Design

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Abstract

Project Scope

Acknowledgement

Customer Needs

Target Summary

Concept Generation

Possible Concepts

Calculations

Abstract Team 524 desires to design and produce a fully functional 3D printed RC aircraft. This aircraft will compete in the SAE Aero Design Competition against other conventional model aircrafts. This will be achieved with the help and guidance of the Florida Space Grant, Dr. Chiang Shih, and Dr. Shayne McConomy. While some aspects can be easily replicated from previously published designs, some changes are needed to fuse the 3D printing method due to size and weight. The 3D printers available for our project have a small print bed of 12x 7 x 7 inches, so it is important to print the components of the aircraft in sections so that they can be easily fastened or taken apart. There will be a loss of stability and strength that comes with an assembly of multiple smaller pieces, as opposed to having one single aircraft body with the

Project Plan

internal supports that are present in the design. With this applied constraint in mind, the design and assembly of our aircraft becomes more complex. The 3D print design criterion is challenging because plastic material is denser than commonly used aircraft materials such as balsa wood and carbon fiber. Additional alterations can be made to account for the added load. A variety of 3D printing techniques have proven to be useful in improving the body form, weight and load carrying capacity for the aircraft. Through analysis, the team was led to develop an aircraft with a high-capacity subsonic fuselage, front tapered wings replicating the Selig S1223 airfoil, and a tricycle landing gear. As many outside surfaces as possible will be printed using nylon material. A virtual model has been created using the CAD software CREO Parametric to create 3D printer ready files.

Acknowledgement Our senior design group would like to thank the NASA Florida Space Grant Consortium for sponsoring our project. Since 1989, FSGC has been supporting the expansion and diversification of Florida’s space industry, through providing grants, scholarships, and fellowships to students. We are very grateful for the opportunities that FSGC has granted for us.

We would also like to than Florida State University’s Innovation Hub and their staff for providing our team with 3D printing materials and tools. Lastly, we want to thank our advisors, Dr. Shayne McConomy and Dr. Chiang Shih for their guidance throughout our project. Their vast knowledge and expertise helped us in many ways, but especially in broadening our engineering minds. Together they supported our team in bringing our aircraft into fruition. We are very grateful.

Project Scope Project Description The objective of this project is to engineer, build, and compete a validated scaled aircraft, one which adheres to rules from the SAE Aero Design competition. Key Goals We will represent FAMU-FSU College of Engineering by attending and competing with an original designed aircraft. The aircraft will be engineered and fabricated to follow the competition rules of both the SAE aero design regular class competition. We will focus on many, but not all, competition scoring parameters to earn a high ranking. These parameters shall be determined by the design team. Once built, the aircraft will undergo testing and verifications before competing to ensure eligibility. Although the project will be funded by the Florida Space Grant, Team 524 will seek additional funding from outside sources. Market We have no intent of creating a marketable product. However, because our product will compete in a competition with the scoring of the design and performance done by the competition judges, it is important to appeal to those who will make jurisdictions to maximize contest points. Assumptions Meeting the expectations set by our shareholders and competition judges will require additional funding. Expenses to enter the competitions and buy the necessary materials to build our aircraft are not fully covered by the Florida Space Grant. Therefore, we will have to seek additional funding to complete the project. All team members have read the competition rulebooks and are fully aware of any design restrictions. [SM1] Any prizes or awards earned due to the competitions will be evenly distributed between all members of the team. Shareholders The shareholders for the SAE Aero Design Competitions Project: Dr. Shayne McConomy Dr. Chiang Shih Florida Space Grant FAMU-FSU College of Engineering

