COLLEGE OF ENGINEERING BULACAN STATE UNIVERSITY CITY OF MALOLOS, BULACAN

MANUS FACTUS I
Abstract This study is a collaborative project with the 4th year Manufacturing Engineering and Management students which aims to build Manus Factus I-a remote controlled plane using plywood as its primary material. Manus Factus I is 2 meters long, engine-driven and capable of flying up to 3 kilometers through the air supported by the action of air against its wings.

I.

INTRODUCTION

Flexibility. Innovation. Intelligence. These are important qualities demanded from engineers in today's fast-paced and ultra-modern world, qualities that are developed through an engineering education that is high tech, multi-disciplinary and equipped by substantial knowledge. Such education is offered by hybrid courses that are formulated from the conventional engineering courses. Here in Bulacan State University, students get that education and more from the Manufacturing Engineering and Management course under the College of Engineering. Only few and selected universities in the Philippines offer the said course. MEM (Manufacturing Engineering and Management) is an interdisciplinary engineering course that integrates mechanical engineering, electronics engineering, computer studies and modern management into a single five-year degree program. In addition to this, students are taught to apply mathematics, engineering design methods, manufacturing materials and processes, electronics, computer studies,

automation technology and the management of people and technology to answer the needs of the growing manufacturing industry in the Philippines. In accordance to this, MEM also specialize production of aircraft as part of its curriculum. Though in real life situation, actual production of aircraft at large scale is impossible at the school grounds due to the reasons that the production of one aircraft takes very long years of planning and the funding is beyond expensive. However, an airplane, as a highly sophisticated flying vehicle, might as well be produced in a small scale without leaving the principles that are also implemented when manufacturing large scale aircrafts.

II.

Study Objectives
To utilize the knowledge learned in our course duration focusing basically on MEM 452 (Tool Engineering: Aircraft Production, Jigs and Fixtures) To continuously improve our abilities as manufacturing engineering and management students by triggering our strengths and weaknesses. To make our study as the precursor of the development of the project Unmanned Air Vehicle Project of B.S.U..

III.

Conceptual Framework
INPUT PROCESS
Brainstorming -balsawood -spars -adhesives
-Servo -fuel pump -wirings -propeller

OUTPUT
Remote Controlled Airplane

Raw Materials -ply wood -stocks -hinges -birchwood -nitro fuel -screws&bolts
-fuel hose -switch -wood glue -fuel tank

Project Visualization Designing and Computation Purchasing Fabrication

-threads
-battery -fuel filters -spinner -engine

Tools & Equipments -coping saw

-hack saw -boring machine -finishing tools -sanding block -paint brush

Testing Maintenance

Human Ware -machinists

IV.

Project Duration: Total no. of weeks: 11 weeks No. of man hours: 17 hours per week Product Breakdown:
1. Air Frame a. Wings b. Fuselage c. Tail Section d. Landing System 2. Power Plant a. Engine b. Spinner c. Propeller d. Engine Mount 3. Systems 3.1 Avionics a. Receiver (RX) b. Transmitter c. Servo d. Battery e. Switch f. Wiring g. On Board Igniter *optional 3.2 Fuel System a. Fuel tank b. Fuel Hose c. Fuel Pump

V.

VI. Methodology I. PART BY PART ASSEMBLY

A. B. C. D. E. WING FUSELAGE TAIL SECTION LANDING GEAR ENGINE MOUNT

F. FUEL TANK MOUNT G. WING ATTACHMENT

II.

METHODOLOGY OF THE PROJECT

1. Learned the concept of production planning & control. 2. Learned different concepts in tool engineering. 3. Exposure about the concept of the specific project to be made. -Visualization of a real prototype remote controlled plane. -Witnessed live test flights of several kinds of remote controlled planes in Pulilan, Bulacan. 4. Proper Documentation

A. Wing 1. Exposure to various airfoils profiles such as NACA 4521, Clark Y- 21, Gotingen, etc. 2. The proponents learned the different characteristics of the airfoil and selected Clark Y-21 as the airfoil to be used. 3. Select an aspect ratio (AR). The proponents used AR=6.25. 4. Plot the airfoil to its actual chord using AutoCAD. 5. Make a stainless steel pattern traced from the cut printed AutoCAD airfoil drawing. 6. From that selected wing dimensions the proponents will come up with wing generate wing plan form (3 view drawing: front view, side view and top view) 7. Estimate the overall weight of the aircraft that will serve as the basis in determining the structural of the wing. 8. Applying the Shear & Moment Diagram of the wing base.. .. FOR THE RIBS: 1. Make layout of the pattern in plywood in preparation for cutting. On cutting, few light passes is recommendable. 2. Determine the location of the slots of the spars, lightening holes and leading edge. Lightening Holes (*computation) 3. Produce slots for the upper and lower spars on the cut ribs. 4. Using the drilling machine, create lightening holes on the ribs. 5. Hold all the ribs together side by side using the clamper. Use crosscut saw/ hack saw to cut the leading edge. This process is reversible. FOR UPPER AND LOWER SPARS 1. Cut the upper and lower spar made by birch wood with the dimensions of 100x1x1 cm. 2. Determine the spar location based on the usual airfoil angle of attack based on its characteristic curve.

