VORTEX Vertically Optimized Research, Testing, & EXploration
Spring Final Review
Team Mohamed Aichiouene Stephen Albert Joseph Buescher Bill Chabot Customer: Steve Borenstein Colton Cline Brandon Cummings Advisor: Donna Gerren Roland Ilyes Delaney Jones Project Manager: Bill Chabot Cameron Kratt Michael Patterson Joseph Rooney Justin Troche Project Purpose Design Solution CPE’s Requirements Risks Validation Project Planning Backup Slides 2
Project Overview Mission Statement 3
VORTEX
In order to expand the capabilities of the IRISS center and TORUS project in gathering meteorological data and understanding the formation of supercell thunderstorms, the VORTEX team will bring Vertical Takeoff and Landing (VTOL) functionality and extended endurance to the RiteWing Drak airframe.
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Mission CONOPS 4
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Summary of Results 5
Level 1 Level 2 Level 3 All motors and actuators shall be successfully integrated with the flight All external (non-native) sensors are Avionics & controller. The telemetry link shall be successfully integrated with the avionics - Electronics maintained with less than 50% packet loss system. within 2 km of the ground station. Both the VTOL and fixed-wing modes have valid dynamic models to ensure active The aircraft shall autonomously execute a stabilization is possible. Ensure that the The aircraft can autonomously execute a full mission profile, transitioning between Autonomy chosen avionics package interfaces takeoff and landing. flight modes, and land within a 1.5 meter successfully with propulsion system, radius of a target location. sensors, and connectivity with ground station. The aircraft shall have an autonomous return to loiter function if telemetry is lost for Safety an extended period (90 seconds) as well as - - capability to terminate the flight immediately upon command from the GSE
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Summary of Results 6
Level 1 Level 2 Level 3 Show on a static test stand that the Maintain tethered hover at 2 m of altitude for 30 Aircraft shall demonstrate takeoff ability via propulsion system is capable of producing seconds as well as demonstrate capability to RAP-Cat launch system as well as Flight enough thrust to provide a TWR greater transition to horizontal flight while aircraft is demonstrate full transition from vertical to than 1 mounted to a test stand horizontal flight modes. The aircraft shall cost no more than The aircraft shall cost no more than $900, The aircraft shall cost no more than $1000, not Budget $1250, not including IRISS avionics not including IRISS avionics package or including IRISS avionics package or batteries package or batteries batteries The propulsion system shall maintain required thrust output for the equivalent of 1 hour cruise and 2 takeoffs and landings Demonstrate 1 hour of flight cruise as well Endurance (approximately 1hr 16 minutes) on a static - as 2 takeoffs and landings test stand in simulated freestream conditions of 18 m/s with >15% battery remaining A finite element analysis of the modified The aircraft will have full integration capabilities air-frame will be performed to The airframe shall withstand axial and Airframe with RAPCat launch system, and show that it demonstrate that it can withstand the lateral forces up to 10G. can withstand the forces due to acceleration. required forces with a FOS of 1.7
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management 7
Design Description Critical Project Elements 8
Element Justification
Vertical Takeoff and Landing Primary deliverable of project. (VTOL)
Structure Structure must withstand forces of takeoff, flight, and (STR) landing.
Endurance Aircraft must be able to maintain flight for the required (END) duration of 1 hour plus takeoffs and landings.
Aircraft must autonomously perform mission flight Automation profile as well as controlling takeoff, landing, and (AUT) transitions.
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Functional Requirements 9
FR1 VTOL The aircraft shall be a VTOL conversion of the COTS Ritewing RC “Drak” airplane kit
FR2 END The aircraft shall have an endurance of 1 hour with 2 takeoffs and landings
The aircraft shall be able to autonomously execute all aspects of its mission from first FR3 AUT takeoff through final landing
FR4 AUT The aircraft shall maintain communication with the ground station up to a distance of 2km
FR5 STR The aircraft shall be capable of carrying a 0.5kg payload
FR6 STR The aircraft shall be capable of taking off from existing RAPCat launch system
The airframe, propulsion system, and required mounting hardware shall cost no more FR7 VTOL than $1000 per aircraft
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Final Design 10
Empennage Rear Vertical Motor
Pitot Probe
Key Parameters Dimensions: ● Wingspan: 1.55m ● Tip-to-Tail: 1.10m Weight: GPS Navigation ● 6.0kg
Forward Tilting Motors
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Final Design 11
Reinforced Stabilizer Landing Skids
Cutout for LiDAR RAPCat Bracket and Landing Leg
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Final Design 12
Elevon Servos
Custom Li-Ion Battery Pack
Power Module RC Receiver
LiDAR
IRISS Avionics Board 0.5kg Payload
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management System Functional Block Diagram 13
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Changes Since TRR 14
Electronics ● Upgraded tilt servos for higher torque ● Airspeed sensor protocol changed to I2C
Structures TRR ● Mass of tilt rotor wing mount reduced ● Reduced characteristic drag ● Increased structural support in rear motor mount
Aerodynamics ● Designed and manufactured empennage
Automation ● Initial aircraft tuning in hover ● Integrated LiDAR SFR
