2002 Design Task: (Option 1) High Performance Multi-Role Unmanned Aerial Vehicle (UAV)

AERO 4400 Aircraft Design 3 6 credit points 2002 Design Task: (Option 1) High Performance Multi-Role Unmanned Aerial Vehicle (UAV)

Assessment: This task, with four (4) hand-in assignments (detailed separately) and associated presentations, final report, poster(s) and model(s) forms 100% of this course. Please note Item I of Appendix A for task requirements. Marking will be approximately based on Item II of Appendix A. Final assessment will be based on a combination of individual and team components, including peer assessments. Teams and Task Option allocations will be finalised in week 1.

Design Objectives and Requirements powerplants. A recent engine development provides a REQUEST FOR PROPOSAL (RFP - Option 1): High potential opportunity to develop a HALE UAV. Performance Multi-Role UAV Opportunity thus exist to evaluate the feasibility and cost effectiveness of such UAVs. I. Opportunity Description Australia is a vast country which has: • clear surveillance requirements for defence, Williams International is working on a cooperative coastwatch, and the monitoring and protection of effort with NASA, called the General Aviation Propulsion (GAP) Program, aimed at revolutionizing the environment and coastal natural resources; and reviving the once flourishing light aircraft • rich mineral wealth deposits which needs to be industry in the U.S. In this program, Williams exploited with due consideration to environmental International is developing the FJX-2 turbofan impact; engine for use in the next generation of four- and • a harsh climate, requiring understanding to support six-passenger general aviation airplanes. the population areas; and hence • potentially a good domestic market for Unmanned The FJX-2 is much smaller than the smallest Aerial Vehicles (UAVs). commercial turbofan of today. It is in the 700-lb The recent (2001) deployment of the Northrop Grumman thrust class and weighs less than 100 pounds. The Global Hawk High Altitude Long Endurance (HALE) engine is in development and will be flight-ready in UAV in Australia has led to much interest in acquiring the year 2000. The primary goal of the FJX-2 is such a capability. A recent market survey1 indicated affordability. It will allow jet-powered airplanes to be strong opportunities for high-altitude, long endurance priced competitive with today's general aviation (HALE) UAVs with around 100kg payload, 50-100 piston-powered planes. km/h cruising/loitering airspeed, and greater than 24 With turbofan power, this new generation of hours endurance. Although there are many UAV airplanes will fly faster, have longer range, be more systems either in operation or under development world- comfortable and quiet, and set a new standard in wide, there are few that could be considered affordable general aviation safety. to commercial operators that have attributes suitable to Based on its very low noise level, light weight, low operation for commercial purposes. High costs are emissions, low fuel consumption, and low cost in partly because most systems have been developed for quantity production, the FJX-2 engine will be a military markets and roles, and therefore subject to major factor in reviving the once flourishing light stringent military specifications. It is believed that aircraft industry. developments specifically aimed at commercial operations and therefore with attributes tailored to Engine Characteristics commercial requirements are more likely to be Thrust Class ...... 700 lbf acceptable to the civilian UAV market, with obvious Overall Length ...... 41.0 in opportunities in an increasingly cost-conscious defence Diameter ...... 14.5 in market. Weight ...... < 100 lbs

