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Group 05010 Team Leader Walter Strassburg Chief Engineer Gabe Marciano Joe O’Bryant Iheanyi Umez-EroniniTaylor ValentineGreg Weimer Team Mentor Dr. Jeff.

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Presentation on theme: "Group 05010 Team Leader Walter Strassburg Chief Engineer Gabe Marciano Joe O’Bryant Iheanyi Umez-EroniniTaylor ValentineGreg Weimer Team Mentor Dr. Jeff."— Presentation transcript:

1 Group Team Leader Walter Strassburg Chief Engineer Gabe Marciano Joe O’Bryant Iheanyi Umez-EroniniTaylor ValentineGreg Weimer Team Mentor Dr. Jeff Kozak HMMWV UAV Deployment & Ground Sustainment System

2 Needs Assessment  Currently, the technology to make an autonomous military weapon such as the DP-5X exists with minor setbacks: Transportation Guidance Communications  Project will fulfill transportation criteria for the DP-5X.

3 Initial Scope  12/06/04 Project Requirements Trailer and launch system must:  Transport: Delicate machinery (300lbs)  Maintain safety of crew (2 person)  Enable: Unmanned landing on trailer Waterproof storage of all components  Be shock mounted with tie down system  Be operable by low echelon military personnel  Have a low cost

4 Current Requirements  Project Requirements Trailer and launch system must:  Transport: UAV (300lbs) Fuel sufficient for 72 hours of sustained flight (1200lbs) Extra rotor blades for UAV Payload (250lbs and ~$1Million) Crane to support lifting of helicopter and adjustment of engine CG Ramps to load and unload aircraft Additional fluids and UAV support equipment  Maintain safety of crew (2 person)  Enable waterproof storage of all components  Provide electrical service for UAV and electrical components  Have a low cost  Be operable by low echelon military personnel

5 System Design Components Waterproofing Ramps Boxes Fuel Containers Trailer Type Lift Mechanism Crane Holding Mechanism Attachment Points Blade Packaging Payload Packaging Power Supply Adapter Power Converter Module Battery Charging Module

6 Preliminary Designs

7 8 Blades Payload(s)Crane Electrical Interface Canopy 24 Cubic Feet of Fuel Distributed Over 4 Corners DP-5X FCS Tools And Misc. fluid/gear Required Load Organization

8 Feasibility Assessment  15 Subsystems >54 Concepts

9 Feasibility Assessment  Weatherproofing CANVAS WITH FRAME SNOWMOBILE TYPE TONNEAU COVER

10 Pugh Charts

11 Comparison of Attributes

12 Feasibility Assessment  Ramps Individual Folding Tailgate U-Haul Style Telescoping  Storage Boxes Custom Order Pre-Built New Design  Trailer Deck Flatdeck Extended Flatdeck Partially Enclosed  Fuel Container Custom Bladder Pre-Built Bladder “Jerry Cans” New Design  Lift Mechanisms 4-Bar Scissor Crane Fold-Down Sides  Launch Platform Tri-fold Deck Bi-fold Roof Flat Deck Ground  Crane Manual Manual, Folding Powered, Folding  Holding Mechanisms Latches Ratchet Tie-Down Self Clinching Tie-Down Rotor Catch Ring  Attachment Points Protruding Clip Recessed D-Ring Clinching Cam  Payload Packaging Cabinets w/foam Floating Net Self-Level Suspension  Blade Packaging Shelves Foam Block Shredded Foam  DC-DC Converter VTC 1015 VTC 1500 Traco Schaefer Self Designed  12 Volt DC Charger Power Stream Major Power GSL

13 Electrical Subsystem Overview  Given a HMMWV’s 24V- 60A electrical system, provide the ability to: Charge the UAV batteries. Power the computer station. Power any additional devices needed to implement system design.  Initial Ideas: Power Inverter Gasoline powered Generator Combination of DC input devices and Power Inverter

14 Electrical Subsystem Design  Provides necessary power connections.  Parts are modular and can be replaced individually.  Safety and ease of use is maintained via plug/play capability.

15 Feasibility Assessment Concept 1Concept 2Concept 3Concept 4Concept 5 AttributeWeightMP VTC1015 ||Traco 53622SP C3822Self DesignedMP VTC1500 Lead Time40%43312 Cost20%12253 Availability from Multiple Distributors10%42212 Ruggedness20%33413 Ease of Integration into Design10%33353 Raw Score Normalized Score Concept 1Concept 2Concept 3 AttributeWeightPST-DU700MP BCD600GSL Maximizer Lead Time40%432 Cost20%432 Availability from Multiple Distributors10%242 Ruggedness20%332 Ease of Integration into Design10%444 Raw Score Normalized Score V DC Battery Charger 24V to 12V DC-DC Converter

16 Electrical Design Issues  Problem: Resistance of wires is an issue when transmitting power over long distances.  Solution: Calculate maximum resistance tolerated and choose wires based on that value.