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Elements Critical for Project Success 15
Vertical Takeoff and Landing ● Tricopter configuration with tilting front motors ● High discharge custom battery Structures ● Forward tilt motor mounts ● Rear vertical motor mount Endurance ● Empennage for better stability and horizontal cruise ● High voltage custom battery Automation ● Rangefinding lidar ● ArduPilot parameters tuned to match aircraft configuration ● Various flight mode settings and autonomous mission profiles
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management 16
Test Overview Test Overview 17
Functional Element Test Description Status Requirement
Wing Motor Verification of FEM model and testing 1 FR6 STR Complete Mount Stress structural limits of wing motor mounts
Battery Verify and prove the assembled battery meets 2 FR2 END Complete Endurance modeled capacity performance
Testing thrust and power draw in static 3 FR1 VTOL Static Motor Complete conditions
4 FR3 AUT Controls Verify that control surfaces actuate properly Complete
5 FR3 AUT LiDAR Testing LiDAR system for accuracy Complete
Verify/test avionics package and 6 FR4 AUT Telemetry Complete communications
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Test Overview 18
Functional Element Test Description Status Requirement
Dynamic Testing thrust and power draw in flight 7 FR2 END Complete Motor conditions
Car Top 8 FR2 END Obtain aerodynamic forces to validate CFD Complete Aerodynamic
RAPCat Validate that Drak fits into existing RAPCAT Planned 9 FR6 STR Integration bracket and test launch procedure 4/19-4/23
10 FR1 VTOL Hover Verify stability in hover Complete
11 FR2 END Full Flight Verify that Drak can execute the mission Planned 4/21
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Wing Motor Stress Testing 19
What and Why: ● Verification of FEM simulations; ensuring requirements met ● Increasing load applied to end of motor arm / wing assembly ● Removes risk of failure during maximum loading in flight
Testing Procedure: ● Wing spars clamped to table ● Weight incrementally added to the end of the motor arm in 0.5kg increments
Requirement Description
FR 6 RAPCat Compatibility Motor mount Withstand 5G acceleration DR 6.2 Complete structural test during RAPCat launch Withstand 10G during takeoff DR 6.5 and landing operations
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Battery Endurance Testing 20
What and Why: ● Verification of custom battery assembly functionality ● Reduces the risk of power capabilities for the aircraft
Static Test Thrust Testing Procedure: Stand ● Verify battery cell balanced voltage ● Maintained a cruise condition current draw until battery voltage drops below 18V Test Board
RC Power benchmark Meter Static Test Setup (in-action) Exposed battery view Software Complete Battery Test Overview
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Static Propulsion Test Stand 21
What and Why: Propulsion test stand setup ● Test for thrust, power, and endurance requirements for the propulsion subsystem ● Using RC Benchmark software to track specific test properties: ○ Current draw ○ Thrust ○ RPM ● Motor and load cells contained in plexiglass & chicken wire box
Testing Procedure:
● Configure battery, motor, ESC, and propeller ● Use RC benchmark software to manually toggle throttle power input Requirement Description
Complete Endurance of one hour with FR2 two takeoffs and landings
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Avionics System Progress 22
Component Progress Details
Servos Functional Actuating and Connecting, calibrated and trimmed.
Telemetry Functional Mission Planner & Ground Station Communicating
GPS verified on Mission Planner, Showing position GPS Functional accurately Pitot-Static Functional Calibrated and Installed on VORTEX aircraft. Tube Lidar Functional Reporting data accurately.
Battery Functional Powering system without issue.
ESC’s/Motors Functional Driving motors as expected and producing sufficient thrust.
Other Functional EKF & IMU calibration completed (Pre-flight check)
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Avionics System 23
Provided avionics package Avionics package with custom battery
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Telemetry Test Overview 24
What and Why: ● Aircraft must to maintain communication with GS computer up to 2km with <50% packet loss
Testing and Verification: ● Acquire AC-DC auxiliary power outlet convertor ● Take plane and avionics out to road with 2km stretch ● Initialize powered avionics at ground station ● Drive powered avionics 2km away ● Check telemetry package connection
Requirement Description
The aircraft shall maintain communication with the FR 4 Complete ground station up to a distance of 2km
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Controls Overview 25
What and Why: ● All 5 servos need to be actuating within physical range ● Elevons and tilt servos need to be trimmed ● ESC’s range and trim values need to be set ○ Values too high can damage the ESC’s
Prediction and Verification: ● Find servo travel per (µs). Example: Δ훳 = 0.085°/μsec ● Find the endstop of the servo: 0 angle ● Find angle of zero to flat with the wing mount. Example: 76° Complete ● Program angles as PWM signals. Example: ○ Minimum: -7° from X-Y plane: 69°/Δ훳 = 811.8μs ○ Maximum: 125° from X-Y plane: 201°/Δ훳 = 811.8μs Requirement Description ● Set Trim angle. Example: 76°/Δ훳 = 2364.7μs ● Trim expected output to physical output Verify that control surfaces FR 3 actuate properly
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management LiDAR Test Overview 26
What and Why: 3D printed Downward pointing LiDAR ● Needs to handle reflective, LiDAR mount disjointed, high debris surfaces ● Height set using tape measure, static testing ● Measurements recorded on LeddarTech Configurator
