1. Detailed Design Review Tethered Glider P14462 12/10/201314462

2. 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 12/10/201314462

3. Engineering Requirements 12/10/201314462

4. 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 12/10/201314462

5. 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 12/10/201314462

6. 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 http://www.wesspur.com/throw-line/zing-it-throw-line.html 12/10/201314462

7. 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): 1531-538. American Institute of Aeronautics and Astronautics. Web. 7 Dec. 2013.. 12/10/201314462

8. Tether Drag Total tether drag of DynaGlide tether: 27.063 N Negligible force compared to the lift and drag 12/10/201314462

9. Tether-Wing Attachment Setup 12/10/201314462

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 12/10/201314462

11. Tether-Wing Attachment Setup 12/10/201314462

12. Tether-Wing Attachment Stress Analysis Plate material: Polycarbonate Max stress: 38.4 GPa Max allowable: 55 GPa 12/10/201314462

13. Tether-Wing Attachment Displacement Analysis Plate material: Polycarbonate Max deflection: 0.002 in 12/10/201314462

14. Bridle Setup 3 point bridle with extra support line Use crimps for permanent attachments Adjustable fuselage tether to change bridle angle 12/10/201314462

15. Bridle Setup 12/10/201314462

16. Base Station - Week 6 Concept ●Concept from week 6, selected by week 9 ●Consists of 2 potentiometers and 1 load cell 12/10/201314462

17. Base Station - Detailed Design 12/10/201314462

18. Base Station - Detailed Design 12/10/201314462

19. Exploded View of Upper Portion 12/10/201314462

20. 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 12/10/201314462

21. 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 12/10/201314462

22. 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 0.0036” under the max loading of 1200 lbs ●The thicker shaft allows for tapping in order to connect the load cell Selection: 12/10/201314462

23. Pillow Block Screw Pullout T=300 lbf x y Selection: 4 #12-10 machine screws ¾” C-D grade plywood http://www.grabberman.eu/Me dia/TechnicalData/452.pdf 12/10/201314462

24. Plywood Flexing ●Modeled as an isotropic material, although wood is anisotropic ●Showed max deflection of 0.503E-05 inches 12/10/201314462

25. 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 12/10/201314462 Source: www.buildgp.com/DocumentViewer.aspx?repository=bp&elementid‎

26. 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 12/10/201314462

27. Exploded View of Lower Portion 12/10/201314462

28. 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 12/10/201314462

29. 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. 12/10/201314462

30. 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 http://www.grabberman.eu/Me dia/TechnicalData/452.pdf 12/10/201314462

31. Sheet Metal Plate Max deflection of ~ 0.003 inches

32. Base Station – Cross Section View 12/10/201314462

33. Base Station Animation 12/10/201314462

34. NI USB-6210 16 bit Resolution = 10/(2^16) = 0.000153 12/10/201314462

35. 3140_0 S Type Load Cell (100-500kg) 12/10/201314462

36. 1046_0 PhidgetBridge 4-Input Resolution = 5/(2^24) = 0.000000298 12/10/201314462

37. Potentiometers 2 pots required. 1 turn ~ 270 degrees Between 1K-10K Resistance Linear Bourns brand Potentiometers from Gomes still need to be spec out 12/10/201314462

38. DAQ Operational Flowchart

39. DAQ Programming Flowchart

40. Wiring Schematic for DAQ 12/10/201314462

41. Bill of Materials - Full

42. Bill of Materials – Already Have

43. Bill of Materials – Need to Buy

44. Bill of Materials - Possible Savings

45. Glider Configuration for Experiments Total configurations: 2590 Range:  Beta = 90-98 [deg]  Wind Speed = 4-10 [m/s]  Tether Length = 20-30 [m]  Flight Radius = 10-18 [m] Force [lbs]Wind Speed [m/s] Radius [m] Beta [deg] Tether Length [m] 334.36937159230 309.52357169230 349.04447189330 Filtered:  Force = 300-350 [lbs]  Wind Speed = 7 [m/s]  Tether Length = 30 [m] 12/10/201314462

46. Regression Analysis including Wind Force = -1523.83 + 44.6977 WindSpeed - 22.0839 Radius + 16.3528 Beta +11.4661 TethLen Analysis of Variance Source DFSeq SS F P Regression 4 14445969 580.40 0 WindSpeed 1 6413421 2006.60 0 Radius 1 2623543 887.44 0 Beta 1 2732563 524.19 0 TethLen 1 2676441 430.13 0 Error 2583 16072377 Total 2587 30518346 12/10/201314462

47. Why the high error ? 12/10/201314462

48. 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 1074979 Beta 1039829 TethLen 772033 Radius*Beta 383755 Radius*TethLen 263954 Beta*TethLen 312236 Radius*Beta*TethLen818325 Error25853236 Total 30518346 12/10/201314462

49. Interaction plots for Tension 12/10/201314462

50. Main effects on tension 12/10/201314462

51. Graphical Sensitivity (contour plots) of each factor 12/10/201314462

52. Graphical Surface plots 12/10/201314462

53. Test Plan 12/10/201314462

54. 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 MassTensionTeam04/18/2014 12/10/201314462

55. Risk Assessment - Full 12/10/201314462

56. Risk Assessment - High Priority/New 12/10/201314462

57. Project Plan 12/10/201314462

58. MSD II Plan 12/10/201314462

59. MSD II Plan (Continued) 12/10/201314462

60. 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 12/10/201314462

61. 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 12/10/201314462

62. Questions? 12/10/201314462