Detailed Design Review Tethered Glider P14462 12/10/2013 14462 - - PowerPoint PPT Presentation

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Detailed Design Review Tethered Glider P14462 12/10/2013 14462 - - PowerPoint PPT Presentation

Dec 13, 2022 174 likes •808 views

Detailed Design Review Tethered Glider P14462 12/10/2013 14462 Outline Engineering Requirements Glider Status Tether Design Base Station Design DAQ System Bill of Materials DOE ANOVA Analysis Test Plan MSD II

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SLIDE 1

Detailed Design Review

Tethered Glider P14462

12/10/2013 14462

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SLIDE 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

12/10/2013 14462

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SLIDE 3

Engineering Requirements

12/10/2013 14462

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SLIDE 4

Glider Status

  • Art’s Plane
  • Suffered Multiple

Crashes

  • Totalled
  • 1st Bixler
  • Few flights on first

day

  • Missing in swamp
  • 2nd Bixler
  • On order

12/10/2013 14462

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SLIDE 5

1st Bixler

  • Learned how to glue

glider and set up receiver

  • Needed to be

modified due to poor manufacturing

  • Drilled out interfering

plastic/wood

  • Bixler was tail heavy

12/10/2013 14462

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SLIDE 6

Tether Design

  • DynaGlide Throw Line
  • Material: Dyneema with Vinyl Coating
  • Vendor: WesSpur
  • Diameter: 1.8mm
  • Tensile Strength: 1000 lb
  • Highly Visible
  • Price: $39.00 for 200 feet

http://www.wesspur.com/throw-line/zing-it-throw-line.html

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SLIDE 7

Tether Drag

  • Numerical

Approximation

  • Calculates:
  • Tether Drag
  • Tension Change
  • Tether Angle

Change

Rajani, Ashok, Rajkumar Pant, and K. Sudhakar. "Dynamic Stability Analysis

  • f a Tethered Aerostat." Journal of Aircraft 47.5 (2010): 1531-538. American

Institute of Aeronautics and Astronautics. Web. 7 Dec. 2013. <http://arc.aiaa.org/doi/pdf/10.2514/1.47010>.

12/10/2013 14462

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SLIDE 8

Tether Drag

Total tether drag of DynaGlide tether: 27.063 N Negligible force compared to the lift and drag

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SLIDE 9

Tether-Wing Attachment Setup

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SLIDE 10

Tether-Wing Attachment

  • Tether may rip EPO foam

if attached directly

  • Design plate to rest on

top of wing

  • Distributes load
  • Foam is minimally

damaged

  • Tethered over carbon

fiber spars

  • Material: Polycarbonate

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SLIDE 11

Tether-Wing Attachment Setup

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SLIDE 12

Tether-Wing Attachment Stress Analysis

Plate material: Polycarbonate Max stress: 38.4 GPa Max allowable: 55 GPa

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SLIDE 13

Tether-Wing Attachment Displacement Analysis

Plate material: Polycarbonate Max deflection: 0.002 in

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SLIDE 14

Bridle Setup

  • 3 point bridle with extra support line
  • Use crimps for permanent attachments
  • Adjustable fuselage tether to change bridle angle

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SLIDE 15

Bridle Setup

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SLIDE 16

Base Station - Week 6 Concept

  • Concept from week 6,

selected by week 9

  • Consists of 2

potentiometers and 1 load cell

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SLIDE 17

Base Station - Detailed Design

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SLIDE 18

Base Station - Detailed Design

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SLIDE 19

Exploded View of Upper Portion

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SLIDE 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

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SLIDE 21

Shaft Selection

T=1200 lbf RR=600 lbf RL=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

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SLIDE 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:

12/10/2013 14462

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SLIDE 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

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SLIDE 24

Plywood Flexing

  • Modeled as an

isotropic material, although wood is anisotropic

  • Showed max

deflection of 0.503E-05 inches

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SLIDE 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 12/10/2013 14462 Source: www.buildgp.com/DocumentViewer.aspx?repository=bp&elementid

