s ~ 34.54 mph

AoA

Lift (N)

Drag (N)

Lift/Drag

Cl

CD

9

30.8

2.21

13.9

0.852

0.0613

10

32.6

2.47

13.2

0.901

0.0684

No wake region

15 mph

AoA=10 deg

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Budget

Income

Expenditure

$3500 - ASGC

$1,160 - Competition Fees

$300 - Dr. Norwood

$310 - Plane Construction

$200 - Mr. Ethan Brown

$2400 - Travel Expenses

$250 - Garmin

$270 - Electrical Components

$100 - The Giving Table

​

​

​

$4350 - Total Budget

$4100 - Total Expenses

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Budget (Cont’d)

Competition Fees

​

Travel

​

Registration

$1,000

Lodging

$408

SAE Membership

$50

Gas

$1,450

FAA Registration

$5

Food

$400

Insurance

$75

Trailer Rental

$105

Printing

$30

​

​

​

​

​

​

Plane

​

Electrical

​

Wood

$142.75

Motor

$49.95

Covering Material

$65

Power Limiter

$70

Wheels

$25

Servos

$50

Aluminum

$75

Battery

$47.66

Total

$4103

Propellers

$50

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Schedule

Primary Project Steps

Start/Completion

Duration (Days)

Current

Parts Research and Design

Sept 4 - Nov 3

61

100%

Prototype Construction

Nov 10 - Jan 12

60

0%

Part Testing and Modification

Nov 17 - Jan 12

67

5%

Final Design Report Fall

Dec 11

20

33%

SAE Report/Technical Info

Jan 8 - Feb 2

26

0%

SAE Competition

Mar 9 - Mar 11

3

0%

Final Design Report Spring

May 3

40

0%

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Testing

  1. CNC Cutting Tests
  2. Structural testing
  3. Motor/Thrusting tests (w/ various propellers)
  4. Loading and unloading Practice
  5. Test Flights

​

  1. Nov. 28th - Dec. 8th
  2. Dec. 15th - Jan. 5th
  3. Dec. 11th - Jan. 8th

​

  • Jan. 5th - Jan. 29th

​

  • Jan. 26th - Mar. 9th

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Moving Forward

  • STAR-CCM+ Simulations
  • Final Design Report
  • Order final electrical and mechanical parts
  • Cut wood and assemble plane
  • Testing and improving design/prototype
  • Reports for SAE and JBU

​

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Upcoming Purchases

2 x Blue UltraCote Polyester Covering Roll

2 x Yellow UltraCote Polyester Covering Roll

7 x Servos

1 x Power Limiter

1 x Basher Battery, 4000 mAh

1 x Tacon Motor

4 x Propellers, Various

3 x Aluminum, Various Sizes

3 x Wheels, Various Sizes

​

Additional Wood as necessary

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Conclusion

Thanks to our sponsors:

​

​

​

​

​

​

Thank you for attending!

Questions?

The Giving Table

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Appendices

SAE - Society of Automotive Engineers

ASGC - Arkansas Space Grant Consortium

FAA - Federal Aviation Administration

RC -- Remote Controlled

FEA - Finite Element Analysis

CFD - Computational Fluid Dynamics

CL/CD - Coefficient of Lift/Drag

CNC - Computer Numerical Control

ESC - Electronic Speed Controller

LiPo - Lithium Polymer

C - Discharge Rate (1/hour)

KV - Motor Speed Constant (RPM/volt)

​

BEC - Battery Eliminator Circuit

LOS - Loss of Signal

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Abbreviated Technical Analysis Plan

Technical Analysis

Software/Equipment Used

Course

Computational Fluid Dynamics

STAR-CCM+

Solidworks

Fluid Mechanics: ME-4323

Oral Presentation and Communication

Microsoft Powerpoint

​

Design Lab: EN-3222

Thermal Sciences: ME-3223

Budgeting

Microsoft Excel

Design Lab: EN-3222

Simulation/Finite Element Analysis

Solidworks

STAR-CCM+

Finite Element Analysis: ME-4303

​

Technical Writing

Microsoft Word

Electronics I: EE-3313

Power and Energy Analysis

Matlab

Multimeter

Power Systems: EN-3343

Electronics I: EE-3313

Electrical System Analysis

Multimeter

Electronics I: EE-3313

CAD Modeling

Solidworks

Design Lab: EN-3222

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Electrical Calculations

Capacity: 1000 W / 22.2 V * 3 min / .8 discharge = 168.92 A*min = 2.82 Ah = 2820 mAh minimum

C rating: 1000 W / 22.2 V = 45.045 A :: 45.045 A / 3000 mAh = 15.02 C minimum

P rating: 1000 W / .85% load for max eff = 1176.47 W for peak efficiency

Torque Eq: 8.5*(10^-6)*.072*(chord^2*speed^2*length*sin(surf def)*tan(surf def)/tan(serv def))

Variables: chord = 2.5 in, speed = 35 mph, length = 21 in, surface deflect = 45°, servo deflect = 45°

Result: Torque=1.14 kg*cm minimum

ESC’s A: 1000 W / 22.2 V = 45.045 A peak draw

BEC’s A: .9 A peak * 5 servos = 4.5 A peak draw

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Wing Rod Decision Matrix

​

​

Option 1

Option 2

Option 3

Option 4

Option 5

Factors

Weight

3/4" Solid Rod

3/4" Hollow Rod

1/2" Solid Rod

1/2" Hollow Rod

1/2“ Wooden Rod

Weight

0.35

1

2

4

5

5

Cost

0.15

3

2

5

3

4

Strength

0.3

5

4

3

2

1

Airfoil Room

0.2

2

2

4

4

4

Total

1

2.7

2.6

3.85

3.6

3.45

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Tail Tubing Matrix

​

​

Option 1

Option 2

Option 3

Option 4

Option 5

Factors

Weight

1" 6061 Aluminum

1 1/4" 6061 Aluminum

1" PVC

1 1/4" Square Wood

Balsa Tail

Weight

0.4

3

2

5

4

5

Cost

0.2

2

1

3

4

4

Strength

0.1

5

5

2

1

4

Manufacturability

0.3

4

4

1

2

1

Total

1

3.3

2.7

3.1

3.1

3.5

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Body Material Decision Matrix

​

​

Option 1

Option 2

Option 3

Option 4

Factors

Weight

LitePly "Box"

Balsa "Box"

"Shape 2"

Mixed Wood Box

Weight

0.4

1

4

5

3

Cost

0.15

3

2

4

3

Strength

0.25

5

2

4

4

Manufacturability

0.2

5

4

1

4

Total

1

3.1

3.2

3.5

3.4

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Wing FEA, Closeup

6061 T6 Aluminum:

Sut = 45000 psi

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