Aircraft Design Project Memorandum

Transcription

1 Date: 9 September 2013 To: Aircraft Design Project Team From: Prof. Jeremy Laliberté, Project Manager Subject: 4th Year Aerospace Engineering Project (Aircraft) Course AERO 4907A-13 1 General The Carleton UAV Team will undertake the design, fabrication and testing of two different uninhabited aerial vehicle (UAV) systems this year. The first system is GeoSurv II a geophysical survey UAV under development with Sander Geophysics Ltd (SGL) since The second is the Corvus UAV system whose conceptual and preliminary design and basic operational concept was developed by the Teams.. A list of the most important technical tasks identified to date by the Lead Engineers is provided in Annex A. Additional tasks will be identified by team members as they prepare the project plan during the first two weeks of the term. Below is a summary of the high level tasks that apply to most or all of the Team: 1. GeoSurv II Prototype investigate high speed taxi test accident, re-design radio system to increase range, manufacture new components (propulsion system, main landing gear, empennage and fuselage), re-assemble aircraft, revise test plans, carry out ground testing and high speed taxi test in Winter term with a test flight if conditions permit. 2. Corvus Demonstrator complete detailed design, fabrication and assembly of wing and fuselage, integrate propulsion system, test and integrate flight avionics system (MicroPilot) and prepare for taxi testing in Winter Term, complete hardware-in-theloop test system with ArduPilot. 3. Avionics Test Beds Complete the assembly of the trainer aircraft, conduct test flights with ATB-10 to gain field testing experience. Results of ATB-10 flights will be used to develop a basic flight mechanics model of the aircraft. 4. Improve and maintain the project documentation system (solid model, manufacturing drawings, configuration databases, design reports, etc.); Support outreach, open house and fund raising activities (e.g. CUESEF, CSES and external) Page 1 of 11

2 2 Project Planning To prepare for the work associated with the two aircraft systems described above, all groups will carry out the following activities during September: o Under the Lead Engineers direction, the teams will become familiar the results of the work from teams prior to 2012 accessible from the project web page and the new culearn site: o logon: uav password: spitfire o Design reports (pre-2011): o Data for the year and onwards will be stored on the project culearn site. This site will be accessible to all students and Lead Engineers. o Each design group will define plans for both terms including tasks and milestones. The plans shall be compatible with the stated project objectives and shall include preparation of a high level project schedule, work breakdown structure (WBS) and necessary purchases. Lead Engineers will support the identification of milestones compatible with the objectives. The Design Integration group will collect inputs to prepare the master schedule, WBS and budget. o Accurate and timely formal and informal communication is critical to the success of projects such as this. The means of formal team communication will be provided to the students and it is their responsibility to use these tools in a professional manner to maintain open and timely communications. o Additional Pro/E, CFD and FEA training will be provided as required. This year s baseline Project Plan (Tasks, Schedule, Budget) will be developed over a two week planning period with the Lead Engineers that will be kicked off during the first meeting on 9 September As the first deliverable in this process, on Monday 16 September 2013 each group will present its summary task list to the entire team. Then, during the meeting on 23 September 2013, the Team will present the high level project plans for GeoSurv II and Corvus for the Fall and Winter terms. Final decisions on the direction of the project will then be made by the team and development work will proceed iteratively during the two terms. Internal team reviews will be held regularly to ensure that the design meets the requirements and the project is on schedule. The Project Plan is a document that is to be updated based on project progress and experience. While Integration will be responsible for maintaining the Plan, each group is responsible for reviewing it and updating as needed. Page 2 of 11