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SLIDE 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

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SLIDE 27

Exploded View of Lower Portion

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SLIDE 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

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SLIDE 29

Sleeve Bearing

T=1200 lbf hs

b

H R

L

R

R

Selection: 0.752” x 1” Ultra Tough Oil Lubricated Bronze Flanged

Sleeve Bearing

  • Utilized Excel to calculate various reaction

forces for different hsb, 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. 12/10/2013 14462

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SLIDE 30

Angle Iron Pullout and Shear

F=300 lbf 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

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SLIDE 31

Sheet Metal Plate

  • Max deflection of ~ 0.003 inches
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SLIDE 32

Base Station – Cross Section View

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SLIDE 33

Base Station Animation

Base Station Animation

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SLIDE 34

NI USB-6210

16 bit Resolution = 10/(2^16) = 0.000153 12/10/2013 14462

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SLIDE 35

3140_0 S Type Load Cell (100-500kg)

12/10/2013 14462

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SLIDE 36

1046_0 PhidgetBridge 4-Input

Resolution = 5/(2^24) = 0.000000298 12/10/2013 14462

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SLIDE 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

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SLIDE 38

DAQ Operational Flowchart

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SLIDE 39

DAQ Programming Flowchart

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SLIDE 40

Wiring Schematic for DAQ

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SLIDE 41

Bill of Materials - Full

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SLIDE 42

Bill of Materials – Already Have

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SLIDE 43

Bill of Materials – Need to Buy

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SLIDE 44

Bill of Materials - Possible Savings

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SLIDE 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] 334.3693 7 15 92 30 309.5235 7 16 92 30 349.0444 7 18 93 30 Filtered:

  • Force = 300-350 [lbs]
  • Wind Speed = 7 [m/s]
  • Tether Length = 30 [m]

12/10/2013 14462

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SLIDE 46

Regression Analysis including Wind

Force = -1523.83 + 44.6977

WindSpeed - 22.0839 Radius + 16.3528 Beta +11.4661 TethLen Analysis of Variance Source DF Seq SS F P Regression 4 14445969 580.40 WindSpeed 1 6413421 2006.60 Radius 1 2623543 887.44 Beta 1 2732563 524.19 TethLen 1 2676441 430.13 Error 2583 16072377 Total 2587 30518346

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SLIDE 47

Why the high error ?

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200

  • 200
  • 400

99.99 99 90 50 10 1 0.01

Residual Percent 500 400 300 200 100 200

  • 200

Fitted Value Residual 140 70

  • 70
  • 140
  • 210
  • 280

160 120 80 40 Residual Frequency 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 1 200

  • 200

Observation Order Residual

Normal Probability Plot Versus Fits Histogram Versus Order

Residual Plots for Force

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SLIDE 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*TethLen 818325 Error 25853236 Total 30518346 12/10/2013 14462

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SLIDE 49

Interaction plots for Tension

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SLIDE 50

Main effects on tension

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SLIDE 51

Graphical Sensitivity (contour plots) of each factor

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SLIDE 52

Graphical Surface plots

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SLIDE 53

Test Plan

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SLIDE 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 Tension Team 02/28/2014 Varied Tether Length Model Sensitivity Team 03/14/2014 Varied Wind Speed Model Sensitivity Team 03/28/2014 Varied Beta Angle Model Sensitivity Team 04/04/2014 Varied Flight Path Radius Model Sensitivity Team 04/11/2014 Varied Glider Mass Tension Team 04/18/2014

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SLIDE 55

Risk Assessment - Full

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SLIDE 56

Risk Assessment - High Priority/New

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SLIDE 57

Project Plan

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SLIDE 58

MSD II Plan

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SLIDE 59

MSD II Plan (Continued)

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SLIDE 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

12/10/2013 14462

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SLIDE 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

12/10/2013 14462

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SLIDE 62

Questions?

12/10/2013 14462