Testing Procedure: Complete ● Set LiDAR at known distance ● Test distances read off Requirement Description ● Verify accuracy is within FR 3 Autonomous mission execution range Vertical accuracy of <10cm is ● Perform test over multiple DR 3.4 desired in takeoff and landing LiDAR test surfaces when below GPS altitude of 5m stand assembly Complete mission profile without DR 3.5 pilot input
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management LiDAR Test Overview 27
Readings Over Water Testing in variable conditions Highly Reflective Surfaces ● Branches/bushes ● Water ● Aluminum foil
LeddarOne LiDAR
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Dynamic Motor Testing Overview 28
Summary: ● Test thrust requirements in dynamic cruise conditions (loss in efficiency) ● Using RC Benchmark software to track specific test properties ● Motor and load cells elevated on car top test stand traveling at cruise speeds (40 mph)
Testing Procedure: ● Similar to static test stand: configure battery, motor, ESC, and propeller ● Use RC benchmark software to manually toggle throttle power input
Complete Dynamic motor test stand mounted
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Aerodynamic Test Stand Overview 29
What and Why: Requirement Description 1 Hour endurance, 2 Takeoffs FR 2 ● Lift and drag produced from aircraft need verified and Landings Cruise speed shall be at least ● Dynamic testing data is crucial without wind tunnel testing DR 2.7 ● Accelerometer on roof for imparted vibration data 18 m/s
Calibration and Testing: ● 4-Load cells & accelerometer connected to ArduinoMega ● Testing: ○ AoA is set on structure ○ Load cells and Accelerometer are tared before ○ Test is run at nominal speed; Data is saved
Complete Electronics Package
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Aerodynamic Test Stand Overview 30
AoA adjustment capability
Load cell & amplifier configuration
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Aerodynamic Test Stand Overview 31
*Car behind test vehicle is designated chase car with additional team members
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management RAPCat Integration Overview 32
FR6 The aircraft shall be capable of taking off from existing RAPCat launch system
What and Why: ● Rapid Acceleration Pneumatic Catapult ● RAPCat hook incorporated into the bottom of the fuselage
Testing and Verification: ● Complete one RAPCat launch directly into horizontal flight ○ Alternate: Complete a bungee launch into horizontal flight
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Hover Testing Overview 33
What and Why: Verification Methods:
● Ensure stability in hover modes ● Data logs saved by GCS ● Show motors are capable of providing enough ● Visual inspection, watch for oscillations thrust ● Pilot input - How well does it respond? ● Test various PID parameters to optimize hover ● Demonstrate hover stability in stability QStabilize/QHover modes
Requirement Description The aircraft shall be able to Testing Process DR 1.1 sustain hover using its own thrust system On-board flight controller shall DR 3.2 control propulsion system and flight surfaces The aircraft shall Manually Fly Inspect Change PID DR 3.5 autonomously hover without Aircraft Behavior Gains pilot input
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Full Test Flight 34
What and Why: Test Schedule ● Full Planned Mission ● Check Endurance/Autonomy Requirements Google Maps view of first full flight test ● Shortened Schedule due to More on this later Weather/Scheduling
Requirement Description The aircraft shall have an FR 2 endurance of one hour in addition to two takeoffs and landings. Aircraft shall be able to autonomously execute all aspects FR 3 of its mission from takeoff through landing.
On-board flight controller shall control propulsion system and DR 3.2 flight surfaces
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Full Flight & Future Tests 35
Flight mission profile RAPCat Integration 60 minutes Planned ● Verify the connector fits correctly 4/19-4/23 ● Execute launch procedure Takeoff Cruise Land Takeoff Cruise Land Hover Test Vertical Flight Cruise Flight ● Execute static full mission profile Complete ● Show stability in hover
Full Flight Test ● Execute realistic full mission profile Planned similar to CONOPS 4/21-4/30
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management 36
Test Results Wing Stress Testing Results 37
Downward Stress (Landing): ● 10G requirement is 1.9kg (18.65N) ○ Tested to 2.1kg (20.5N) ○ No FOS calculation ● Small bending in arm and wing
Upward Stress (Takeoff): ● Requirement of 2.5kg (24.5N) ○ Tested incrementally to 6.6kg (64.7N) ○ 2.6 FOS ● Extreme bending in arm and wing
● Only small (<1mm) plastic deformation after test
RAPCat Launch/Compatibility Complete ● Upcoming
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Battery Endurance Testing Results 38
● Endurance Test: ○ Manually maintained expected cruise current draw of ~8A ○ Run time of 110 minutes ○ Capacity of 15Ah compared to ideal 16Ah ● Conclusion: ○ Battery capacity meets expected performance for 1 hour cruise flight and the manufacturing data are satisfactory
Requirement Description
Endurance of one hour with FR 2 two takeoffs and landings
Complete
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Static Propulsion Test Stand Results 39
APC & Aeronaut Propeller Comparison
Conclusion: For our selected design size and conditions, the APC props offer more thrust for the same power as well as lower cost and lead time
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Static Propulsion Test Stand Results 40