17 Vibration Analysis of Critical Components  Helicopter and payload must be protected from vibration during high speed transportation over rough terrain  Terrain 65 mph requirement  Defined by the sponsor “Rough terrain” approximation  Sinusoidal Ground Profile  10” amplitude  48” wavelength  A fairly conservative estimate  Payload Protection Delicate payload must be protected from accelerations in excess of 2.5 g’s during transportation  Helicopter Protection Acceleration of helicopter must not exceed 3 g’s No additional vibration isolation needed  Stock trailer suspension meets this requirement

18 Vibration Analysis of Critical Components  Mathematical Model Calculated/estimated values for trailer tires, springs, dampers System of second order differential equations describing 3 degree of freedom system under forced oscillation Input into Simulink

19 Vibration Analysis of Critical Components Matlab Simulation

20 Vibration Analysis of Critical Components

21  Packaging foam selected for padding material ILD (Indentation Load Deflection) calculated from desired spring constant Two layers of 3” thick foam to provide adequate travel Sides of payload container will be lined as well A cost effective solution Available from

22 Fuel Tank Selection  Tanks need to conform to trailer loading plan Located under toolboxes Space interrupted by the wheel wells  Tanks must be suitable for military transport Ballistic tolerant Prevent sloshing  Fuel Safe Fuel Bladders Available in custom shapes and sizes Semi-rigid – able to deform slightly to absorb shock Can be manufactured to military specs Contain foam baffles to prevent fuel from sloshing

23 Integration: Requirements  Trailer Design- Built off of a standard military HMMWV trailer matching the off-road capabilities of the HMMWV itself.  Trailer must carry 1200lbs of JP8 fuel, storage for eight main rotor blades each six feet in length, delicate storage for $1MM payload, UAV with folded tail, 500 lb. crane, electrical ground sustainment equipment, and FCS tools as well as miscellaneous fluids and solider gear. Must be waterproof.  Major issue is carrying all required loads while remaining within the trailer’s rated load capacity of 3000 lbs. Standard military LTT-FE HMMWV off- road trailer from Silver Eagle Inc.

24 Integration: Fuel Storage  Fuel containers are simple sheeted steel framework with custom manufactured bladders within, specifically designed to provide required volume while keeping CG low and weight distributed.  Standard trailer deck does not extend to the outer corners of its frame. This area is required for all loads to be contained on the unit.  Issues: Many parts require extensive welding and accurate cutting. Steel is durable and military tough, however it is also very heavy reducing the amount of cargo the trailer will be able to carry.

25 Integration: Payload, Blades, Tools…  Storage boxes designed according to volume required per contained load, as well as symmetric, structural design for future launch/landing platform to be added at a latter date.  Payload boxes in the front of the unit were not able to be made square due to the turning radius of the crane’s power pack. Payload boxes are top loading for vertical lifting access.  Blade storage box consists of a side loading 84” long compartment with a single shelf integrating a divider/cushion system.  The two door compartment tool box on the opposite side will provide storage for and operation of the system’s electrical requirements, FCS tools, miscellaneous fluids, and solider supplies.

26 Integration: Crane  The Crane serves as a winch to raise and lower the UAV up/down a ramp, lift the payload into place for assembly, and adjust engine location for CG optimization. It is also able to lift the entire UAV to a future platform height.  The Crane mounts on a 12” x 12” flat mounting plate at the front of the trailer.  The mounting plane was raised and strengthened to provide the necessary area for mounting the crane and reduce torsional stresses induced on the trailer tongue frame by distributing the load.

27 Integration: Weatherproofing  A simple tube supported canvas cover bungee corded to the trailer frame will keep the UAV dry and serve as protection from the elements.  The canvas and tube frame is completely removable allowing two men to quickly unload and prepare the UAV for launch.

28 8 Blades Payload(s)Crane Electrical Interface Canopy 24 Cubic Feet of Fuel Distributed Over 4 Corners DP-5X FCS Tools And Misc. fluid/gear Required Load Organization

29 Stress Analysis of Major Structural Areas  Cube dimensions = 22’’ x 33’’ x 15’’  Cube Volume = 10,890 in 3  Density of JP8 fuel of 6.7 labs/gal  1 gallon = 231 in 3  Overall concentrated Force = 315.8lbs  Max. Stress = 15,245 lb/in 2  Max. deflection = 4.55 x in.  Max. allowable stress = 100,000 lb/in 2

30 Stress Analysis of Major Structural Areas  The weight of the fuel, as well as an additional 1,000lbs. (1600lbs.)  Trailer must be operational in rough terrain with bumps causing a force of up to three times that of gravity, therefore this entire load is multiplied by 3g.  Load is distributed.  Max deflection =.0106 inches

31 Budget  Trailer  Crane  Tool boxes  Ramps  Fuel bladders  Tie downs  Steel tubing  Electrical wiring  Electrical connectors  Foam padding  Travel  Office supplies  Miscellaneous  Total

32 Final Purchase Prices

33 Future Work Schedule  Finalize design optimization  Review final design with sponsor May require an additional visit  Acquire materials for construction  Begin product construction  Finish construction  Testing and evaluation  Write CDR

34

35 Questions?

36 Another UAV  The AAI Shadow TUAV

37 Launch and Recovery

38 Portable Ground Control Stations


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