MAKE TO INNOVATE Final Review – Spring 2019 Cardinal Flight Project Overview

Activity Report

Design Review

• Design Constraints • Current Design • Proposed Changes AGENDA • Design Risks

Budget Status

Future Work

Conclusion PROJECT OVERVIEW Project Executive Summary Project Photo

From Left to Right: Back Row: Andrew Scherping, Miguel Sanchez, Kyle McKinney, Dillan Lein, Joe Cairo, Spencer Nord, Jeremy Rutledge, Ted Pernula, Derrek Brock, Nels Benson Front Row: Cole Drenth, Alex Winter, Spencer Eaton, Ethan Witt, Alex Scott, Josh Neumann, David Eddy, Carter Lomicka

Make to Innovate (M:2:I) PROJECT OVERVIEW Spring 2019 Project Faculty Dr. A Ram Kim Adviser

Project Xiaosong Du – PhD student Technical Advisers Eli Lockwood – Scaled Composites PROJECT

OVERVIEW Project Team Joseph Cairo – Aerospace Engineering Lead

Project Stake Dan Buhr – Collins Aerospace Holders

Make to Innovate (M:2:I) PROJECT OVERVIEW Spring 2019 Project Organization Chart

Project Lead Joe Cairo

Aerodynamics and Structures Electrical Team Software Team Team Lead Lead Lead David Eddy Kyle McKinney Alex Scott

Aerodynamics and Structures Electrical Team Software Team Team Ted Pernula Spencer Eaton Derrek Brock Nels Benson Ethan Witt Dillan Lein Josh Neumann Cole Drenth Carter Lomicka Spencer Nord Alex Winter Andrew Scherping Jeremy Rutledge Differentiation

Motor Arrow

X8

Modular Fuselage Kestrel X Project Plan

Project Semester Goals Semester Objectives • Successful flight of Deliverables • Design and Kestrel X • Operational collision implement a new • Design collision avoidance systems innovative UAV avoidance system • SolidWorks model every academic • Design modular of modular fuselage year fuselage • Kestrel X’s first flight

Make to Innovate (M:2:I) PROJECT OVERVIEW Spring 2019 ACTIVITY REPORT Milestones, Tasks, and Health Report MILESTONES MILESTONES MILESTONES TASK BREAKDOWN AERO AND STRUCTURES

. Milestone 1 – Complete Kestrel X . Milestone 2 – Design Multi-purpose Flight Structure . Task 1: Finish Aircraft Components . Task 1: Develop Concept Models . Deadline: April 6, 2019 . Deadline: March 1, 2019 . Task 2: Final Assembly and Testing . Task 2: Create SolidWorks Model . Deadline: May 3, 2019 . Deadline: March 16, 2019 . Task 3: ANSYS Analysis . Deadline: April 6, 2019 TASK BREAKDOWN ELECTRICAL . Milestone 1: Flight Test Kestrel X . Milestone 2: Fly Collision Avoidance Mission and Complete Electrical System for Modular Plane . Task 1: Complete the wiring of Kestrel X . Task 1: Refurbish All Flyable Cardinal Flight vehicles . Deadline: March 1, 2019 . Deadline: April 12, 2019 . Task 2: Program Kestrel X . Task 2: Add an autonomous Flight Control System to . Deadline: March 8, 2019 all vehicles . Task 3: Tune Kestrel X on ground . Deadline: April 19, 2019 . Deadline: April 30, 2019 . Task 3: Flight test all vehicles separately . Task 4: Fly Kestrel X . Deadline: April 30, 2019 . Deadline: May 4, 2019 . Task 4: Design Electrical System for the new project . Deadline: May 3, 2019 TASK BREAKDOWN SOFTWARE

. Milestone 1: Create simulation that . Milestone 2: Fly two planes at once on a collision has two planes on a collision course course . Task 1: Make a code to get information and . Task 1: Test a basic Python Script in control two planes at once Mission Planner . Deadline: April 12, 2019 . Deadline: March 1, 2019 . Task 2: Assign priority values to each plane . Task 2: Make a script to control a single . Deadline: April 19, 2019 simulated plane . Task 3: Test code with planes on the ground . Deadline: March 15, 2019 . Deadline: April 30, 2019 . Task 3: Make a script that takes plane’s . Task 4: Test Program while in air position and velocity vectors . Deadline: May 3, 2019 . Deadline: March 23, 2019 PROJECT HEALTH REPORT AERO AND STRUCTURES

. Issues . Choosing a good design out of Kestrel X Test our ideas . Kestrel is unrepairable . Foreseeable Issues None . Remaking Kestrel . Solutions

Kestrel X Assembly . Listing Pro’s and Con’s of all our Fuselage SolidWorks Model ideas ANSYS Analysis PROJECT HEALTH REPORT ELECTRICAL

. Issues Kestrel X Flight . Kestrel was much more complicated than expected Kestrel X Control Test . Kestrel had a rapid unplanned disassembly. . Foreseeable issues Kestrel X Program . Kestrel is still tough to control. . Will not have enough thrust with current setup. Kestrel X Wiring . Possible solutions Modular Fuselage Electrical System . Larger props, lighter frame. PROJECT HEALTH REPORT SOFTWARE . Issues . Inexperience with Mission Program Ground Test Planner Program Test Flight . Controlling two planes within Mission Planner . A* algorithm without a software engineer Collision Avoidance Script . Flight testing Kestrel X taking time . Solutions . Extensive research on how to use None Mission Planner . Will test code on on the ground before in the air . Gain exp PROJECT REVIEW Overview PROJECT OVERVIEW AERO AND STRUCTURES

