MSD 1 WEEK 6 SYSTEM DESIGN REVIEW Team 15462 Rochester Institute of Technology College of Engineering P1546210/2/2014 1.

P15462

MSD 1 WEEK 6 SYSTEM DESIGN REVIEW

Team 15462Rochester Institute of Technology

College of Engineering

10/2/2014 1

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AGENDA

Background (10 minutes) Problem Statement Customer Needs Engineering Requirements Week 3 action item review

10/2/2014

System Analysis Functional Decomposition Areas of Design Solution Brainstorming Selection Criteria Concept Generation Pugh Chart Final System Selection Concept Feasibility Updated Project Plan System Architecture Risk Assessment

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PROBLEM STATEMENT

The goal of this project is to design, build, and reliably test an unpowered, human-controlled tethered glider specifically for use as an Airborne Wind Turbine system (AWT).

250m

100m

100m

250m10/2/2014

CUSTOMER NEEDS

Customer Need # Importance DescriptionCN1 9 Tethered glider system (with electric prop assist for launching) that

demonstrates at least 3 minutes of continuous circular flight path with taunt tether.

CN2 1 Clean appearanceCN3 9 Human controlled planeCN4 3 No special flight skill requiredCN5 9 Use existing base station designCN6 9 Tether tension is measured and recorded during flightsCN7 9 Tether direction is measured and recorded during flightsCN8 9 Videos with accompanying data files of all flight tests (even ones that don’t

work)CN9 9 Able to survive crashes with minor repairs (short downtime)

CN10 9 Replaceable PartsCN11 3 Maintenance GuideCN12 9 Design a robust glider which meets the above repair requirements and can

be piloted in the cyclical path.

P1546210/2/2014

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ENGINEERING REQUIREMENTS

10/2/2014

Rqmt. # Importance Type Source Engr. Requirement (metric) Unit of Measure Marginal Value Ideal Value Comments/Status Test (Verification)

S1 9 Aero CN1 Drag Coefficient -- 0.2 0.05 Calculation & XLFR5

S2 9 Aero CN1 Lift Coefficient -- 0.7 1 Calculation & XLFR5

S3 3 Aero CN1 Wingspan ft 3.3 3 Customer Constraint Tape Measure

S4 3 Aero CN4 Cooper-Harper Rating -- 3 1 Subjective

S5 3 Aero CN3 Flight Stability Binary Marginal Complete Static Stability Criteria Calulation & Flight Testing

S6 3 Aero CN11 Profile of Surface for Airfoil Manufacturing in 0.1 0.05 GD&T ASTM Standard

S7 9 Aero CN1 Efficiency of Wing - 0.82 0.9 Calculation

S8 1 Aero CN1 Fixed Angle of Attack deg 0 3 Protractor

S9 9 Electrical CN7 Horizontal Potentiometer Recording Binary Marginal Complete Capability Exists (P14462) LabVIEW

S10 9 Electrical CN7 Vertical Potentiometer Recording Binary Marginal Complete Capability Exists (P14462) LabVIEW

S11 9 Electrical CN1 Electronics Weight lbs 0.484 0.4 Motor not included Scale

S12 9 Financial CN1 Initial Cost $ 250 200 BOM

S13 3 Financial CN10 Repair Cost $ 100 50 BOM

S14 9 Mechanical CN6 Tether Tension lbs 5 23 Capability Exists (P14462) LabVIEW

S15 9 Mechanical CN1 Mechanical Weight lbs 4 3 Scale

S16 9 Mechanical CN1 Service Ceiling ft 75 100 FAA Regulation LabVIEW

S17 3 Mechanical CN1 Flight Path Diameter ft 25 50 LabVIEW

S18 9 Mechanical CN1 Maximum Glider Speed mph 30 45 LabVIEW

S19 3 Mechanical CN1 Fuselage Cross Sectional Area in2 20 16 Caliper

S20 9 Mechanical CN9 Fuselage Material Tensile Strength psi CF is ideal material MatWeb Lookup