One of the constraints for lowering the cost of UAV This engine is also known as the Williams EJ22. There airframes has been the availability of suitable are manned aircraft designs under development which uses two of these engines, eg. V-JET II and Eclipse 500. A contest is currently underway to design such a single 1 engine 2-seat aircraft, more information being located at Wong, et. al., “Study of the Unmanned http://www.x-plane.com/design.html. The X-Plane Aerial Vehicle (UAV) Market in Simulation Software used there may be optionally used Australia”, Aerospace Technology Forum in this task, if so desired. Report, August 1997. II. Project Objective autonomous flight controller(s), appropriate Your company wants to explore the feasibility of surveillance sensor(s), and Ground Command and building a new family of aircraft, powered by one Control station(s). The choice and relative merit of Williams International FJX-2/EJ22 turbofan engine, which is left to the designer, as long as mission to target this potentially growing UAV marketplace. The requirements are met. objective is to provide your management with a • Payload: Electro Optical (EO), Infra-Red (IR), conceptual design of a highly capable low-cost UAV and/or other surveillance sensors up to a maximum system to suit a variety of missions. The cost of at least 232 kg (510 lb). effectiveness of this new concept must be illustrated with comparisons to existing systems. Tradeoff studies • Maximum Empty Weight: 1500 lbs (682 kg). should be incorporated to show that the concept is a • Appearance: The aeroplane should be aesthetically balanced and optimum design. If the company plans to pleasing. pursue this new development program, the target date for entry into service is the year 2004. Certification: • The UAV airframe should be designed to meet the A perusal of the history of UAV development would draft CASA UAV Design requirements (see separate reveal a long list of programme failures due to mission attachment), with guideline reference to JAR-VLA. requirement growth or changes (eg. The Aquilla and Notes: Outrider UAVs), which would seemingly rule out the development of multi-role UAV systems. These high- • All performance requirements, including those cost failures have taught the UAV industry that the key presented here and those specified by the respective to successful UAV programmes is a firm definition of a regulations, should meet the regulatory values and mission and stick to it (eg. Pioneer, Predator, Aerosonde definitions. UAVs). However, because UAV application to many • Aircraft which are predicted to significantly surpass market sectors are still unexplored, the opportunity is the specified design parameters are acceptable, still clearly there for low-cost multi-role high provided this can be justified as a cost or performance UAVs to operationally trial new High marketability tradeoff. Altitude Long Endurance missions before they are firmly defined. Although recognised to be only around 15% of • Roles such as Search and Rescue (SAR), Powerline the total cost of UAV systems, the airframes remain a inspection, Coastwatch, Telecommunications Relay, critical element to meet any mission performance Bushfire Command and Control, or any other objectives (eg. Endurance, speed, range). market identified roles should be explored and detailed. III. Requirements and Constraints Structural Layout:

Configuration Selection Criteria: A conceptual structural layout of the aircraft is required along with a material breakdown. Advanced materials The final configuration proposed shall be selected on the may be used in an attempt to reduce the empty weight of basis of the lowest development cost and satisfy all of the aircraft. However, any potential cost penalties from the requirements contained within the RFP. using advanced materials should be addressed.

Flight Capability: Aerodynamics: • Maximum Speed: Highest possible. Consideration of advanced technologies may be included • Loiter Speed: lowest possible. in the configuration. However, the technology must prove to be affordable, reliable and easily maintainable. • Cruise: Endurance no less than 24 hours, which includes a full power and minimum time climb from Development and Acquisition Cost: sea-level to >40,000 ft cruise altitude. Cost estimates are required to develop, manufacture, and • Field Performance: The UAVmust be capable of certify the aircraft. Any advances in materials, operating from hard surfaces (bitumen, concrete) aerodynamics, or systems should be adequately and firm grass runways. Required runway length addressed in the cost estimate. should be based on operating into and out of an airport surrounded by 50' obstacles, and an outside Cost estimates should be based on a production run of a air temperature (OAT) at sea level of ISA +15 number of units selected by the designer in response to degrees Celcius. an estimate of the market niche, in Year2002 dollars. Any engineering or manufacturing features to reduce the • Powerplant: one Williams International FJX- cost should be explained. A breakdown of the total 2/EJ22 turbofan engine. development cost for the aircraft should be included as • Systems: The complete system should include at well as the resulting acquisition cost for the aircraft least aeroplane(s) fitted with off-the-shelf assuming a reasonable profit margin. A brief description of the life cycle cost model should be included. 7) Aircraft component weight statement. Show a IV. Data Requirements weight breakdown of major components and systems, and aircraft centre-of-gravity envelope. The final proposal, based on the previously stated objectives, requirements and constraints, should include 8) Aircraft drag polars and lift curves in the cruise sections and data on, but not limited to the following: configuration, and in the takeoff and landing Configuration Sizing and Optimisation: configurations. Show an estimated drag build up for both cruise and landing configurations. 1) Describe the optimisation study used to minimise 9) A summary of the stability and control analyses is the development cost of the aircraft. Justify the final design and describe in detail the technologies required including a description on how the and technical approach used to accomplish the empennage and control surfaces were sized. requirements. This should include performance 10) Describe the major systems on the aircraft including graphs for high lift, propulsion, conversion, or other flight controls, ice protection, electrical, hydraulic, profiles for landing and take off. Describe tradeoffs environmental control system, and cockpit controls. made and justify final concept selection. 11) Provide fly-away cost for a production run of the 2) Describe the process for sizing the aircraft. Provide decided number of aircraft. carpet plots used to optimise the final selected design. Identify the most restrictive constraints in the design. Performance Data 1) Performance analysis detailing field length, mission 3) Describe the advantages and disadvantages of your time and endurance, comparing with other similar design. Make comparisons, where relevant, to UAVs. existing aircraft with similar capabilities. 2) Stability and control analysis verifying that the 4) Development and manufacturing cost analysis design conforms to applicable stability and control including sensitivity studies to verify minimum cost criteria. design. Include a discussion of how systems design, aerodynamics, propulsion, material 3) Provide performance estimates and demonstrate selection, configuration layout and other factors aircraft stability for all flight and loading affect cost. Report production cost with conditions. development amortised over a number of units 4) Weight and balance analysis for each loading selected by the designer in response to an estimate condition showing weight and centre of gravity are of the market niche. within limits for applicable stability and control criteria. Design Data 5) A flight envelope (altitude vs. speed) and a V-n 1) Table of the aircraft external dimensions and areas diagram is required. 2) Aircraft 3-view dimensional drawing, including: 6) A detailed description of each leg of the mission • Three view configuration drawings and tables of showing aircraft weight, fuel used, time, distance, external dimensions; altitude, speed, etc. • Inboard profiles, indicating the location and 7) Show that the cruise speed and altitude used in the nature of primary structure; design mission is optimum for the final aircraft. • Description of aircraft systems with layout 8) The effects of varying payload on range should be drawings; shown. 9) The effects of altitude and aircraft weight on takeoff • Layout of sensor(s), communication links, and distance, climb gradient, and landing distance other avionics; should be shown. 3) Location and volume of fuel tanks