3 3 Project Organisation The design team will be divided into four Groups during the first project meeting on 9 September The Lead Engineers, working with the student group members will define the breakdown of individual responsibilities within the Groups. The Integration Group will prepare a contact list for the team. The Groups and their respective Lead Engineers are as follows: Design Integration and Mission Analysis (INT) Prof. Laliberté o 2 students Aerodynamics and Propulsion (AER) Prof. Gaydos o Nominally 7-8 students Structures and Mechanical Systems and Propulsion (STR) Prof. Tan o Nominally 7-8 students Avionics and Flight Test (AFT) Prof. Laliberte, Mr. Bauer and Dr. Paul Pace o Nominally 7-8 students Students will be expected to communicate and work across group boundaries. Many major project tasks and systems will be worked on by teams of students from across multiple groups as outlined in Annex A. This emulates some aspects of a matrix organization in industry. The general responsibilities of the various project Groups should be reasonably clear from their names. However, some students may not be clear about the Design Integration and Mission Analysis Group s (INT) responsibilities; they apply across the project and include: Coordination of compliance documentation and special flight operations certificates Configuration management Design integration, aircraft solid models and drawings (models and drawings of components shall be supplied by the team members), databases, register of documents and (e.g. Design Reports and drawings) Organizing flight tests the development of specific Flight Test Plans is the responsibility of the appropriate technical groups and the Flight Test Group. Mission analysis and simulation for both aircraft Air vehicle documentation and weight control, weight and balance, system costs Updating the GeoSurv II System Design Requirements Document with input from SGL. Organization of the air vehicle assembly and integration Project web page updates, preparation of Minutes of meetings, integration of project schedule from group inputs Pro/E training for the team members After the first meeting, each group shall appoint a liaison engineer to work with the Design Integration Group on issues of conflict resolution, configuration management, inter-group communications and certification. Additionally, if another group is unsure of the specific point of contact within another group for a particular topic, they should contact the liaison engineer first. The liaison engineers will also share responsibility for preparing the Group Progress reports, managing the DR database and compiling Group Plans with the Design Integration Group. Page 3 of 11

4 4 Major Project Milestones The team, as mentioned in the Introduction, shall prepare the overall work schedule for the project incorporating the milestones below. The following milestone dates must be met for the project. Additional specific deliverable dates may be established as the project progresses. At the Fall Design Review, all groups undertaking new designs or detailed designs will be expected to present their proposed designs for approval for manufacturing or to proceed to subsequent design phases. Fall Term o Project Kick-off Meeting 9 September 2013 o High level task outline from each Group: 16 September 2013 o Baseline Project Plan 23 September 2013 o First Design Report to LEs for review End of October o Fall Design Review (FDR) 29 November 2013 o Hand in all Fall term work 9 December 2013 Winter Term o Winter Term Kick-Off Meeting 6 January 2014 o MAE Engineering Design Forum 5 April 2014 o Final Report Draft for LE Review 31 March 2014 o Final Project Deliverables (group submission) 9 April Communications Good communication within and between groups is essential as emphasised above. As in previous years, we will be using weekly team meetings, a web-based memo system, shared project drive and a site hosted on Carleton s Learning Management System - culearn. The project drive will be discussed in further detail below. There are two project meetings per week: Team meetings will be held on Mondays from 0835 to 1125 in Room 3103CB, to review progress, identify problems and decide on courses of action. Each meeting will begin with opening remarks by the Project Manager and Lead Engineers, followed by brief presentations by one (occasionally more as needed) representative of each group to discuss major work packages. This change will shorten the meetings and allow the group to focus on the progress of each work package. While there are no set time limits for these presentations, each group should focus on technical progress and problems. The work status shall be presented with reference to each group s project plan and schedule. Integration will keep a record of decisions and action items arising from the main meeting to be posted on the project website each week. Following the main meeting, the groups will have breakout meetings as needed. A second 3-hour group meeting timeslot (Fridays ) is to be used for technical work and group meetings. Each group may move this slot to a different day/time if desired. Attendance of all team members at both weekly meetings is mandatory. Page 4 of 11