Customers The customers for this project are Dr. Chiang Shih, Dr. Shayne McConomy, the Florida Space Grant, the SAE Aero Design judges, and the specific events that the aircraft will be competing in. Needs Assessment GENERAL AIRCRAFT REQUIREMENTS GENERAL AIRCRAFT REQUIREMENTS Competing designs are limited to fixed wing aircraft only. The wings of the aircraft will be fixed to the body of the aircraft. All aircraft must be controllable in flight. The aircraft is controlled by the user during flight. If an aircraft is equipped with a wheeled landing gear, the aircraft must have some form of ground steering mechanism for positive directional control during takeoffs and landings. Ground steering mechanism will be present in final product. All aircraft must utilize either a spinner or a rounded model aircraft type safety nut. Aircraft will have either a spinner or rounded model aircraft safety nut. Metal propellers are not allowed. Propellers of the aircraft will be made of non-metals materials. The use of lead in any portion of any aircraft (payload included) is strictly prohibited. The aircraft (including solder) will be lead-free. The payload cannot contribute to the structural integrity of the airframe. The payload of the aircraft will not help support the structure of the aircraft. Aircraft must be powered by the engine(s)/motor on board the aircraft. Aircraft will be powered by an onboard motor. Aircraft control surfaces and linkage must not feature excessive slop. Aircraft control surfaces and linkage must not feature excessive slop. All control clevises must have additional mechanical keepers to prevent accidental opening of the control clevis in flight. Accidental opening of the control clevis will be prevented with additional mechanical keepers. All electric powered aircraft MUST use a discrete and removable red arming plug to arm and disarm the aircraft propulsion system. The aircraft will have a desecrate and removable “kill switch” to arm and disarm the aircraft. MATERIAL AND EQUIPMENT RESTRICTIONS The use of Fiber‐Reinforced Plastic (FRP) is prohibited on all parts of the aircraft. Exceptions to this rule include: commercially available FRP motor mount, propeller, landing gear and control linkage components. Exploration of alternative materials is encouraged. The aircraft will not contain any Fiber-Reinforced Plastic on any parts of the aircraft. Elastic material such as rubber bands shall not be used to retain the wing or payloads to the fuselage. No elastic material will be utilized in the final product. AIRCRAFT SYSTEM REQUIREMENTS AIRCRAFT SYSTEM REQUIREMENTS The aircraft shall be propelled by a single electric motor (no multiple motors), but with no restrictions as to which make or model of motor. The aircraft will be propelled by a single electric motor. Gearboxes, belt drive systems, and propeller shaft extensions are allowed as long as a one‐to‐one propeller to motor RPM is maintained. One-to-one propeller to motor RPM will be maintained. Regular Class aircraft must be powered by a commercially available Lithium‐Polymer battery pack. Aircraft will be powered by a commercially available Li-ion battery. AIRCRAFT SYSTEM REQUIREMENTS If a separate battery is used for the radio system, the battery pack must have enough capacity to safely drive all the servos in the aircraft, taking into consideration the number of servos and potential current draw from those servos. If a separate battery is used for the radio system, the battery pack will have enough capacity to safely drive all the servos in the aircraft. PAYLOAD REQUIREMENTS Both the Passenger Cabin and Payload Bay must be designed for ease of access to both Passengers and Luggage. The passenger cabin and payload bay will be designed for ease of access to both passengers and luggage. Regular Class aircraft shall have a single fully enclosed Payload Bay for carrying Luggage. Aircraft will have a single fully enclosed payload bay for carrying luggage. Luggage shall consist of the payload plates and support structure used to retain the weight(s) in the Payload Bay. Luggage will consist of the payload plates and support structure used to retain the weight(s) in the payload bay. Regular Class aircraft must position all Passengers in a single Passenger Cabin. The aircraft will have a single cabin space to hold passengers. DR. SHIH’S DIRECTION The wings of the aircraft should be traditional and the data for this should already be readily available. The wings of the aircraft will be traditional, fixed aircraft wings. Focus your research on the impact force when landing the aircraft The aircraft must be able to withstand any possible crash. The structure/frame of the aircraft will need to be the strongest component. The aircraft frame will be durable and able to withstand any forces that it may encounter from takeoff to landing.

General Requirements

Restrictions

System Requirements

Payload Requirements

Advising Direction

Customer Statement

Competing designs are limited to fixed wing aircraft only.

All aircraft must be controllable in flight.

If an aircraft is equipped with a wheeled landing gear, the aircraft must have some form of ground steering mechanism for positive directional control during takeoffs and landings.

Interpreted Need

The wings of the aircraft will be fixed to the body of the aircraft.

The aircraft is controlled by the user during flight.

Ground steering mechanism will be present in final product.

Customer Statement

Interpreted Need

Customer Statement

Interpreted Need

Customer Statement

Interpreted Need

Customer Statement

Interpreted Need