FOR LEADING EDGE STOCK ---FOR AILERON STOCK --FOR WING ASSEMBLY 1. Divide the meter sticks into two crosswise and produce two pairs of 1x1x1 cm; this will serve as the wing spars (lower and upper spars). 2. Attach the ribs to the upper and lower spars with the distance of 10cm each rib. 3. Insert the body connector to the hole of leading edge and trailing edge. 4. Between the upper and lower spar, the _______that will serve as the strength of the wing. 5. Make a box for the servo provided that the location of the box would not affect the balance of the wing. 6. On the leading edge attach soft balsa wood that will serve as the leading edge stock. 7. On the trailing edge, attach soft balsa wood that will serve as a trailing edge stock. 8. On the leading and trailing edge, wound around the cap strip. 9. Using the sanding block, refine the surface of the leading edge that will match the contour of the foil. 10. Attach cap strips to each ribs. 11. Attach the aileron stock to the trailing edge using the hinges. 12. Cover the skeletal framework of the wing with balsa sheets. 13. Make the connecting rod for the servo to aileron stock.

VII. Financial Study:

A. BILL OF MATERIALS 1. Air Frame Qty. Article / Description 16 Ribs 4 Spars Aileron Hinges Adhesives Fasteners Plans Jigs 1 Landing Gear Strut 2 Landing Gear Tires

Item No.

Unit Price

Cost

Total Cost: 2 Power Plan Qty Article / Description Engine Engine Mount Fasteners Spinners Propellers Starters

Item No.

Unit Price

Cost

Total Cost: 3. Avionics Qty Article / Description 1 Receiver *borrowed 1 Transmitter *borrowed 5 Servo 2 Battery 2 Switch 3 Wiring

Item No.

Unit Price

Cost

Total Cost:

4. Fuel Qty 1 1 1 2

Article / Description Fuel Hose Fuel Tank Fuel Pump Fuel Filters

Item No.

Unit Price

Cost

Total Cost: B.TOOLING EXPENSES C. OTHER EXPENSES: Transportation Communication Food Labor

FINAL COSTING WITH BORROWING: FINAL COSTING WITHOUT BORROWING: __

VIII. Documentation

JULY 13, 2012 FRIDAY (8:00 9:45am)

OBJECTIVES: To choose a name for the product Planning Breakdown Brain-storming Grouping

OUTPUT:
PRODUCT NAME: Manus Factus I GROUPINGS: Central programme/planning group

Methods Engineering Group: Jayrald Tagaban Josef Justin Galicia Peejay Soringa Shop Progress Group: Val Salamat Lloyd Pe Criselito Rastica

Scheduling Group: Charmaine Yumul Crizza Darlene Asilom Materials Planning Group: Nesirine Hernandez Marylouie Gatuz Tool Engineering Group: Jay Tristan Salas Mark Angelo Santiago Virgilio Santos

Auxiliary Group: Jaybee Arvin

Dyan Stanley Norman Paulo Michael Charles Daniel Ace

JULY 15, 2012 SUNDAY (8:30 11:00am)

OBJECTIVE: To expose the students to various kinds of RC Planes o Jessica o Regginald o Nesirine o Marylouie o Beejay o Charmaine Yumul o Charmaine Ponti o Crizza o Vergel o Tristan o Cris o o o o o o o o o o o Michael Charles Peejay Dyan Jaybee Aleli Allan Stanley Val Justin Mark

JULY 17, 2012 TUESDAY

OBJECTIVES: Planning Breakdown o all

JULY 23, 2012 MONDAY (10:50 11:20am)

OBJECTIVE: To layout airfoil design of CLARK Y-21 in Autocad Jessica Reggi Jayrald

July 27, 2012 FRIDAY (8:30 9:19am)

OBJECTIVES: To generate construction manual for Remote Control Airplane Methods To list all necessary materials (raw materials) To identify every single part and material needed for the construction of the project To enumerate every single tool, its quality and condition in building the project To produce comprehensive blueprint of the entire project

OUTPUT:

B1
B1 EH B1 BC B1 BCR B1 BCRS B1 CRGR B1 CWR B1 CWCR B1 CRGE B1 CGTE B1 SHTH B1 CGTTH B1 CRTH B1 CRTHCo B1 CGRM B1 CGTM

BODY 1
ELECTRONICS HOLDER BELL CRANKS BELL CRANK RUDDER BELL CRANK RUDDER SCREW CONTROL ROD GUIDE FOR RUDDER CONTROL WIRE RUDDER CONTROL WIRE CRIMPS CONTROL ROD GUIDE FOR ELEVATOR CONTROL GUIDE TUBE FOR ELEVATOR SERVO HOLDER THROTLE CONTROL GUIDE TUBE THROTLE CONTROL ROD FOR THROTLE CONTROL ROD FOR THROTLE COLLAR CONTROL GUIDE RUDDER MAIN CONTROL GUIDE TUBE MAIN

B3
B3 FW B3 FWBN B3 EML B3 EMR B3 EMBN B3 EMBNFW

BODY 3
FIREWALL (MADE OF PLYWOOD) FIREWALL BOLTS AND NUTS ENGINE MOUNT LEFT ENGINE MOUNT RIGHT ENGINE MOUNT BOLTS AND NUTS ENGINE MOUNT BOLTS AND NUTS FIREWALL

ES
ES RX ES SVO

ELECTRONICS
RECEIVER SERVO (S-3000C)

ES BAT ES YC ES SW

BATTERY Y CONNECTOR SWITCH

PP
PP E PP T PP S P PP S H1 PP S H2 PP S H3 PP S S

POWER PLANT
ENGINE TANK PROPELLER HOSE 1 HOSE 2 HOSE 3 SPINNER

B4

BODY 4
HORIZONTAL STABILIZER VERTICAL STABILIZER

B5
B5 LGSR B5 LGSL B5 LGT B5 WC B5 SS B5 TG B5 H B5 TGS B5 TGT B5 TGWC

BODY 5
LANDING GEAR STRUT RIGHT LANDING GEAR STRUT LEFT LANDING GEAR TIRE WHEEL COLLAR SET SCREW TAIL GEAR HOLDER TAIL GEAR SPRING TAIL GEAR TIRE TAIL GEAR WHEEL COLLAR

JULY 31, 2012 TUESDAY (10:50am 12:00pm)

OBJECTIVES: Regrouping (11:00 11:15am) all To list the remaining materials needed for the construction of the project (11:15 11:50am) Nesirine Vergel Regginald Cris Tristan Paulo Mark To produce copies of plan (10:50 11:20am) Val Dyan Cris

OUTPUT:
Methods Engineering Group: Jayrald Tagaban Stanley Joseph dela Cruz Shop Progress Group: Val Salamat Virgilio Santos Scheduling Group: Charmaine Yumul Crizza Darlene Asilom Materials Planning Group: Nesirine Hernandez Marylouie Gatuz Tool Engineering Group: Jay Tristan Salas Mark Angelo Santiago Documentation: Beejay Jaype Jaybee Bernardo Auxiliary Group Leaders: Charmaine Anne Ponti Josef Justin Galicia

AUGUST 3, 2012 FRIDAY (7:30 10:00am)

OBJECTIVES: To make a list of the measurement of screws & different parts of the plane (7:30 10:00am) Marylouie Wing (8:20 8:55am) Jayrald drawing Justin Body2(head) (8:19 10:00am) To list the remaining materials needed for the RC Plane (7:20 10:00am) Nesirine Lloyd To schedule the activities for the following weeks (8:19 8:55am) Dyan Crizza Charmaine Yumul To list the tools needed for the project (8:19 9:05am) Tristan Mark Vergel To make a draft of the documentation (8:30 10:00am) Charmaine Ponti Beejay Jaybee To create methods in making the project (8:19 10:00am) Stanley Val Arvin To estimate the cost of materials (8:44 9:50) Allan Aleli To layout the plan of the project in Autocad including the measurements (9:00 10:00am) Jayrald

Methods Engineering Group: Jayrald Tagaban Stanley Joseph dela Cruz Josef Justin Galicia Shop Progress Group: Val Salamat Criselito Rastica John Paulo Pagtalunan Arvin Santos Norman Perez Scheduling Group: Charmaine Yumul Crizza Darlene Asilom Dyan de Guzman Materials Planning Group: Nesirine Hernandez Marylouie Gatuz Lloyd Pe Peejay Soringa Daniel Tool Engineering Group: Jay Tristan Salas Mark Angelo Santiago Charles Francia Virgilio Santos Ace Anthony Gurion Documentation: Beejay Jaype Jaybee Bernardo Charmaine Anne Ponti Michael Francia

IX. Evaluation and Testing X. Recommendations