5 6 Work Breakdown Structure (WBS) Each group will develop and present a high level task breakdown as part of the project plan review on 23 September The "charge" numbers or WBS codes open for this phase of the project will be posted on the web page once the WBS is complete. Only the listed numbers can be used. Additional numbers can be requested as the work progresses. Until the full WBS is complete, all team members shall use the following WBS codes for tracking their time on blank timesheets which can be found on the project website: 1.0 Project Management and Administration 1.1 Team and group meetings 1.2 Review of previous work 1.3 Planning 1.4 Pro/E training Following the development of the project plan each group will track its work under major WBS headings corresponding to each Work Package: 2.0 GeoSurv II Prototype 3.0 Corvus Demonstrator 7 Safety and Project Facilities Members of the team working on the project must follow the posted safety rules of the facility they are using (e.g. MAE Machine Shop, Composites Shop, etc.). Additionally, since some groups work with carbon fibre composites on this project, there shall be no infusion, cutting, sanding or drilling of carbon fibre composites in the UAV room or main MAE Structures Lab. This is both for personal safety and to prevent damage to sensitive electrical equipment by conductive carbon fibres. Any work of this type with carbon fibre composites must be done in the MAE composites shop following the posted safety procedures. The Department has implemented a new policy only students who have completed training with composites will be allowed to use these facilities. The Project Manager will organize the training for UAV project students expected to use the facilities. The Team has at its disposal the following dedicated facilities: MAE Meeting Rooms MC, 3149ME, 3103CB, 3124ME: These are large meeting rooms that can be booked by students and Lead Engineers for meetings as needed. A smaller room, 3131ME, is also available for smaller groups. See the MAE Office for bookings on a first come first serve basis. UAV Project Workspace ME: Structures Lab within which there is a UAV Project Room. This room is used for work on the various Avionics Test Bed Aircraft, storage and maintenance of UAV equipment and hardware and mechanical assembly work. Page 5 of 11

6 8 Deliverables There are several types of documents that team members are responsible for submitting throughout the year, in electronic and/or paper format. 8.1 Fall Group Progress Reports Each Group shall submit at the end of the Fall Term, a group progress report. Each Group will submit one combined report outlining Summary of Fall Term Plan, Tasks Accomplished, Problems Encountered, Summary of Hours and List of Design Reports for the Fall Term. 8.2 Design Reports (DRs), Solid Models and Drawings All the work shall be covered by design reports prepared to the requirements of [1] and especially the design report notes on the web page. Lead engineers will require each team member to submit a design report on a specified topic by the end of October These reports will be reviewed by the Lead Engineers for compliance with the DR requirements on the Project website and feedback will be provided [1,2]. DRs shall be prepared using MSWord or Mathcad, with standard templates provided on the project website. It is also required that any supporting files (in the appropriate format) be submitted to INT with the DR (e.g. Mathcad files, Excel worksheets, Matlab code, drawings, etc). All DRs are assigned a report number by Group Liaisons. Detailed DR writing guidelines can be found on the project website. All approved solid models will be assigned a unique ID number by Integration and must follow the applicable standards for the type of drawing, e.g. composite part, metal part, assembly, etc. Format of two-dimensional drawings not derived from the solid models should be discussed with the relevant Lead Engineer. Shop drawings must meet the requirements of [3]. Integration will maintain the Pro/E solid model and its associated database and exercise configuration control over the solid model. 8.3 Individual Timesheets Every team member shall keep track of the time spent on project work, and shall submit a timesheet for weekly approval by their Lead Engineer. Students will use the WBS codes to charge their time against. All timesheets must be handed in at the end of the term. A timesheet template can be found on the website you must have your Lead Engineer initial each week s total hours. 8.4 Fall Term Project Deliverables On 9 December 2013 by 1600 each group will submit to the MAE Department Office a single work package for marking consisting of the following: Group progress report all completed and checked design reports for each student in the Group completed and fully initialled timesheets for all students Any other work completed throughout the term including Design Approval Packages, Design Change Requests and Test Plans (these should all be captured and numbered as DRs). Page 6 of 11

7 9 Formal Fall Design Review A formal Fall Design Review will be held on 29 November During the review, each team member will be allowed 8 minutes plus 2 minutes for questions, to present her/his term work. 10 Filing System The documentation system for this project is a mixture of paper and electronic records as is typical in industry and government organizations. An electronic folder structure will be established by Integration on the shared UAV Project network drive. The INT Group will provide instructions on how to map to the current network drive and to the read only archives of previous years. Do not make a copy of the entire previous year s drive only copy the files you need for your present work. 11 Marking Performance of each team member will be individually assessed on the basis of the work accomplished in the assigned area of responsibility. Each team member will be required to make two oral presentations of her/his work at the two formal reviews in November and March. The two term performance evaluations by Lead Engineers and will include attendance, quality and quantity of work, contributions to technical and non-technical activities and meetings, team performance and leadership. The fall term evaluation will consider the work packages defined in Section 8. At the end of the winter term, the team will submit a formal report in addition to all the design reports for both terms. The total (two terms) marking scheme is as follows: Design Review presentations 20% (10% Fall, 10% Winter) Performance evaluations 40% (20% Fall, 20% Winter) Written reports (DRs and formal report) 35% Group self-assessment (entire project) 5% 12 References 1. Department of Mechanical and Aerospace Engineering Project Management Manual Issue No.1, September 2000, posted on culearn 2. DR Writing Notes, posted on culearn, 3. 2D Drafting Notes and Common Errors, posted on culearn Page 7 of 11

