Detailed Design Review Tethered Glider P /10/

Outline Engineering Requirements Glider Status Tether Design Base Station Design DAQ System Bill of Materials DOE ANOVA Analysis Test Plan MSD II Plan Work Breakdown Risk Assessment 12/10/

Engineering Requirements 12/10/

Glider Status Art’s Plane o Suffered Multiple Crashes o Totalled 1 st Bixler o Few flights on first day o Missing in swamp 2 nd Bixler o On order 12/10/

1 st Bixler Learned how to glue glider and set up receiver Needed to be modified due to poor manufacturing o Drilled out interfering plastic/wood Bixler was tail heavy 12/10/

Tether Design DynaGlide Throw Line o Material: Dyneema with Vinyl Coating o Vendor: WesSpur o Diameter: 1.8mm o Tensile Strength: 1000 lb o Highly Visible o Price: $39.00 for 200 feet 12/10/

Tether Drag Numerical Approximation Calculates: o Tether Drag o Tension Change o Tether Angle Change Rajani, Ashok, Rajkumar Pant, and K. Sudhakar. "Dynamic Stability Analysis of a Tethered Aerostat." Journal of Aircraft 47.5 (2010): American Institute of Aeronautics and Astronautics. Web. 7 Dec /10/

Tether Drag Total tether drag of DynaGlide tether: N Negligible force compared to the lift and drag 12/10/

Tether-Wing Attachment Setup 12/10/

Tether-Wing Attachment Tether may rip EPO foam if attached directly Design plate to rest on top of wing o Distributes load o Foam is minimally damaged Tethered over carbon fiber spars Material: Polycarbonate 12/10/

Tether-Wing Attachment Setup 12/10/

Tether-Wing Attachment Stress Analysis Plate material: Polycarbonate Max stress: 38.4 GPa Max allowable: 55 GPa 12/10/

Tether-Wing Attachment Displacement Analysis Plate material: Polycarbonate Max deflection: in 12/10/

Bridle Setup 3 point bridle with extra support line Use crimps for permanent attachments Adjustable fuselage tether to change bridle angle 12/10/

Bridle Setup 12/10/

Base Station - Week 6 Concept ●Concept from week 6, selected by week 9 ●Consists of 2 potentiometers and 1 load cell 12/10/

Base Station - Detailed Design 12/10/

Base Station - Detailed Design 12/10/

Exploded View of Upper Portion 12/10/

Design Focus - Upper Portion Wanted minimal flexing on the shaft in order to prevent bearing seizure Wanted to prevent screw pullout Wanted minimal plywood flexing Ensure top bolt did not tear through plywood due to loading 12/10/

Shaft Selection T=1200 lbf R R =600 lbfR L =600 lbf x y ●Wanted to minimize deflection, bending stress, and moment of inertia of shaft ●Utilized Excel and varied L and R and calculated corresponding deflections and max stress 12/10/

Shaft Selection Continued ¾” x 7’’ AISI 1566 Steel shaft ●Only 4” of the shaft will be between the bearings, which is the length used for deflection and stress calculations. ●With these values the shaft will deflect ” under the max loading of 1200 lbs ●The thicker shaft allows for tapping in order to connect the load cell Selection: 12/10/

Pillow Block Screw Pullout T=300 lbf x y Selection: 4 #12-10 machine screws ¾” C-D grade plywood dia/TechnicalData/452.pdf 12/10/

Plywood Flexing ●Modeled as an isotropic material, although wood is anisotropic ●Showed max deflection of 0.503E-05 inches 12/10/

Bolt Tear Through ●Wanted to prevent the bolt from tearing through the plywood ●A 3 inch washer was added to distribute the loading on the face of the plywood 1200 lbf 170 psi Without Washer: Compressive stress on the plywood of 8692 psi. The maximum allowable compressive stress for loading perpendicular to the face grain is between ~ 900 – 1500 psi With Washer: Compressive stress on plywood of 170 psi, within the allowable stress 1200 lbf 8692 psi 12/10/ Source:

Pillow Block Bearings Selection: ●Shaft will insert and then be screwed down with set screws ●Do not need to be thrust bearings, as platform will rotate ¾” Stamped-Steel Mounted Ball Bearings—ABEC-1 12/10/