4) Location of the major systems on the aircraft V. Additional Supporting Data

5) Drawings showing the conceptual structural layout The aircraft must be powered by a Williams of the aircraft Include an illustrated description of International FJX-2 (EJ22) Turbofan. The thermocyclic the primary load bearing airframe structure and cycle of this engine is claimed to be similar to the best state rationale for material selection. engines used in current bizjets, so any required information not yet publicly available can be estimated 6) Material breakdown of the aircraft using available scaling methods. Appendix A I. Proposal Requirements The technical proposal is the most important factor in the award of a contract. It should be specific and complete. While it is realised that all of the technical factors cannot be included in advance, the following should be included and keyed accordingly: 1. Demonstrate a thorough understanding of the Request for Proposal (RFP) requirements. 2. Describe the proposed technical approaches to comply with each of the requirements specified in the RFP, including phasing of tasks. Legibility, clarity, and completeness of the technical approach are primary factors in evaluation of the proposals. 3. Particular emphasis should be directed at identification of critical, technical problem areas. Descriptions, sketches, drawings, systems analysis, method of attack, and discussions of new techniques should be presented in sufficient detail to permit engineering evaluation of the proposal. Exceptions to proposed technical requirements should be identified and explained. 4. Include tradeoff studies performed to arrive at the final design. 5. Provide a description of automated design tools used to develop the design.

II. Basis for Assessment

1. Technical Content (35 %) This concerns the correctness of theory, validity of reasoning used, apparent understanding and grasp of the subject, etc. Are all major factors considered and a reasonably accurate evaluation of these factors presented?

2. Organisation and Presentation (20 %) The description of the design as an instrument of communication is a strong factor on judging. Organisation of written design, clarity, and inclusion of pertinent information are major factors.

3. Originality (20 %) The design proposal should avoid standard textbook information, and should show the independence of thinking or a fresh approach to the project. Does the method and treatment of the problem show imagination? Does the method show an adaptation or creation of automated design tools.

4. Practical Application and Feasibility (25 %) The proposal should present conclusions or recommendations that are feasible and practical, and not merely lead the evaluators into further difficult or insolvable problems. AERO 4400 Aircraft Design 3 6 credit points 2002 Design Task: (Option 2) Single Jet Sportplane

