1. iClean - Loitering attack UAV CDR June 27 th, 2012 Aerospace Faculty, Technion, Haifa Moshe Etlis Daniel Levy Mor Ram-On Matan Zazon Ya’ara Karniel Meiran Hagbi Oshri Rozenheck Yanina Dashevski Nathaniel Lellouche Menahem Weinberger Supervised by Dror Artzi

2.  PDR Overview  Remarks from PDR  Airfoil and Propeller Selection  Geometry Improvements  Performance Calculations  Wing Detailed Design  Wings’ Folding Mechanism  System Installation Layout  Weight and Balance  Wind Tunnel Model Design  Wind Tunnel Test  Conclusions and Recommendations Table of Contents

3. Operational capabilities:  Suicide UAV.  Endurance: 5 hr.  Range: 400 NM (approx. 750 Km)  Man in the loop.  Launching System: Mobile Ground Launcher with as many as possible UAV's ready to be launched. Target definition and acquisition:  Target type: Static and mobile.  Truck Target: detection range of 30 Km, recognition of 12 Km.  Target acquisition: Day and Night Capabilities. Attack capabilities:  Warhead: Approx. 20 Kg.  Attack capabilities: Any angle - vertical or horizontal.  Low Cost UAV unit. PDR Overview - Customer Specifications

4. Diving at 150 kt BOOM!! Launch Climb to 5000 ft Cruise at 5000 ft at approx. 80 kt Loiter at 5000 ft at approx. 60 kt Mission Profile

5. PDR Overview - Chosen Components Sensor: Controp ESP 600C (27 lbs, X15 zoom lens, 0.7-22.6 degrees FOV). Engine: 3W 275 XiB2 (26 HP, 15.5 lbs). Launching Method: Booster rocket (Launched from a canister).

6. PDR Overview - 2 Configurations AB

7. PDR Overview - Final Geometry for PDR

8. Remarks and Solutions

9. Airfoil Selection NACA 0012Eppler 560 NACA 0012Eppler 560Improvement (%) Max C L 0.9721.82788 Max L/D40.6360.0848 Stall angle7.514.593

10. NACA 0012Eppler 560NACA 4412Improvement (%) Max C L 0.9721.8271.50721 Max L/D40.6360.0857.2095 Stall angle7.514.56142 Airfoil Selection NACA 4412

11. Consulting the engine data and information. The chosen engine 3W:275 XiB2 TS (from the PDR). Engine rotation speed : 1000-7000 RPM power : 26 horsepower =~ 19300 watts. Weight: 15.5 lbs=~ 7 Kg. two blade propeller : 26x16 or 26x14 (“) 3 blade propeller : of 22x14 or 24x14 (“). Propeller Selection

12. (From our engine data): engine max RPM is 7000 RPM = 116.67 round per second. Max speed at - 180 Propeller Selection - Calculations – Needed Pitch

13. Our propeller is a 2 bladed-back- folding propeller at the size of 25X18. Propeller Selection - Calculations – Needed Diameter Direction of flight

14. Stability Solution: Changing the Configuration

15. 40%-60% Configuration’s Stability

16. Geometry as shown at PDR: Geometry Improvements The final geometry for CDR:

17. Old: The fuselage becomes thinner in the middle of it and then expends New: The guideline of the fuselage as much as monotonic as possible New: Wings’ hinges are covered New: 40-60 canard Old: 25-75 canard Old: Wings’ hinges were exposed Geometry Improvements

19. ValueProperty Airfoil (EPPLER 560) Aspect ratio Spans Reference lift area Weight Aerodynamic center’s position UAV’s Properties Fuselage Vertical tail

20. Assumptions:     The body as a lift generator componemt:   Lift Coefficient’s Properties

21. ValueProperty Lift coefficient slope Lift coefficient as a function of angle of attack Minimal lift coefficient at height of 0ft and 5000ft Maximal lift coefficient Stall angle Zero lift angle Lift Coefficient’s Properties

22. Assumptions:   Drag Coefficient’s Properties

23. ValueProperty Wing’s induced drag coefficient Canard's induced drag coefficient UAV’s drag Fuselage's induced drag coefficient UAV’s total induced drag coefficient Drag Coefficient’s Properties

24. ValueProperty Velocity ValueProperty Maximum thrust Minimum thrust Thrust for cruise flight Minimum velocity (stall) - height of 0ft and 5000ft. Assumption: Cruise flight: Assumptions:  Cruise flight  Maximal velocity: Engine Thrust

25. Assumption & data: Constant: Range & Endurance ResultProperty Range for climb Endurance for climb Minimum range for cruise Maximum endurance for cruise Final results:

26. r L F R Booster Rocket Angle

27. Time of opening the wings: Velocity: Density: The mass : :The lift coefficient The acceleration of the booster: Area of wing that creates the lift: The force that booster applies: The lift: The total moment: 27 Assumptions and data: Booster Rocket Angle

29. Wing Detailed Design

30. The lift load distribution on a trapeze wing: Wing Detailed Design - Load Distribution

31. Assuming this lift load distribution the resultant force is:

32. Wing Detailed Design - Web Thickness

33. Wing Detailed Design - Flange Area 140010005000bl [mm] 348.592203936593643 0.123.281433.52 Flanges bl [mm]

34. Wing Detailed Design - Skin Thickness Thickness [mm] 140.80.25 70.40.5 35.21 23.51.5 16.252 132.5 Material 706.3Carbon Fibers 290.4Aluminum 2024-T3 270.8Aluminum 7075-T6