.Fully modular fuselage design .Variable fuselage size .Quick wing mount .Easy access fuselage .Easy to manufacture .Short setup time PROJECT OVERVIEW ELECTRICAL

. 4 Aircraft .Kestrel X .Arrow .X8 . .Similar set ups Control System .PixHawk .Motors .Servos .1-4 batteries Kestrel Electrical System

Secondary Electrical System PROJECT OVERVIEW SOFTWARE . Design a collision avoidance system . Operates through Mission Planner . Runs through a ground control station . Potential collisions are based on proximity . A* algorithm . Creates efficient course adjustments PROJECT REVIEW Constraints PROJECT CONSTRAINTS AERO AND STRUCTURES

.Constraints .Versatile Fuselage .Variable CG .Interlocking Body Sections .Issues . Designing sections . Interlocking section methods . Ease of access to internal components . Solution . Interlocking sections using “Hooks”

Fuselage Section PROJECT CONSTRAINTS ELECTRICAL .Kestrel X .Tilt Wing .10 Motors .Broken

. Motor Glider and X-8 . Systems already in place . Make Autonomous

. Arrow . Existing System Motor Glider electrical system PROJECT CONSTRAINTS SOFTWARE 1 Constraints: . Unfamiliarity using ground control software (MP) . Difficulty using multiple ports (MP) . Finding + using compatible syntax (MP + Python) . Inexperience with software development 2 . Complexity of A* algorithm

1: “Get Mission Planner.” Software Asset Management – Microsoft SAM, www.microsoft.com/en-us/p/mission-planner/9nblggh4tx29?activetab=pivot%3Aoverviewtab 2: “The Python Logo.” Python.org, www.python.org/community/logos/. PROJECT REVIEW Final Design FINAL DESIGN Backbone/Tail Boom: • Act as attachment point for the AERO AND STRUCTURES fuselage pieces • Will connect to an adjustable tail boom

Removable Tail Sleeve: • Bolts onto I beam to Modularity: Fuselage: act as safety net for • Each Fuselage piece will have 2 • Rounded Rectangular shape friction failure friction clamp devices to place them at • Made out of foam with a fiberglass • Change sleeve length any desired location shell with inner dimensions of 5x6 for Increased • Each piece will have a metal clip on inches Moment for larger the bottom to make sure the pieces • Multiple various length sections fuselage stay together will make the plane modular configurations • One specific section will have wing • The nose cone will have a removable attached tip for possible motor placement FINAL DESIGN

.Kestrel X ELECTRICAL . 10 Motors . 4 Batteries . Controller: PixHawk

.Modular Fuselage .Anticipate similar design to X-8 and Old Glider X8 electrical .Waiting for final design on the modular vehicle system

.Arrow .Single motor .MPPTS for solar power .Controller: PixHawk

.X8 and Motor Glider .Single motor .Controller: Pixhawk FINAL DESIGN SOFTWARE

.Mission Planner

.One ground station communicating with multiple

aircraft

.One python script to send commands

.Use the A* algorithm to determine a new path to

avoid a possible collision PROJECT REVIEW Future Work PROPOSED CHANGES AERO AND STRUCTURES

.Bolt nose cone for friction failure safety net

.Quick connect power plugs between sections

.Side clips protrude from bottom

.Landing Gear Sections

.C clamp pin design PROPOSED CHANGES ELECTRICAL . Modifying vehicles to be compatible with autonomous flight . Including the collision avoidance software in the programming of the vehicles . Figure a better power solution for kestrel . Replacing older electronic components used in the Motor Glider and X8 PROPOSED CHANGES SOFTWARE

. Each plane run its own script in the GSC

. Remove the ground control station and each plane

operate independently

. Different algorithm for avoidance PROJECT REVIEW Encountered Risks DESIGN RISKS AERO AND STRUCTURES

.New Fuselage Design .Modular design may not provide sufficient strength .Connection points will not properly secure sections DESIGN RISKS ELECTRICAL

. Kestrel . Not enough power to hover . Control issues with vertical to horizontal flight

. X8/Motor Glider . Control System Failure . Autonomous failure

Side view of Kestrel DESIGN RISKS

• Risks SOFTWARE • Program not working perfectly in the air, or not fast enough would result in a collision • Program not being feasible with Mission Planner’s constraints • System not being useful for future work because it is non-transferrable to an active collision avoidance system. BUDGET Status and requests BUDGET STATUS Current Expenses Future Expenses

Item Cost $0 Monokote $21.99

Pixhawk 4 mini $180.00

Total $201.99

Current funds $4031 FUTURE WORK FUTURE WORK

. Start work on new innovative UAV: 2019-2020 academic year . Hoping to continue our work with innovative UAV’s designs and begin the construction of our modular fuselage

Arrow’s First Flight CONCLUSION CONCLUSION . Cardinal Flight Faculty and Technical . Sponsors Advisors .Dr. Bella Kim .Xiaosong Du .Eli Lockwood .AirPad Stuorg Advisor . Matt Nelson . Support . ABE water jet lab . M2I lab . PowerFilm Solar EXTRA SLIDES Aircraft Differentiation

Motor Glider Arrow

X8

Modular Fuselage Kestrel X