8 Annex A: Top Level Project Task List for The following is a list of the major objectives to be completed by the UAV Project Team. It will be up to the individual Groups to identify the specific tasks and steps required to meet these objectives by the end of the project year. The Design Integration Group will work with the technical groups to create a Work Breakdown Structure (see culearn for sample) listing group tasks and subtasks based on the list below. The list provided below is a starting point and tasks will be added or removed as the term progresses. NOTE: For all static ground testing of major flight components, a proof test load of 50% of design limit load is used. 1. Project Management and Administration 1.1. All Groups Complete all outstanding Design Changes Requests Update configuration management database for GeoSurv II Prototype, and Corvus 1.2. Design Integration and Mission Analysis Prepare updated WBS for overall projects with inputs from all technical groups Manage culearn documentation system Continue migration of Design Reports to new culearn system 1.3. Aerodynamics Design flight test plan for Corvus and ATB Structures and Mechanical Systems Organize mechanical hardware, manufacturing supplies and structures hardware in the UAV Workspace 1.5. Avionics and Flight Testing Apply for SFOC Renewal for ATB-10 and Corvus Organize and keep organized all equipment involving avionics and flight test Assemble and test high wing trainer aircraft Follow-up on order for new ATB replacement aircraft purchased in April Battery care, maintenance and safety. This is a separate task which touches both air vehicles. With the knowledge and care required with modern batteries, one student will have to take responsibility. 2. GeoSurv II - Prototype 2.1. Design Integration and Mission Analysis Continue to develop STK capability for mission simulation link STK with Matlab nonlinear model developed in project years and add visualization capabilities using FlightGear for end-to-end mission simulations Monitor weight and balance and longitudinal static stability of all aircraft Complete integration of solid models for GeoSurv II and Corvus Prototypes 2.2. Aerodynamics Finalize and test non-linear model of GeoSurv II developed in Matlab and conduct trial flight test in the simulation environment, this includes updating model to reflect the most recent aircraft configuration Complete aerodynamic analysis of new V-empennage including location, centre of gravity and control surface sizing Review GeoSurv II performance analysis from previous years. Update performance analysis accounting for recent modifications (e.g. V-empennage, drag Page 8 of 11

9 with fixed landing gear, etc.) and size and select a new propulsion unit and submit an application to CUESEF for funding for the engine. Detailed design of engine installation, propeller selection, performance and ground testing plan. Work with Avionics to identify possible options for onboard generators to replace battery power systems. Current engine will be inspected for damage, run on test stand and integrated into new fuselage for high speed taxi and flight tests Complete design, analysis and manufacturing of GeoSurv II engine dynamometer test stand including high speed chain, starter, instrumentation and lubrication system Carry out detailed static and dynamic stability analysis of improved prototype with new components in collaboration with Structures and Flight Test. Update nonlinear model with new parameters and update performance analysis with new weights Design and simulate flight test program for GeoSurv II using non-linear model and FlightGear or X-Plane. Preliminary determination of autopilot GeoSurv II Final Design Using lessons learned from the current GeoSurv II Prototype Design, begin the design process for the GeoSurv II Final air vehicle. Refer to Sander Geophysics Systems Requirements Document Review previous performance and sizing calculations and use actual asbuilt weights to estimate critical weights of new design Structures and Mechanical Systems Fuselage Complete design and manufacture of new hatches for next generation fuselage. Carry out static testing of hatches using flight loads provided by Aerodynamics and Avionics Groups Review location of all holes and cut-outs in the new fuselage Prepare final revised assembly drawings for new fuselage and Landing Gear Complete detailed design of nose landing gear. Review design requirements and consider off-the-shelf alternatives if resources are limited Complete installation of wheels for main landing gear Define requirements for, design, manufacture, install and test main wheel braking system for GeoSurv II Prototype as recommended following the March 2012 High Speed Taxi Test Accident Wing No changes proposed inspect wings and re-install Empennage Work with Aerodynamics to complete aeroelastic analysis of new empennage Review detailed mechanical design of the new V-empennage including control surface integration, servo installation, load analysis. Manufacture and integrate into airframe. Design was completed in the year, but final manufacturing and assembly drawings are needed Composite manufacturing process design and trials Carry out static tests on empennage to verify limit load capacity. Page 9 of 11

