HALE UAV Preliminary Design SAURON

AERSP 402B
Spring 2014 Team: NSFW

Nisherag Gandhi Doug Rohrbaugh

Thomas Gempp Gregory Snyder

Steve Stanek

Victor Thomas

Mission Statement
To design a High Altitude / Long Endurance (HALE) UAV using alternative fuel sources to support homeland security efforts with a concentration in long term border security.

Design Changes
v1 v4

v2 v5

v3 v6

Sauron v7

Design Changes Wing and Tail

Design Changes Landing Gear

Dimensions
Parameter
Airfoil Span (ft.) Reference Chord (ft.) Area (ft.2) Cruise CL Span Efficiency

Wing
SM701 128.6 4.0 557.5 0.66 1.01

Tail
Jouk0015 18.0 2.5 45.0 0.09

Max CL
Power Generated (kW) Aspect Ratio Neutral Point Location (ft.) C.G. Location (ft.)

1.4
16.93 29.6 13.4 13.2

Wing/Tail Lift Distribution

Structures Materials
HexPly M91 - Epoxy Matrix for primary aerospace structure High residual compression strength after impact (CAI) Supports automated manufacturing HexTow IM10 - Carbon Fiber 12k tow Suitable for weaving, prepregging, filament winding, braiding, and pultrusion Enhanced tensile properties Highest commercially available tensile strength

M91/IM10

* Avg. cost: $45/lb.

Structures Materials
HexTow IM10 Carbon Fiber
# of Filaments Filament Diameter (microns) Tensile Strength (MPa) Tensile Modulus (GPa) Strain (%) Density (g/cm3) 12000 4.4 6964 310 2.0 1.79

Epoxy-Fiber (Prepreg) Combination (M91/IM10) Theoretical Values

Cured Ply Thickness (in) Fiber Volume (%) ~ 0.0072 ~ 58.9

Laminate Density (g/cm3)

Laminate Modulus (GPa) Tensile Strength (MPa)

~ 1.4
~ 200 ~ 3620

Wing Spar Design

Wing Weight and Lift Distribution

Wing Moment and Stress

Wing Deflection

Wing Deflection Analysis

H &V Stabilizer Spar Design

Horizontal Stabilizer Lift Distribution

H. Stabilizer Moment and Stress

H. Stabilizer Wing Deflection

Vertical Stabilizer Weight and Lift Distribution

V. Stabilizer Moment and Stress

V. Stabilizer - Deflection

Weight Breakdown
Aircraft Part
Wing Fuselage Horizontal Stabilizer

Empty Weight (lbs)

126.89 32.77 10.24

Parameter Total Empty Weight Battery

Empty Weight (lbs) 404.44 180.00

Vertical Stabilizer
Solar Cell Wing Spar

3.98
87.53 70.38

Payload Total

250.00 834.44

Vertical Stab Spar

Horizontal Stab Spar 4 Motors Fuselage Formers Gear System Total Empty Weight

0.71
1.87 16.00 15.00 40.00 404.44

Control Surfaces

Aileron
Control Surface Area: 3% Pcruise|61k ft = 13.8 deg/sec Pstall|61k ft= 11.5 deg/sec Required Aileron Deflection =10

Elevator
Lift Coefficient, CL Elevator Deflection () 1.55

Control Surface Area: 46.7% Pitch Rate= 9 deg/sec Required Elevator Deflection= -2.6

0.1

0.4
0.66 1.0 1.4

0.90
0.25 -0.74 -2.14

Rudder
Control Surface Area: 42.9% Rudder Deflection: 20 Maximum Sidewash: 10 Max Crosswind: 12.5 ft/s

Control Surface Demo

Airfoil Selection
Wing Airfoil H&V Stabilizer Airfoil

Updated Drag Analysis

Updated Drag Analysis

Sea Level 45,000 feet 61,000 feet 79,000 feet

Stall Speed (ft/s)