S21 9 Mechanical CN9 Wing Material Tensile Strength psi Foam Mat'l Comparison MatWeb Lookup

S22 3 Time CN9 Repair Downtime hour 24 1 Stopwatch

S23 3 Time CN8 Time Between Flights min 30 5 Stopwatch

S24 3 Time CN4 Training Flight Hours hour 12 1 Training Documetation Stopwatch

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ENGINEERING REQUIREMENTS ADDITIONS

10/2/2014

Rqmt. # Importance Type Source Engr. Requirement (metric) Unit of Measure Marginal Value Ideal Value Comments/Status Test (Verification)

S7 9 Aero CN1 Efficiency of Wing - 0.82 0.9 Calculation

S8 1 Aero CN1 Fixed Angle of Attack deg 0 3 Protractor

S11 9 Electrical CN1 Electronics Weight lbs 0.484 0.4 Motor not included Scale

S12 9 Financial CN1 Initial Cost $ 250 200 BOM

S15 9 Mechanical CN1 Mechanical Weight lbs 4 3 Scale

S19 3 Mechanical CN1 Fuselage Cross Sectional Area in2 20 16 Caliper

S20 9 Mechanical CN9 Fuselage Material Tensile Strength psi CF is ideal material MatWeb Lookup

S21 9 Mechanical CN9 Wing Material Tensile Strength psi Foam Mat'l Comparison MatWeb Lookup

S22 3 Time CN9 Repair Downtime hour 24 1 Stopwatch

S23 3 Time CN8 Time Between Flights min 30 5 Stopwatch

S24 3 Time CN4 Training Flight Hours hour 12 1 Training Documetation Stopwatch

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GLIDER PURCHASE

UMX Radian BNF

For use as Practice Tethered Glider

Onboard Electronics Included

Folding Prop

Purchased from E-Flite via Amazon $89.99 +ship

Radio from P14462 (Professor Kolodziej) Futaba 6EX-PCM

Shipping ETA 10/1/2014

10/2/2014

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GLIDER PURCHASE

10/2/2014

Wingspan: 28.7 in (730mm)Overall Length: 16.5 in (418mm)Flying Weight: 1.50 oz (43 g)Motor Size: 8.5mm coreless brushed motorRadio: 4+ channel transmitter required

CG (center of gravity): 1.22 in (31mm) back from the leading edge of wing at wing root

Recommended Battery: 1S 3.7V 150mAh 25C LiPoFlaps: NoApprox. Flying Duration: 8-10 minutesCharger: 1S 300mA LiPo USB ChargerAssembly Time: Less than 1 HourAssembly Required: Yes

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AERO CLUB FLIGHT FAMILIARIZATION VIDEO

10/2/2014

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AGENDA

Background Problem Statement Customer Needs Engineering Requirements Week 3 action item review

10/2/2014

System Analysis Functional Decomposition (5 min) Areas of Design (3 min) Solution Brainstorming Selection Criteria Concept Generation Pugh Chart Final System Selection Concept Feasibility Updated Project Plan System Architecture Risk Assessment