Exploded View of Lower Portion 12/10/

Design Focus - Lower Portion Wanted to ensure sleeve bearing did not deform under worst-case scenario loading Wanted to prevent screw pullout Ensure sheet metal flexed minimally under applied load 12/10/

Sleeve Bearing T=1200 lbf hsbhsb H RLRL R Selection: 0.752” x 1” Ultra Tough Oil Lubricated Bronze Flanged Sleeve Bearing ●Utilized Excel to calculate various reaction forces for different h sb, and compared versus the max allowable force on the inner walls of the bearing ●For worst case scenario chosen bearing will see 5100 lbs and it is capable of handling 6016 lbs. 12/10/

Angle Iron Pullout and Shear F=300 lbf F=200 lbf Selection: 1”x1”x1/8” angle iron with #12 screws 6 vertical screws, and 4 horizontal ¾” C-D grade plywood dia/TechnicalData/452.pdf 12/10/

Sheet Metal Plate Max deflection of ~ inches

Base Station – Cross Section View 12/10/

Base Station Animation 12/10/

NI USB bit Resolution = 10/(2^16) = /10/

3140_0 S Type Load Cell ( kg) 12/10/

1046_0 PhidgetBridge 4-Input Resolution = 5/(2^24) = /10/

Potentiometers 2 pots required. 1 turn ~ 270 degrees Between 1K-10K Resistance Linear Bourns brand Potentiometers from Gomes still need to be spec out 12/10/

DAQ Operational Flowchart

DAQ Programming Flowchart

Wiring Schematic for DAQ 12/10/

Bill of Materials - Full

Bill of Materials – Already Have

Bill of Materials – Need to Buy

Bill of Materials - Possible Savings

Glider Configuration for Experiments Total configurations: 2590 Range:  Beta = [deg]  Wind Speed = 4-10 [m/s]  Tether Length = [m]  Flight Radius = [m] Force [lbs]Wind Speed [m/s] Radius [m] Beta [deg] Tether Length [m] Filtered:  Force = [lbs]  Wind Speed = 7 [m/s]  Tether Length = 30 [m] 12/10/

Regression Analysis including Wind Force = WindSpeed Radius Beta TethLen Analysis of Variance Source DFSeq SS F P Regression WindSpeed Radius Beta TethLen Error Total /10/

Why the high error ? 12/10/

DOE ANOVA Analysis Analysis is based off of above equation Experiment was run using the following Factor Type Levels Values Radius fixed 9 10, 11, 12, 13, 14, 15, 16, 17, 18 Beta fixed 8 91, 92, 93, 94, 95, 96, 97, 98 TethLen fixed 11 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 Analysis of Variance for Force for Tests Source Seq SS Radius Beta TethLen Radius*Beta Radius*TethLen Beta*TethLen Radius*Beta*TethLen Error Total /10/

Interaction plots for Tension 12/10/

Main effects on tension 12/10/

Graphical Sensitivity (contour plots) of each factor 12/10/

Graphical Surface plots 12/10/

Test Plan 12/10/

Test Plan Varied wind speed: Dependent on environment Varied glider mass would be an additional test if time allows Component/System Tested Specification Tested Responsibility Completion Date Experimental Proof of Theoretical Model TensionTeam02/28/2014 Varied Tether LengthModel SensitivityTeam03/14/2014 Varied Wind SpeedModel SensitivityTeam03/28/2014 Varied Beta AngleModel SensitivityTeam04/04/2014 Varied Flight Path RadiusModel SensitivityTeam04/11/2014 Varied Glider MassTensionTeam04/18/ /10/

Risk Assessment - Full 12/10/

Risk Assessment - High Priority/New 12/10/

Project Plan 12/10/

MSD II Plan 12/10/

MSD II Plan (Continued) 12/10/

Work Breakdown Matt – Building glider, attaching bridal, flying tethered glider Paul - Building glider, attaching bridal, flying tethered glider Jon – Machine parts, assemble base station Kyle - Machine parts, assemble base station Bill – Create LabVIEW code, test DAQ equipment, Saj- Update project timeline, develop more detailed test plans from DOE, maintain transparency between team and customer/guides All – Assist in base station build 12/10/

Summary Engineering Requirements Glider Status Tether Design Base Station Design DAQ System Bill of Materials DOE ANOVA Analysis Test Plan MSD II Plan Work Breakdown Risk Assessment 12/10/

Questions? 12/10/