Cruise Speed (ft/s) Max Speed (ft/s) Total Drag (lbs)

37.0
44.4 113.0 18.4

83.9
100.7 191.5 20.3

122.3
146.8 245.3 22.5

188.7
226.5 294.0 26.9

Power Required (kW)

Reynolds Number CDo Oswalds Efficiency Max L/D

1.05
1,129,663.40 0.0087 0.76 46.7

2.7
626,856.80 0.01 0.73 42.4

4.3
429,692.6 0.0105 0.69 38.2

8.1
274,504.6 0.0125 0.63 31.9

Updated Power Analysis

48 hour UAV Power Plan
16 14 12 Previous Power Calculation Current Power Calculation

Power (Kilowatts)

10 8 6 4 2

10

15

20

25

30

35

40

45

50

Time (hours)

Takeoff
Parameter Sea Level Denver Afghanistan

Ground Roll [ft] Vtakeoff [ft/s]

dab|35ft [ft] dab|50ft [ft] Dtotal|35ft [ft] Dtotal|50ft [ft] Thrust [lbs]

Landing
Parameter
Va [ft/s] a [deg] Radius [ft] Flare Height [ft] Flare Speed [ft/s] da35ft [ft] da50ft [ft] df [ft] VTD [ft/s] Thrust [lbs]

Sea Level

Denver

Afghanistan

Constraint Diagram

Original

Current

Cost Analysis
Fixed Costs for 5 Developmental Aircraft:
Engineering Costs: $29,869,717.35 Flight Test Ops: $17,638,487.67 Tooling: $4,567,827.99

Pricing

Pricing Summary
1 Design Aircraft Engineering Costs Flight Test Ops Tooling Costs Manufacturing Costs Quality Control Costs Total Materials Costs Design Materials Costs Production Materials Costs Total Frame Costs Minimum Price Per UAV $ $ $ $ $ 3,411,149.77 490,688.06 889,569.58 741,307.99 148,261.60 $ 14,924,534.27 $ $ $ $ 2,146,868.71 2,223,923.96 741,307.99 1,482,615.97 10 100 5 $ 29,869,717.35 $ 17,638,487.67 $ $ $ $ $ $ 4,567,827.99 65,298,136.52 9,393,025.19 15,567,467.69 741,307.99 14,826,159.71 $ 183,206,365.99 $ $ $ $ 26,353,922.21 74,872,106.51 741,307.99 74,130,798.53 $ 285,693,781.52 $ 41,096,561.54 500 1000

$ 149,002,905.04 $ 741,307.99

$ 148,261,597.05 $ 531,727,226.80 $ 531,727.23

$ 60,725,386.10 $ 60,725,386.10

$ 75,229,305.63 $ 7,522,930.56

$ 146,192,608.09 $ 1,461,926.08

$ 340,366,373.41 $ 680,732.75

* +$2M per for custom sensory packages

Comparison to Competitors
RQ-1/MQ-1 Predator
Unit Cost: $4.03M 360 Built

RQ-4 Global Hawk

Unit Cost: $131.4M 42 Built

MQ-9 Reaper
Unit Cost: $16.9M 104 Built

Solara 50/60
Unit Cost: $1-2M N/A Built

14 Days Til Graduation

Questions?

Double Camera

Summary
Parameter Aspect Ratio Empty Weight Ratio Battery Weight Ratio Battery Charge Density (watt-hr./kg) Solar Cell Efficiency L/D Value Parameter Sea Level 45,000 ft. 61,000 ft.

Stall Speed (ft./sec) Cruise Speed (ft./sec) Total Drag (lbs.)

Max L/D Power Required to Cruise (kw) CL at Cruise Reynoldss Number at Cruise

Wing Loading (lbs./ft. )

Takeoff Weight Payload (lbs.) Wing Area (ft. ) Proj. Wing Span (ft.) Ref. Chord Length (ft.) Oswalds Efficiency Thrust to Weight Ratio
2