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Detailed Design Review

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 Plan Work Breakdown Risk Assessment. 12/10/2013 14462.

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Detailed Design Review

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  1. Detailed Design Review Tethered Glider P14462 12/10/2013 14462

  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

  3. Engineering Requirements 12/10/2013 14462

  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

  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

  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 12/10/2013 14462

  7. Tether Drag • Numerical Approximation • Calculates: • Tether Drag • Tension Change • Tether Angle Change Rajani, Ashok, Rajkumar Pant, and K. Sudhakar. "Dynamic Stability Analysis of 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

  8. Tether Drag Total tether drag of DynaGlide tether: 27.063 N Negligible force compared to the lift and drag 12/10/2013 14462

  9. Tether-Wing Attachment Setup 12/10/2013 14462

  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 12/10/2013 14462

  11. Tether-Wing Attachment Setup 12/10/2013 14462

  12. Tether-Wing Attachment Stress Analysis Plate material: Polycarbonate Max stress: 38.4 GPa Max allowable: 55 GPa 12/10/2013 14462

  13. Tether-Wing Attachment Displacement Analysis Plate material: Polycarbonate Max deflection: 0.002 in 12/10/2013 14462

  14. Bridle Setup • 3 point bridle with extra support line • Use crimps for permanent attachments • Adjustable fuselage tether to change bridle angle 12/10/2013 14462

  15. Bridle Setup 12/10/2013 14462

  16. Base Station - Week 6 Concept • Concept from week 6, selected by week 9 • Consists of 2 potentiometers and 1 load cell 12/10/2013 14462

  17. Base Station - Detailed Design 12/10/2013 14462

  18. Base Station - Detailed Design 12/10/2013 14462

  19. Exploded View of Upper Portion 12/10/2013 14462

  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 12/10/2013 14462

  21. Shaft Selection y T=1200 lbf x RL=600 lbf RR=600 lbf • 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 12/10/2013 14462

  22. Shaft Selection Continued Selection: 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 12/10/2013 14462

  23. Pillow Block Screw Pullout y T=300 lbf x Selection: 4 #12-10 machine screws ¾” C-D grade plywood http://www.grabberman.eu/Media/TechnicalData/452.pdf 12/10/2013 14462

  24. Plywood Flexing • Modeled as an isotropic material, although wood is anisotropic • Showed max deflection of 0.503E-05 inches 12/10/2013 14462

  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 8692 psi 1200 lbf 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 42.44 psi, within the allowable stress 42.44 psi Source: www.buildgp.com/DocumentViewer.aspx?repository=bp&elementid‎ 12/10/2013 14462

  26. Pillow Block Bearings • Shaft will insert and then be screwed down with set screws • Do not need to be thrust bearings, as platform will rotate Selection: ¾” Stamped-Steel Mounted Ball Bearings—ABEC-1 12/10/2013 14462

  27. Exploded View of Lower Portion 12/10/2013 14462

  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 12/10/2013 14462

  29. Sleeve Bearing T=1200 lbf H RR hsb • Utilized Excel to calculate various reaction forces for different hsb, and compared versus the max allowable force on the inner walls of the bearing RL Selection: 0.752” x 1” Ultra Tough Oil Lubricated Bronze Flanged Sleeve Bearing 12/10/2013 14462

  30. Angle Iron Pullout and Shear F=300 lbf Selection: F=200 lbf 1”x1”x1/8” angle iron with #12 screws 6 vertical screws, and 4 horizontal ¾” C-D grade plywood F=300 lbf http://www.grabberman.eu/Media/TechnicalData/452.pdf 12/10/2013 14462

  31. Sheet Metal Plate • Max deflection of ~ 0.003 inches

  32. Base Station – Cross Section View 12/10/2013 14462

  33. Base Station Animation Base Station Animation 12/10/2013 14462

  34. NI USB-6210 • 16 bit Resolution = 10/(2^16) = 0.000153 12/10/2013 14462

  35. 3140_0 S Type Load Cell (100-500kg) 12/10/2013 14462

  36. 1046_0 PhidgetBridge 4-Input Resolution = 5/(2^24) = 0.000000298 12/10/2013 14462

  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 12/10/2013 14462

  38. DAQ Operational Flowchart

  39. DAQ Programming Flowchart

  40. Wiring Schematic for DAQ 12/10/2013 14462

  41. Bill of Materials - Full

  42. Bill of Materials – Already Have

  43. Bill of Materials – Need to Buy

  44. Bill of Materials - Possible Savings

  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] • Filtered: • Force = 300-350 [lbs] • Wind Speed = 7 [m/s] • Tether Length = 30 [m] 12/10/2013 14462

  46. DOE Analysis including Wind • Force = -1523.83 + 44.6977 • WindSpeed- 22.0839 Radius + 16.3528 Beta +11.4661 TethLen Analysis of Variance Source DFSeq SS F P Regression 4 14445969 580.40 0 WindSpeed 1 6413421 2006.60 0 Radius 1 2623543 887.44 0 Beta 1 2732563 524.19 0 TethLen 1 2676441 430.13 0 Error 2583 16072377 Total 2587 30518346 12/10/2013 14462

  47. Why the high error ? 12/10/2013 14462

  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

  49. Interaction plots for Tension 12/10/2013 14462

  50. Main effects on tension 12/10/2013 14462

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