Tested Sizes Measured variables: Propeller Style [Diameter x Pitch] (limited by max motor power) ➢ Torque ➢ Thrust 9x5 9x6 ➢ Voltage 10x5 10x6 10x7 Aeronaut Electric ➢ Current 11x5 11x7 Carbon Light ➢ 12x5 12x7 RPM (optical sensor) 13x7 13x8 ➢ Power ➢ Prop Efficiency ➢ ESC input 11x4.5 11x5.5 APC Thin Electric 13x8 Final Design: Front Props: 13x8 APC Electric [2820 550KV motor] Complete Rear Prop: 11x5.5 APC Electric [2820 860KV motor]*new
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Controls Test Results 41
Control RC Autonomous Input Response Response
Ailerons ✓ ✓
Elevator ✓ ✓
Tilt-Servos ✓ ✓
ESCs ✓ Planned Successful servo RC communication Requirement Description ● Servo’s stop at correct angles: preventing servo Verify that control surfaces actuate burnout DR 3.3 properly ○ PWM calculations were correct ● Servo’s are all actuating correct directions Complete ● Control surfaces are trimmed with airfoil
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Telemetry Verification 42
98% Telemetry Packets Received
Aircraft location >2km away
Complete
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Telemetry Results 43
The aircraft shall maintain communication with the ground station up to a distance of FR4 2km with less than 50% packet loss
Design Aspects: ● Radio package with receiver and transmitter ● One end interfaces directly with avionics package ● Connects directly to a laptop for real time data gathering and control
Requirement Satisfaction: ● Successful communication with less than 3% packet loss
Complete
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management LiDAR Test Results 44
Concrete Surface, Daylight Over Aluminum Foil Mimicking High Reflective Surfaces
Trial Set LiDAR LiDAR Trial # Set Height(cm) # Height(cm) Reading(cm) Reading(cm)
1 180.3 183.489 +/-0.25 1 160.0 166.294 +/- 0.25
2 175.3 174.981 +/-0.25 2 109.2 114.776 +/- 0.25
3 132.1 135.509 +/- 0.35 3 88.9 94.742 +/- 0.15
4 81.3 84.074 +/- 0.20 4 27.94 33.274 +/- 0.20
5 10.0 13.183 +/- 0.20 5 11 13.732 +/- 0.10
Requirement Description ● Maintains a maximum difference of about 7.5 cm from set height Vertical accuracy of <10cm is ● Meets requirement of 10cm accuracy desired in takeoff and landing DR 3.4 ● Ready to be used for landing, will add to accuracy of firmware when below GPS altitude of 5m Complete mission profile Complete DR 3.5 without pilot input
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Lidar vs Barometer 45
Data Logs, LiDAR(red) and Barometer(green) data Field Testing the LiDAR ● Much less noisy and accurate compared to barometer ● Redundant altitude sensing for landings and takeoffs ● Barometer starts to fail due to ground effect/prop wash
Requirement Description Vertical accuracy of <10cm is desired in takeoff and landing DR 3.4 when below GPS altitude of 5m Complete mission profile DR 3.5 without pilot input
3.4 Complete, 3.5 in progress
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Dynamic Motor Test Results 46
Summary of Results: ● Our propulsion model (Based on aerodynamic data) estimated a cruise flight Thrust of 4N
● Approximate Power value for Cruise flight Target ○ Model: 77.5W ○ Experiment: 150W
Requirement Description 1 Hour endurance, 2 Takeoffs FR 2 and Landings Cruise speed shall be at least DR 2.7 18 m/s
Partially Complete
Conclusion: The test results hold several large sources of error such as wind and vibration, but give us ballpark estimates of power requirements. This 150W requirement
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Aerodynamic Test Stand Results 47
Summary of Results: ● Weather conditions significantly affected data Partially Completed ● AoA fluctuations from angle of road changed data ● Drag was much higher than expected Requirement Description 1 Hour endurance, 2 Takeoffs ○ Load cells not isolated from moving air FR 2 and Landings ○ Airspeed measurement not precise enough Cruise speed shall be at least DR 2.7 18 m/s Reasons for Moving to Hover: ● Schedule and cost impacts in mitigating conditions ● Cost/Benefit - additional testing not worth pursuing
Mitigation Strategies: ● Large FOS in propulsion system ○ Ardupilot allows for VTOL assisted level flight ● Flight speed can be increased -> Increased lift
Vortex modified Drak with RAAVEN Tail
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management RAPCat Integration Status 48
FR6 The aircraft shall be capable of taking off from existing RAPCat launch system
Status: ● RAPCat hook incorporated into the bottom of the fuselage ● Printed part fits on the RAPCat
Plans for Requirement Satisfaction: ● Obtain flight approval from CU flight director ● Launch off bungee or RAPCat with IRISS
Partially Complete
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Hover Test Results 49
Analyzing data from Ground Station Data Logs ● Results from Qhover,(pilot input only to adjust position in case of emergency) ● Pitch/Roll Maintaining Position with Slight Error ● Yaw Oscillations Still Prevalent, but will be damped out with more tuning
Requirement Description On-board flight controller shall control DR 3.2 propulsion system and flight surfaces.
The aircraft shall be capable of completing the DR 3.5 mission profile without pilot input after initial flight configuration.
3.2 Verified, 3.5 in *More GCS Data Logs in Backup Slides progress
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Hover Test Results 50
Hover Thrusting ● Tests show that aircraft can produce enough thrust ● Capable of handling hard inputs ● Motor/Propeller Combinations are successful ● Note Yaw Oscillations but steady behavior
Requirement Description
The aircraft shall be able to DR 1.1 sustain hover using its own thrust system
Complete
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Test Flight Analysis 51
First Test Flight Mission Profile
PreFlight VTOl/Hover Transition Level Flight Glide Crash
● First flight test ended in tragedy ● Flight logs are a huge source of information ● Detailed Crash Analysis followed by major takeaways ● Ready to fly again!
