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The 2010 Cessna/Raytheon Missile Systems Design/Build/Fly Competition Flyoff Was Held at Cessna Field in Wichita, KS on the Weekend of April 16-18, 2010

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The 2010 Cessna/Raytheon Missile Systems Design/Build/Fly Competition Flyoff Was Held at Cessna Field in Wichita, KS on the Weekend of April 16-18, 2010 The 2010 Cessna/Raytheon Missile Systems Design/Build/Fly Competition Flyoff was held at Cessna Field in Wichita, KS on the weekend of April 16-18, 2010. This was the 14th year the competition was held, and participation continued to increase from past years. A total of 69 teams submitted written reports to be judged. 65 teams attended the flyoff all of which completed the technical inspection and 62 teams made at least one flight attempt. More than 600 students, faculty, and guests were present. Good weather allowed for non-stop flights each day with a total of 179 flights during the weekend. 46 Teams were able to obtain a successful scoring flight. Overall, the teams were better prepared for the competition than ever before, which was reflected in the number and quality of the written reports, teams attending the flyoff, completing tech and flying the missions. A historical perspective of participation is shown below. The primary design objective for this year was to accommodate random payloads of mixed size softballs and bats. A delivery flight was first required, where the airplane was flown with no payload. As usual, the total score is the product of the flight score and written report score. More details on the mission requirements can be found at the competition website: http://www.ae.uiuc.edu/aiaadbf First Place was Oklahoma State University Team Orange, Second Place was Oklahoma State University Team Black and Third Place was Purdue University B'Euler Up. The top three teams had a very close competition. Oklahoma State University (OSU) Orange was ahead after all three teams completed the third mission. They then re-flew Mission 2 and dropped their ball loading time from 16 seconds down to 12 seconds to stretch their lead. Purdue and OSU Black then retried their mission 2 but unfortunately both had problems. A full listing of the results is included below We owe our thanks for the success of the DBF competition to the efforts of many volunteers from Cessna Aircraft, Raytheon Missile Systems, and the AIAA sponsoring technical committees: Applied Aerodynamics, Aircraft Design, Flight Test, and Design Engineering. These volunteers collectively set the rules for the contest, publicize the event, gather entries, judge the written reports, and organize the flyoff. Thanks also go to the Corporate Sponsors: Raytheon Missile Systems and Cessna Aircraft Company, and also to the AIAA Foundation for their financial support. Special thanks go to Cessna Aircraft for hosting the flyoff this year. Finally, this event would not be nearly as successful without the hard work and enthusiasm from all the students and advisors. If it weren’t for you, we wouldn’t keep doing it. David Levy and Tom Zickuhr For the DBF Governing Committee Table of Contents 1.0 EXECUTIVE SUMMARY ........................................................................................................................ 3 2.0 MANAGEMENT SUMMARY ................................................................................................................... 4 2.1 Project Management ........................................................................................................................... 4 2.2 Milestone Chart ................................................................................................................................... 5 3.0 CONCEPTUAL DESIGN ......................................................................................................................... 6 3.1 Mission Requirements ......................................................................................................................... 6 3.2 Design Requirements Definition ......................................................................................................... 7 3.3 Solutions, Configurations, and Results ............................................................................................... 9 3.4 Final Conceptual System Selection .................................................................................................. 19 4.0 PRELIMINARY DESIGN ....................................................................................................................... 20 4.1 Design and Analysis Methodology .................................................................................................... 20 4.2 Mission Modeling and Optimization Analysis .................................................................................... 20 4.3 Design and Sizing Trade-offs ............................................................................................................ 21 4.4 Analysis Methods and Sizing ............................................................................................................ 22 4.5 Lift, Drag, and Stability Characteristics ............................................................................................. 29 4.6 Aircraft Mission Performance ............................................................................................................ 32 5.0 DETAIL DESIGN ................................................................................................................................... 35 5.1 Dimensional Parameters ................................................................................................................... 35 5.2 Structural Characteristics and Capabilities ....................................................................................... 36 5.3 System Design, Component Selection and Integration .................................................................... 36 5.4 Weight and Balance .......................................................................................................................... 40 5.5 Flight Performance Parameters ........................................................................................................ 42 5.6 Mission Performance ........................................................................................................................ 42 5.7 Drawing Package .............................................................................................................................. 44 6.0 MANUFACTURING PLAN & PROCESSES ......................................................................................... 49 6.1 Investigation & Selection of Major Components & Assemblies ........................................................ 49 6.2 Milestone Chart ................................................................................................................................. 51 7.0 TESTING PLAN .................................................................................................................................... 51 7.1 Objectives ......................................................................................................................................... 51 7.2 Master Test Schedule ....................................................................................................................... 53 7.3 Flight Test Check List ........................................................................................................................ 53 8.0 PERFORMANCE RESULTS ................................................................................................................ 55 8.1 Subsystems ....................................................................................................................................... 55 8.2 System .............................................................................................................................................. 58 Oklahoma State University Orange Team Report Page 2 of 59 1.0 EXECUTIVE SUMMARY The challenge presented to the team for the 2009-2010 contest consisted of three missions. The first, a ferry mission, required the aircraft to fly two laps around the competition course, with the score determined completion time and overall weight of the aircraft system, including the case. The second mission consisted of a timed loading of a random mix of 11‖ and 12‖ softballs into the interior of the aircraft, followed by three untimed circuits of the course. Finally, the third mission consisted of three timed laps being flown while the aircraft carried up to five ―bats‖ on the exterior of the aircraft. To address these challenges, the team designed an aircraft capable of balancing the requirements posed by each mission, primarily high speed and maneuverability to complete the first and third missions, short loading time to accommodate the second, and overall low system weight for all missions. To improve the aircraft‘s performance in the first mission, great effort was made to minimize the turning radius of the vehicle, in order to reduce the distance the plane had to fly while completing the timed laps. Also, the structure of the vehicle was kept to an absolute minimum to reduce weight. This was accomplished not only through the use of lightweight materials, but also by designing existing structural elements to perform multiple roles. For example, the central bulkhead of the interior payload bay, while acting as part of the softball loading system, was also built to provide the majority of the bending strength to the vehicle. It was integrally connected to the wing mounting, landing gear, and lateral bulkhead systems of the internal structure. Because the key to success in the second mission was having the shortest possible loading time for the internal payload, the team designed
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