Design Objectives and Requirements development which uses two of these engines, eg. V- JET II and Eclipse 500. A contest is currently REQUEST FOR PROPOSAL (RFP - Option 2): underway to design such an aircraft, more information Single Jet Sportplane being located at http://www.x-plane.com/design.html. I. Opportunity Description This design task is based partly on that competition, and the X-Plane Simulation Software may be optionally used if so desired. Williams International is working on a cooperative III. Requirements and Constraints effort with NASA, called the General Aviation Configuration Selection Criteria: Propulsion (GAP) Program, aimed at revolutionizing and reviving the once flourishing light aircraft The final configuration proposed shall be selected on industry in the U.S. In this program, Williams the basis of the lowest development cost and satisfy all International is developing the FJX-2 turbofan of the requirements contained within the RFP. engine for use in the next generation of four- and Flight Capability: six-passenger general aviation airplanes. • Cruise Speed: best possible. The FJX-2 is much smaller than the smallest • Loitre Speed: lowest possible commercial turbofan of today. It is in the 700-lb • Cruise Endurance: maximum possible, which thrust class and weighs less than 100 pounds. The includes a full power and minimum time climb engine is in development and will be flight-ready in the year 2000. The primary goal of the FJX-2 is from sea-level to cruise altitude. affordability. It will allow jet-powered airplanes to be • Take-Off and Landing Distance: The aeroplane priced competitive with today's general aviation must be capable of operating from hard surfaces piston-powered planes. (bitumen, concrete) and firm grass runways typical of General Aviation airports. Required runway With turbofan power, this new generation of length should be based on operating into and out of airplanes will fly faster, have longer range, be more an airport surrounded by 50' obstacles, and an comfortable and quiet, and set a new standard in outside air temperature (OAT) at sea level of ISA general aviation safety. +15 degrees Celcius. Based on its very low noise level, light weight, low • Powerplant: one Williams International FJX- emissions, low fuel consumption, and low cost in 2/EJ22 turbofan engine. quantity production, the FJX-2 engine will be a major • Payload: Two 180 lb (81.8 kg) persons and 150 factor in reviving the once flourishing light aircraft lbs (68.2 kg) total cargo capacity. industry. • Maximum Empty Weight: 1500 lbs (682 kg). Engine Characteristics • Fuselage Size: Minimum fuselage body radius of 2 feet (at least ½ that width for tandem seating Thrust Class ...... 700 lbf arrangement). Overall Length ...... 41.0 in • Appearance: The aeroplane should be Diameter ...... 14.5 in aesthetically pleasing. Weight ...... < 100 lbs Notes: This engine is also known as the Williams EJ22. Such a • Weight and balance shall include all equipment high-efficiency, low-cost jet engine presents an necessary for day or night VFR and IFR flight. opportunity to develop an affordable personal jet Cruise speed and endurance predictions shall be transport using one of these engines, with potential costs done in standard atmospheric conditions. in the 6-figure US$, rather than the current 7-figure US$ • All performance requirements, including those for the smallest jet transports. There are designs under presented here and those specified by the respective regulations, should meet the regulatory 7. Stability, Control and Handling Qualities analysis values and definitions. and discussion which addresses design philosophy, • Aircraft which are predicted to significantly surpass goals, and predictions at various loading the specified design parameters are acceptable, conditions. provided this can be justified as a cost or 8. Design details that decrease the cost of the marketability tradeoff. aeroplane. Structural Layout: The final proposal, based on the previously stated objectives, requirements and constraints, should include A conceptual structural layout of the aircraft is required sections and data on, but not limited to the following: along with a material breakdown. Advanced materials may be used in an attempt to reduce the empty weight of Configuration Sizing and Optimisation: the aircraft. However, any potential cost penalties from using advanced materials should be addressed. 1) Describe the optimisation study used to minimise the development cost of the aircraft. Justify the Aerodynamics: final design and describe in detail the technologies and technical approach used to accomplish the Consideration of advanced technologies may be included requirements. This should include performance in the configuration. However, the technology must graphs for high lift, propulsion, conversion, or prove to be affordable, reliable and easily maintainable. other profiles for landing and take off. Describe tradeoffs made and justify final concept selection. Development and Acquisition Cost: Cost estimates are required to develop, manufacture, and 2) Describe the process for sizing the aircraft. certify the aircraft. Any advances in materials, Provide carpet plots used to optimise the final aerodynamics, or systems should be adequately addressed selected design. Identify the most restrictive in the cost estimate. constraints in the design. 3) Describe the advantages and disadvantages of your Cost estimates should be based on a production run of a design. Make comparisons, where relevant, to number of units selected by the designer in response to an existing aircraft with similar capabilities. estimate of the market niche in Year2002 dollars. Any engineering or manufacturing features to reduce the cost 4) Development and manufacturing cost analysis should be explained. A breakdown of the total including sensitivity studies to verify minimum development cost for the aircraft should be included as cost design. Include a discussion of how systems well as the resulting acquisition cost for the aircraft design, aerodynamics, propulsion, material assuming a reasonable profit margin. A brief description selection, configuration layout and other factors of the life cycle cost model should be included. affect cost. Report production cost with development amortised over a number of units IV. Data Requirements selected by the designer in response to an estimate The final proposal should include, but not be limited to, of the market niche. to the following: Design Data 1. Justify the aircraft configuration by describing the 1) Table of the aircraft external dimensions and areas factors that led to your decisions and the factors that led you away from other configurations. 2) Aircraft 3-view dimensional drawing, including: 2. Dimensioned Drawings and Descriptions: • Three view configuration drawings and tables of external dimensions; a. Configuration description including three-view drawing and table of external dimensions • Inboard profiles, indicating the location and nature of primary structure; b. Inboard profiles, indicating the location and nature of primary structure • Description of aircraft systems with layout drawings; c. Description of aircraft systems with layout drawings • Layout of cabin and cockpit area and instrument panels; d. Layout of the cabin area 3) Interior cabin layout drawing (plan view and cross 3. Description of the process of sizing for performance. section). 4. Performance analysis confirming the requirements from Section III are satisfied. 4) Location and volume of fuel tanks