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Test Flight Analysis, Continued 52
PreFlight VTOl/Hover Transition Level Flight Glide Crash
Analysis
● Steady wind and takeoff location too close to boundary ● Transitioned too quickly, not enough altitude,airspeed ● Ignored pilot input to reach transition state ● Seen in thrust curves from data logs Pilot inputted thrust, jagged Rapid transition between lines QHOVER and FBWA modes
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Test Flight Analysis, Continued 53
PreFlight VTOl/Hover Transition Level Flight Glide Crash
Analysis
● Slow motor tilt rate caused a stall ● Recovered and glided ● Initial EKF error yielded a 15 degree roll bias ● Led to aircraft only achieving a 10 degree bank
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Test Flight Analysis, Takeaways 54
Major Takeaways
● Configure Pitot Probe as digital sensor ● R.I.P. Discordia [Left] ● Alter transition parameters (transition time & servo transition tilt-rate) ● Additional pre-flight checklist ● (Currently Unnamed) procedures VORTEX ready to go ○ Calibrate the airspeed sensor [Below] ○ Let plane rest for >15s after arming (Settles EKF) ● Improve hover tune - reduce yaw oscillation ● Include LiDAR for precise altitude information ● Improve battery restraint system
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management 55
Systems Engineering Systems Engineering Overview 56
Project Handoff to Scoping Customer
Review Project CONOPS Performance
Functional Full System Requirements Verification
Project Subsystem Subsystem Testing and Definition Design Verification Integration
Detailed Component Design Testing Complete Manufacturing In Progress Time
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Scope Refinement /Functional Requirements 57
Original Project Scope Functional Requirements
● Must be based on Standard DRAK wingset ● The aircraft shall be a VTOL conversion of the COTS ● Modified Propulsion for VTOL Ritewing RC “Drak” airplane kit ● 1 Hour Endurance at Cruise ● The aircraft shall have an endurance of 1 hour with 2 ● 2 take-off, 2 landing - must be autonomous takeoffs and landings ● Nose mounted probe to be protected ● The aircraft shall be capable of carrying a 0.5kg payload ● 0.5 kg payload ● The aircraft shall be capable of taking off from existing ● IRISS Avionics Package RAPCat launch system ● Must maintain Catapult launch capability ● The airframe, propulsion system, and required mounting ● Goal: Build Cost less than $1000 (not inc. hardware shall cost no more than $1000 per aircraft avionics) ● The aircraft shall be able to autonomously execute all ● Goal: automated landing to a target/beacon aspects of its mission from first takeoff through final landing ● Land and takeoff from water ● The aircraft shall maintain communication with the ground ● Deployment of a submersible sensor station up to a distance of 2km
* original project scope taken directly from customer proposal presentation
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Requirements Breakdown 58
Functional Requirements
Design Requirements
Subsystem Requirements
Component Requirements
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Trade Studies 59
Configuration Trade Study Tilt Rotor Tail Sitter Hybrid Tilt Wing Double Double Single Inboard Wingtip Option Weight Tri Quad Quint Quad 4L1C 3L1C Push Pull Push Motors Motors Risk 0.2 2.5 2.5 2 2 1.5 4 1 4 4 1 1 Manufacturing/ 0.15 4 3 2 1.5 1 4 5 2 3 1 1 Complexity Weight 0.1 4 3 1 2.5 2.5 4 5 1 2 3 2.5 Hover 0.2 5 5 4 3.5 1 2 1 5 5 2.5 3 Controllability Cruise 0.3 4 3 2 2.5 4 4.5 5 1 2 5 5 Efficiency Cost 0.05 3 2 1 2 4 4 3 1 2 2 2 Total 1 3.85 3.25 2.25 2.43 2.30 3.75 3.30 2.55 3.15 2.75 2.80 Material Trade Study Battery Chemistry Trade Study Carbon Option Weight Li-Po Li-ion NiMH NiCd LiFePO4 Option Weight 3D Printing Aluminum Fiber Rods Discharge Rate 0.2 5 2 2 3 3 Weight 0.35 3 1 5 Energy Density 0.25 2 5 2 1 2 Strength 0.2 3 4 5 Cost 0.2 3 2 4 3 2 Cost 0.3 5 2 1 Lifespan 0.2 1 4 3 4 5 Manufacturability 0.15 5 2 1 Safety 0.15 2 3 4 3 4 Total 1 3.9 2.05 3.2 Total 1 2.6 3.3 2.9 2.7 3.1 Altitude Sensor Trade Study Firmware Trade Study Micro Paparazzi Option Weight LiDAR Sonar Option Weight Ardupilot PX4 iNAV Radar UAV Complexity 0.25 3 3 3 Functionality 0.30 4 5 3 5 Accuracy and Resources and User 0.25 4 5 2 0.3 5 5 3 3 Consistency Interface Size & Weight 0.2 5 3 5 Customer Preference 0.25 5 3 1 1 Resiliency 0.15 4 5 2 Hardware / Software 0.15 5 4 3 3 Cost 0.15 5 3 5 Interface Total 1 4.1 3.8 3.3 Total 1 4.7 4.1 3.2 3.1
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Risk Assessment - Key Risks Identified from CDR 60
Risk Residual # Category Description Consequence Probability Impact Risk Modification Plan Level Risk
Utilize IRISS' existing connection Drak kit backordered, Would not be able to produce second with RiteWing to obtain wing kits 5 Supply/Struct potential supply deliverable for customer, may not have High Medium High Medium outside of standard commercial difficulties backup parts in case of destruction production Ensure spot welder is only used Battery damage Fire/explosion in battery cells, injury to by properly trained individuals, 8 Propulsion Low High High Medium during pack assembly personnel follow strict safety protocols when working with battery cells Coordinate with department to Damage to vehicles, test equipment, create safe testing procedures Car-top safety 11 Testing citations issued for property damage Low High High and equipment, research local Medium considerations or other unknown reasons (?) laws to ensure legality of test operations
Compare FEM to known models Inaccurate FEM Possible material failure, could need to 12 Structures Medium Medium Medium and research minimizing FEM Low model redesign parts error, continually refine models