35. The selected method is the vertical pin for the Advantages below:  Structural simplicity  Load paths determined with Confidence  Minimum volume of hinge  Simple actuator mechanism  Very few moving parts  Minimum weight Wing Detailed Design - Joint Selection

36. A vertical pin through the pivot axis transfer the force-couple from the movable outer wing to the fixed center section Wing Detailed Design - Joint Selection Carbon fiber ± 45 ° Unidirectional Wing's root

37. Wing Detailed Design - Final Formation

38. Wing Detailed Design - Strength Analysis

39. Force and Moment Calculations: Conclusion from Allowable and Actual Stresses Calculations: Wing Detailed Design - Strength Analysis

40. Shear Stress Von Mises

41. Max. Deformation [mm] Material 6 Aluminum 2.3 Carbon Factor Calculation: Wing Detailed Design - Strength Analysis

42. Pre Calculations: the average velocity of the UAV during launch time is: Reference areas : Wings’ Folding Mechanism

43. The wing‘s lift during launch time The wing‘s drag during launch time: Tension Drag Wings’ Folding Mechanism

44. Tension Drag Direction of flight Drag Wings’ Folding Mechanism The wing‘s drag during launch time:

45. Movement limiters Main spring Connecting rods Bearing Wings’ Folding Mechanism - Other Related Parts Design

46. Booster for launch Motor & Propeller Integral fuel tank Warhead EO Sensor Wing & Canard Opening mechanism Avionics Internal Layout

47. S/N Part nameMass[gr] X[cm]My[N*cm] 1StructureFuselage15000 11516922.25 2Wings6740 1459587.313 3Mechanics –wing3500 1454978.575 4Reinforcements- wing2000 1452844.9 5Canard wings4060 55.52210.4873 6Mechanics-canard2000 55.51088.91 7Reinforcements- canard1000 55.5544.455 8Tail2000 1853629.7 9Fuel injection system3000 1303825.9 10Engine 6800 19513008.06 11Fuel15000 107.4815313.901 12Fuel tank1000 107.481020.9267 13Oil1000 1101079.1 14Warhead 20000 7812556.8 15PayloadSensor8000 30.22370.096 16 Battery5000 1808829 17AvionicsComputer+Control system2000 17.5343.35 Total Mass : 98100 CGx[cm]:107.48 Weight and Balance

48. Cg=107.5 cm Cp=111.2 cm Weight and Balance - C.G Location 10% chord stability margin

49. General instructions:  Max. length: 100 cm.  Max. section area: 2-4% of cell’s section area.  Wing tips should be away from the cell’s walls.  Model shouldn’t be too small in order to get accurate results. The model’s scale will be 1:7. Wind Tunnel Model Design

50. Steel reinforcement Hinge Morse cone CanardWing Drawn nose Steel holder

51. Wind Tunnel Model Design Although in order to keep similarityrules, we had to use an air speed that is greater than 80 m/sec for the experiment, we wanted to avoid the situation in which model’s wings can’t handle the lift loads so we lowered the air speed to 45 m/sec.

52. Wind Tunnel Model Design Experiment purpose:  Find the 2D lift coefficient slope, stall angle, pitch and yaw moments coefficients.  Learn about UAV’s stability status.  Learn about situations where a flow separation may occur. Air Speed [m/sec] AOA Range [Degrees] PlaneConfiguration Experiment Code No. 45-16-16LongitudinalOpen73691 45-20-20LateralOpen73732 45-20-20LongitudinalClosed73763 45-20-20LateralClosed73774 45-20-20LongitudinalOpen73815 45-20-20LongitudinalOpen wing only - With tufts73836 45-20-20LongitudinalFuselage only73857

53. The different configurations: Open Closed Open with tuftsOpen, wings only with tufts Fuselage only Wind Tunnel Model Design

54. Wind Tunnel Model

55. Wing Tunnel Test Results Lift Coefficient for Open Configuration The graph above demonstrates the tunnel results of the total lift coefficient as function of angle of attack in comparison to the calculated theoretical lift coefficient.

56. Wing Tunnel Test Results Lift Coefficient for Open Configuration The graph above demonstrates the Lift coefficient as function of angle of attack of each lift-generator part of the UAV.

57. Wing Tunnel Test Results Moment Coefficient for Open Configuration The graph above demonstrates the tunnel results of the total lift coefficient as function of lift coefficient in comparison to the calculated theoretical lift coefficient.

58. Wing Tunnel Test Results Moment Coefficient for Open Configuration The graph above demonstrates the Moment coefficient as function of angle of attack of each lift-generator part of the UAV.

59. Wing Tunnel Test Results Drag Coefficient for Open Configuration The graph above demonstrates the tunnel results of the drag coefficient as function of angle of attack in comparison to the calculated theoretical drag coefficient.

60. Wing Tunnel Test Results Lift Coefficient for Closed Configuration The graph above demonstrates the tunnel results of the total lift coefficient as function of angle of attack in comparison to the calculated theoretical lift coefficient.

61. Wing Tunnel Test Results Moment Coefficient for Closed Configuration The graph above demonstrates the tunnel results of the total lift coefficient as function of angle of attack in comparison to the calculated theoretical lift coefficient.

62. 1. Improving geometry. 2. Performances estimation. 3. Wing design. 4. Wing & canard opening system. 5. Structural analysis. 6. Building a wind tunnel model or airplane model. And more Work Plan for Current Semester – as Seen on PDR

63. 1.Strengthening the wind tunnel model. 2. Perform additional wind tunnel test on the wings and canards in order to evaluate their mutual affect on each other. Conclusions and Recommendations

64. Questions?