10 Engine and Fuel System Review selection process for new engine carried out in the project year Design new engine mount and fuel system. Include Complete Airframe Design static ground test program for complete aircraft refer to and static testing programs for guidance Revise GeoSurv II Assembly Manual as needed Final Design Using lessons learned from the current GeoSurv II Prototype Design, begin the design process for the GeoSurv II Final air vehicle. Refer to Sander Geophysics Systems Requirements Document Avionics, Flight Test and Propulsion Instrumentation Re-install avionics system (flight avionics and instrumentation) into next generation fuselage and complete ground tests on all systems Modify and test instrumentation system as required and install and test in aircraft Liaise with Structures to assure feasible runs for servo cabling and easy connection of servos to cabling; Program radio control systems for V-tail and nose wheel steering Note: From the point of view of the avionics, the change to a V-tail involves only repositioning of the empennage servos and reprogramming of the R/C Tx. Redesign radio control antenna system to increase control range to normal radio control ranges and do relevant range test over the ground and airborne line-of-sight After Aerodynamics has determined the air loads on the new V-tail control surfaces and Structures has proposed the appropriate linkages, check whether the presently held servos will provide sufficient torque Liase with Aerodynamics to support engine test instrumentation design Test the revised antenna installation with all three antennas using a representative lower fuselage hatch Revise the flight avionics installation to place the R/C receivers on the lower fuselage hatch and to make room for the instrumentation system Program the R/C Tx to deal with the V-tail Revise the ignition system design and installation as may be required for the new engine Test the flight avionics in the lab or just on the airframe, depending on timing of other work on the airframe R/C ground range tests on complete air vehicle Flight avionics ground tests Complete overhaul/rebuild (as necessary) of the instrumentation system, including all related programming Assembly of the air data boom and wind tunnel calibration Recalibration of the other sensors of the instrumentation system Page 10 of 11

11 3. Corvus Demonstrator 3.1. Design Integration and Mission Analysis Complete solid model and final assembly drawings for the Covus Prototype Review and confirm weight and balance of final as-built air vehicle Develop test flight mission plans with Aerodynamics 3.2. Aerodynamics Lead group for Corvus flight test planning identify parameters of interest and develop flight test plans. Identify manuvers and data to be collected. Objective of flight testing is to verify and/or determine aircraft performance, endurance, handling and aerodynamic coefficients Static and dynamic aeroelastic analysis of main wing and empennage with a particular focus on dynamic modes (e.g. flutter) Adapt GeoSurv II non-linear model to Corvus identify parameters, experiments and simulations required for this task Based on results of flight testing, begin development of improved Corvus air vehicle outer mould line focus on aerodynamic efficiency. New components must be drop-in replacements for existing airframe structures Structures and Mechanical Systems Complete detailed structural design of wing. Fabricate test article and final components and integrate into overall airframe Carry out fully assembled aircraft structural tests up to 50% of limit load after taxi testing and prior to flight testing Develop complete air vehicle assembly manual 3.4. Avionics and Flight Testing Fall term radio control only Review design of flight avionics and prior hardware selections. First flight an initial tests will be with a radio control-only avionics systems without an autopilot system for the Fall Term Test of proposed R/C antenna locations using either the airframe or a suitable mock-up Bench test of the propulsion system and in-flight termination system Range tests of the R/C system on the ground and also, if possible, with the aircraft on a pole Propulsion system ground testing R/C system ground testing Winter term autopilot Build a bench avionics system using the MicroPilot and install in the Winter Term. NOTE: Design of the avionics physical installation (antennas excepted) cannot be started until the centre of gravity and its range is known Install systems so that the airframe is ready to receive the autopilot Continue development of full hardware-in-the-loop demonstration system to tune the Ardupilot for Corvus. Page 11 of 11