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Risk Assessment - Mitigation Summary 61
Low 4, 7 3 Low 4, 7, 12 1, 3, 11
12 8, 11 2, 6, 13 10 5, 8
Likelihood Medium 2, 6, 13 10 1, 9 Mitigation Likelihood Medium
High 5 High
Low Medium High Low Medium High
Consequence Consequence
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Risk Assessment - Update 62
Risk Description Encountered? Result
Yes - Drak was obtainable but some other Project proceeded according to Backorder of Drak and Supply components required obtaining schedule with no significant delays due other components replacements to component sourcing
Risk of injury during No - Safety protocols were followed and no Battery and propulsion system safely Propulsion battery use/manufacture dangerous situations were encountered performed to expectations
Car-top testing safety No - Safety protocols were followed and no Dynamic testing was performed safely Testing considerations dangerous situations were encountered and data was obtained
Material failure during No - components proved stronger than Components only required replacement Structures operation expected under normal loading when subjected to abnormal forces
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Systems Engineering - Key Challenges and Lessons Learned 63
Challenges Lessons Learned
Clear requirements would help individuals work on components with less Clear requirement breakdown guidance from other team members
Would help individuals understand better how individual subsystems and Cross system requirements components affect the project as a whole
Parallel subsystem testing could help reduce the risk of schedule creep Subsystem testing dependances when a subsystem test runs long
Greater care should be taken when making assumptions early on the Biased assumptions project.
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management 64
Project Management Project Management Summary 65
Key concepts/guidelines:
● Morale ○ Lead by example and stick to your word ○ Set achievable short-term goals to maintain the sense of progress moving forward ○ Don’t take things too seriously ● Minimize micromanagement ○ Trust in team members’ skills and competence ○ Assign reasonable tasks and ensure support is available where needed ● Organization ○ Ensure team members are aware of schedules, assignments, deadlines, etc. ○ Prepare resources/plans for meetings ahead of time whenever possible
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Per Unit Budget 66
Unit Budget Breakdown: Target Budget: $1,000.00 ______Avionics: $125.00 Controls: $246.96 Endurance/Propulsion: $183.55 Structures: $409.86 ______Final Cost Per Unit: $965.37
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Financial Status/ Budget 67
VORTEX Budget Breakdown: $516.42 Total Budget: $5,000.00 ______Confirmed Purchases: $4,683.58
$290.03 Pilot Lab Deposit: -$200.00 $518.30 (assuming is returned) $597.36
Initially Planned Budget Total Expenses: $4,483.58 ______Remaining Balance: $516.42 $1323.76
$1754.13
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Industry Cost 68
Total Hours Cost Per Hr ($65k Salary) Total Salary Cost Materials Overhead Total Cost Worked
4822 $31.25 $150,687.50 $4,483.58 $301,375 $456,546.08
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Acknowledgements
Dr. Donna Gerren - Advising, Guidance, and Moral Support
Steve Borenstein, Michael Rhode, Chris Choate - General guidance and answers to numerous questions
Devesh Sharma - Autonomy, Piloting, PCB Soldering, Component Troubleshooting, and being an all-around champion Thank You
VORTEX
Questions? VORTEX Team Contact Information
Name Role Contact Information Mohamed Aichiouene Controls Lead [email protected] Stephen Albert Manufacturing Lead [email protected] Joseph Buescher Autonomy Lead [email protected] Bill Chabot Project Manager [email protected] Colton Cline Safety and Testing Lead [email protected] Brandon Cummings Propulsion and Endurance Lead [email protected]
Roland Ilyes Software Lead [email protected] Delaney Jones Aerodynamics Lead [email protected] Cameron Kratt Avionics Lead [email protected] Michael Patterson Systems Engineer / Chief Technical Lead [email protected] Joseph Rooney Structures and FEA Lead [email protected] Justin Troche Finance Lead [email protected] 72
Backup Slides Aerodynamic Test Stand Adjustable Angle Bracket 73
● Internal bracket allows spar to slide forwards and backwards to change angle ● Horizontal carbon fiber rod slides inside internal bracket ● Internal bracket will be 3D printed out of PETG
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management More Hover Test Results 74
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Overview and Scope 75
The purpose of the early manufacturing stages with regards to the VORTEX project is to both build and Subsystem Testing Equipment test individual subsystems. Autonomy ● Ardupilot ● Pixhawk 1. Assemble basic functioning subsystems ● LIDAR Test Stand 2. Assemble testing apparatuses 3. Test and simulate realistic performance against Structures ● Dynamic Test Stand modeled performance Propulsion ● Static Test Stand
● Construction Battery Moving forward, each subsystem will be iteratively ● Dynamic Test Stand improved to meet desired performance. Full system testing can begin. Key Software (in-house) Custom Hardware (in-house) Borrowed Hardware
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management LiDAR Data 76
Testing the purchased LiDAR sensor to verify 10cm accuracy
LeddarTech Configurator LeddarTech Configurator ○ Exports data to .txt file ○ USB to UART cable to laptop
LeddarOne Sensor
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Empennage Design 77
Static Equilibrium of Forces
Static Equilibrium of Moments (about wing/body neutral point)
Static Stability
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Canard vs Tail Trade Study 78