5. Discussion of materials selection. 5) Location of the major systems on the aircraft 6. Discussion of engine selection, and propeller selection if appropriate. 6) Drawings showing the conceptual structural layout of the aircraft Include an illustrated description of engine is claimed to be similar to the best engines used the primary load bearing airframe structure and state in current bizjets, so any required information not yet rationale for material selection. publicly available can be estimated using available scaling methods. 7) Material breakdown of the aircraft Appendix A 8) Aircraft component weight statement. Show a I. Proposal Requirements weight breakdown of major components and The technical proposal is the most important factor in systems, and aircraft centre-of-gravity envelope. the award of a contract. It should be specific and 9) Aircraft drag polars and lift curves in the cruise complete. While it is realised that all of the technical configuration, and in the takeoff and landing factors cannot be included in advance, the following configurations. Show an estimated drag build up for should be included and keyed accordingly: both cruise and landing configurations. 1. Demonstrate a thorough understanding of the Request for Proposal (RFP) requirements. 10) A summary of the stability and control analyses is 2. Describe the proposed technical approaches to required including a description on how the comply with each of the requirements specified in empennage and control surfaces were sized. the RFP, including phasing of tasks. Legibility, clarity, and completeness of the technical approach 11) Describe the major systems on the aircraft including are primary factors in evaluation of the proposals. flight controls, ice protection, electrical, hydraulic, 3. Particular emphasis should be directed at environmental control system, and cockpit controls. identification of critical, technical problem areas. Descriptions, sketches, drawings, systems analysis, 12) Provide fly-away cost for a production run of the method of attack, and discussions of new decided number of airframes, including units costs techniques should be presented in sufficient detail for a typical completed aeroplane. to permit engineering evaluation of the proposal. 13) Provide fly-away cost for a production run of 200 Exceptions to proposed technical requirements factory produced aeroplanes. should be identified and explained. 4. Include tradeoff studies performed to arrive at the Performance Data final design. 1) Performance analysis detailing field length, mission 5. Provide a description of automated design tools time and endurance, comparing with other similar used to develop the design. sportplanes. II. Basis for Assessment 2) Stability and control analysis verifying that the design conforms to applicable stability and control 1. Technical Content (35 %) criteria. This concerns the correctness of theory, validity of 3) Provide performance estimates and demonstrate reasoning used, apparent understanding and grasp of the aircraft stability for all flight and loading conditions. subject, etc. Are all major factors considered and a 4) Weight and balance analysis for each loading reasonably accurate evaluation of these factors condition showing weight and centre of gravity are presented? within limits for applicable stability and control criteria. 2. Organisation and Presentation (20 %) The description of the design as an instrument of 5) A flight envelope (altitude vs. speed) and a V-n communication is a strong factor on judging. diagram is required. Organisation of written design, clarity, and inclusion of 6) A detailed description of each leg of the mission pertinent information are major factors. showing aircraft weight, fuel used, time, distance, altitude, speed, etc. 3. Originality (20 %) 7) Show that the cruise speed and altitude used in the The design proposal should avoid standard textbook design mission is optimum for the final aircraft. information, and should show the independence of thinking or a fresh approach to the project. Does the 8) The effects of varying payload on range should be method and treatment of the problem show shown. imagination? Does the method show an adaptation or 9) The effects of altitude and aircraft weight on takeoff creation of automated design tools. distance, climb gradient, and landing distance should be shown. 4. Practical Application and Feasibility (25 %) The proposal should present conclusions or V. Additional Supporting Data recommendations that are feasible and practical, and The aircraft must be powered by a Williams International not merely lead the evaluators into further difficult or FJX-2 (EJ22) Turbofan. The thermocyclic cycle of this insolvable problems.