Criteria Things to Consider Criteria Weight Options Considered LIft and Drag ● Trim Lift Deficit Calculations 25% ● Static Canard Performance ● Estimate Drag, NACA airfoil, Parasite, Induced, etc. ● Effect on Elevon deflection at trim ● Static Tail ● Tail with Elevator Stability ● Static Margin Calculations 30% ● Trim Moment Deficit Calculations ● Stall performance ● Static, dynamic stability
Tail with Elevator won out Weight ● Weight of supplementary components 15% ● Reduces elevon ○ Servos, Spars, Foam deflection ● Shift in center of gravity ● Used by IRISS Complexity ● Supplementary Components 30% ● Heavier than ● Electronics Canard though ● Structure required ● Easy to ● Manufacturability ○ Materials and Methods manufacture ● Design Optimization ○ Expected effort to optimize the design
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management LiDAR Test Stand 79
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management LiDAR Test Stand 80
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Aerodynamic Test Stand - 3D Printed 81
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Custom Battery Progress 82
● On Hand: ● Barriers to Progress ○ Insulator rings ○ Balancing cable not delivered ○ XT90 connectors ○ Waiting on R2R ○ XT60 connectors ○ Spot welding to connect cells ○ MT60 connectors ○ Spot welder supplied by IRISS ○ 10 AWG Wire
Wire Kapton tape ○ ○ 100x LiPo battery cells
Waiting on R2R approval and
balancing cable to begin
manufacturing
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Manufacturing Extra Control Surfaces 83
● Control Surface ○ Same material and manufacturing method as horizontal tail Servo ○ Mounted using Z-Tape ● Servo Control ○ Mounted inset into the Surface horizontal tail ○ Connected to control surface same as wing Mounting example from the wing ● Foam and servo still need to be purchased
Manufacturing of horizontal tail and control surfaces is scheduled to be completed by Feb 11th
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Manufacturing the Tail 84
● Tail Booms ● Cut Foam Horizontal Tail ○ Laser Cut Coroplast ○ CNC Hot Wire Foam Cutter ○ 8 mm thick ○ XPS foam
● Preliminary Dimensions (Subject to Change) ○ 1 m length ○ S = 0.089 m2
○ Vh= 0.6 ○ c = 0.22 m
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Aerodynamic Test Stand: Load Cells 85
Manufacturing Sufficient Brackets Solution: ● Nylon Alloy 3D print bracket for cell to carbon fiber rod ● 90° inner and outer brackets milled from a low carbon steel block
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management 86
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Aerodynamic Test Stand 87
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Static Propulsion Test Stand 88
● Will be assembled by us ● Main Parts ○ Aluminum Extrusion ■ Cut to length/thread ourselves ○ 3 ¼” Acrylic Panels on sides ■ Cut to size ourselves ○ 1” wire screen for front/rear ○ Load Cell/Motor Mount Assembly ■ Lent by DBF
Cutting aluminum extrusion and assembling this week
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Custom Battery Progress 89
Inventory Still waiting for procurement on 1 major part ● Charging pin (delivery eta: unknown)
Deliverables 1. Single simple parallel cell testing (4 cells) Estimated time (1 hour) 2. 1st iteration full battery pack (24 cells) Estimated time (1 day)
Progress Waiting on R2R approval to begin manufacturing
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management LiDAR Test Stand 90
● Test stand has been purchased Set height & tighten ○ Waiting on delivery
● Lidar Mount printed out of PETG and mounts to the center of the cross beam Lidar ○ Holds lidar sensor in vertical orientation at known height
Waiting on Test stand to be delivered LiDAR mount printed Assembled by Feb 5th
*Dimensions in mm
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Motor Arm 91
● Arm mounts printed out of PETG ○ ~10 hours each ○ Hollow to allow for wire channeling ● Motor arm attaches to wing mount by two horizontal 3mm bolts
To be 3D printed by Feb 5th
*units in cm
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Wing Mounting 92
Top ● Wing mounts printed out of PETG ○ ~12 hours total ● Wing mounts held together by glue and forward & rear 3mm bolts in the wing
One set is printed and ready to begin wing load testing
Bottom
*units in cm
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Overview and Scope 93
Purchased or Manufacture Completion Component Status Manufactured Time Date
Drak Wing Kit Purchased/Assembled ~ 3 days Feb 5th-8th Waiting on Adhesive
Wing & Motor Mounts Manufactured/Printed 12 hours Jan 30th Printed
Printed, Waiting on Lidar Test Stand Purchased/Printed 1 hour Feb 5th Delivery
Custom Battery Manufactured 6 hours Feb 3rd Waiting on R2R
Static Test Stand Manufactured 3 hours Feb 4th Waiting on R2R
Dynamic Test Stand Manufactured 4 hours Feb 3rd Waiting on Delivery
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Drak 94
● Three Drak kits purchased and in our possession ○ Backups in case of damage during testingDimensions ● Extra wing set Wingspan: 1.55m ○ Test wing mount loading Length: 1.09m ● Kit includes EPP foam body, coro-plast stabilizers, carbon fiber rods and spars ● Additional assembly tools ○ Adhesive ○ Tape for control surfaces
All Drak kits procured, waiting on adhesive to be delivered To be assembled by Feb 5th-8th
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Manufacturing/Testing Concerns 95
Category Concern Notes
Dynamic Test Stand Primarily safety, Milling and cutting metal, Organizing High testing space, Intense data processing
Static Test Stand Safety, Experience with DBF propulsion testing, Shop Medium work
Custom Battery Packs Shipping parts. Battery pack performance after Medium manufacturing. Safety
Motor Mounts, and Loading Uncertainty in FEM causing failure before the Low Test required loading.
Extra Control Surface Tail booms approx. 40 in, Hot wire foam cutting, Low Optimization Sizing, Ardupilot parameters
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Risk Breakdown 96
Residual Risk # Category Description Consequence Probability Impact Risk Level Risk Modification Plan Level
Simulate sensors and mission aspects, model computing power Data rate from sensor exceeds pixhawk's Data overload sent to flight controller, could cause crash on 1 Autonomy Medium Medium Medium using desktop hardware, use companion computing device if Low capabilities landing or other unpredictable flight performance necessary
Accurate model not finished or model results Battery needs are not fully met resulting in reduced Test models against experimental data, refine model to reflect 2 Endurance Medium Low Medium Low are incorrect to a significant margin endurance or potential failure during flight observations to ensure accuracy
Ensure clearance of aircraft with regards to RAPCat structure, low 3 Structures RAPCat integration design Structural damage to aircraft/launch vehicle Low Medium Medium Low intensity test of compatibility
Plan flights as far ahead as possible and maintain clear 4 Testing Scheduling conflicts with pilot Less flight testing than desired, unfinished testing Low Medium Medium Low communincation with pilot regarding expectations
Drak kit backordered, potential supply Would not be able to produce second deliverable for Utilize IRISS' existing connection with RiteWing to obtain wing kits 5 Supply/Struct High Medium High Medium difficulties customer, may not have backup parts in case of destruction outside of standard commercial production
Inability to test computational speeds and fully functional Simulate sensor output in MissionPlanner, utilize desktop 6 Autonomy Failure to obtain avionics hardware from IRISS Medium Low Medium Low avionics package in first semester capabilities to ensure functionality
Ensure accurate materials simulation by obtaining experimental 7 Structures Material Failure Flight failure, damage to property, personnel injury Low Medium Medium Low test results to validate design specs
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Risk Breakdown 97
Residual Risk # Category Description Consequence Probability Impact Risk Level Risk Modification Plan Level
Ensure spot welder is only used by properly fire/explosion in battery cells, injury to Propulsion Battery damage during pack assembly Low High High trained individuals, follow strict safety Medium personnel protocols when working with battery cells
improper charging, overdrawing current, or Design test procedures within margin of safety Propulsion testing safety considerations undervolting cells may cause permanent Medium Medium Medium of battery capabilities to ensure they are not Low damage to cells exceeding capacity
Motors or propellers on backorder/hard to alternatives may need to be selected that are Design margin into propulsion system to allow Supply/Prop Medium Low Medium Low obtain not ideal component choices for varied component selection
Damage to vehicles, test equipment, citations Coordinate with department to create safe Testing Car-top safety considerations issued for property damage or other unknown Low High High testing procedures and equipment, research Medium reasons (?) local laws to ensure legality of test operations
Possible material failure, could need to Compare FEM to known models and research Structures Inaccurate FEM model Medium Medium Medium Low redesign parts minimizing FEM error, continually refine models
Less performance than predicted from vehicle, Model CFD against known experimental data, Aerodynamics Inaccurate CFD additional energy expenditure or increased Medium Low Medium ensure mesh convergence, account for variance Low flight velocity would be required between CFD and known data
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Interface Control Overview 98
Hardware Software Electronics
Tilt Servo must lift motor LiDAR RS-232 to Avionics Battery to Power Module
Design tail around existing Servo Rail PWM to Servos & Power Module to Avionics structure ESC’s Power Module to 3 - ESC’s RAPCat interfacing Digital Pitot Probe measurement Avionics Servo Rail to Servo/ESC
Avionics to Pitot-Probe
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management Interface Control Overview 99
Battery, Power Module, & ESC ● Battery must provide enough burst current to ESC’s ○ Below continuous 100A limit of Power Module ○ Wires must sufficiently carry large current ● Power module output must be split to 3 ESC’s ○ Special wiring harness created ● Battery and ESC must interface to Power Module
Avionics Board, Servo’s, & ESC’s ● Servo and ESC PWM signal must run off 5V ● Avionics Servo Rail must match physical wiring ○ Servo Rail output set in Mission Planner ○ Aircraft wiring is labeled for rail outputs 1-8
Avionics Board & LiDAR ● LiDAR Required RS-232 Communication W/ 5V ○ Designate COM-5 in MissionPlanner Setup
Design Systems Project Project Overview Testing Backup Slides Description Engineering Management