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FUNCTIONAL DECOMPOSITION

10/2/2014

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FUNCTIONAL DECOMPOSITION

10/2/2014

Reach Desired Altitude

Take-Off Method Engage Tether

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FUNCTIONAL DECOMPOSITION

10/2/2014

Sustain Tethered Flight

Flight Path

Maintain Peak Altitude Cyclical Path

Regulate Tension

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FUNCTIONAL DECOMPOSITION

10/2/2014

Repeatable Flight

Provide Soft Landing Easily Replaceable Parts

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FUNCTIONAL DECOMPOSITION

10/2/2014

Record Data

Respond to on Board Feedback

Integrate with Base Station DAQ Capture Video

Record Angle Record TensionRecord length

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FUNCTIONAL DECOMPOSITION VS.AREAS OF DESIGN

10/2/2014

Areas of DesignTake Off Method

Engage Tether

Maintain Peak Altitude

Maintain

Cyclical Path

Regulate

Tension

Soft Landing

Easily Replace

able Parts

Respond to

feedback

Record Angle

Record Length

Record Tension

Capture Video

Fuselage     x x   x x          Wings     x x   x x          

Horizantal Tail     x x                Fuselage Material           x x          

Wing & Tail Material           x x          On-Board Electronics (Control

Feedback)     x x       x        Take-Off Method x                      

Tether-to-Plane Connection   x x x x   x          Propeller Location x                      

Non-Destructively Achieve Tether Tension x x     x              

Flight Path     x x                Non-Destructive Landing         x   

Base Station Data Collection Program*             x x x x

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AGENDA

Background Problem Statement Customer Needs Engineering Requirements Week 3 action item review

10/2/2014

System Analysis Function Decomposition Areas of Design Solution Brainstorming (2 min) Selection Criteria (2 min) Concept Generation (2 min) Pugh Chart (5 min) Final System Selection Concept Feasibility Updated Project Plan System Architecture Risk Assessment

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BENCHMARKING

Benchmarking Table Ampyx

Wing DesignPositive dihedral, semi elliptical wing, high fixed angle of attack, flaps

Tail Design Large primary T-shaped rudder with small elevatorsFuselage Design Mildly Aerodynamic/Box Fuselage with Protruding Pitot TubeTakeoff Mechanical-Electrical winch systemLanding Lands on underside of fuselage and wingsMaintaining Tension Constant reeling in and out of figure 8 patternTether Length (m) 300-600 metersAverage Kw Creation 15kW

10/2/2014

*Image from Ampyx Power

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SOLUTION BRAINSTORMING (PT.1)

10/2/2014

Fuselage WingsHorizontal

TailFuselage Material

Wing/Tail Material

On-Board Electronics

Take-Off Method

Flying Wing Swept BackCanard EPP EPP

Wireless Transmission

Rocket Engine

Rod Type Swept ForwardRear Tail

ROHACELL Foam

ROHACELL FoamIn-Flight Data

RecorderCompressed Air

CylindersFootball Shaped High Dihedral

H-shape "Other" Foam "Other" Foam With Software Winch

Cylindrical Shape Low Dihedral V-Shape Carbon Fiber Carbon Fiber Without Software Hydraulic Cylinders

Tear-Drop Shape Oblique SweepInverted V-

ShapePlastic Coating Plastic Coating   Spring Loaded

Box Frame "Typical" Blended Wing

"Typical" Shape

Monocoat Monocoat   Throw Glider

  Lifting Body   Other Coating Other Coating   Balloon Launch

 Linear Chord

Variation  Fiberglass Fiberglass   Kite-Run Launch

 Elliptical Chord

Variation  Aluminum Aluminum   Tow with Truck

  Winglets   Plastic Plastic   VTOL

  Bi-Wing  Wood Wood  

Tow with RC plane assistance

  X-Wing   Titanium Titanium   Drop from Tall Tower  Mid Placement         Magnetic Rail Gun  High Placement         Propeller   Low Placement         Powered Wheels  Dragon Scales          Bottle Rockets            Helicopter Propeller

Bend Tree and Slingshot

            Catapult/ Trebuchet            Hot Air Balloon            Diet Coke and Mentos            Zip-line System

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SOLUTION BRAINSTORMING (PT.2)

Tether-to-Plane Connection

Propeller Location

Non-Destructively Achieve Tether Tension

Flight PathNon-Destructive Landing Method

3-Point Bridle Front Hand Spool Horizontal Circle Parachute

2-Point Bridle Middle Automated SpoolOffset Vertical

CircleLanding Wheels

1-Point Fixed Bridle Back On Board Spool Figure 8 Smooth Bottom

1-Point SliderAbove

CenterlineSpring Decellerator Mobius Strip

Separate Tethered Balloon

Ball-in-SocketBelow

CenterlineConstant Force Spring Two Tether Ellipse Reverse Rockets

Set Screw   Nothing (Jerk at Tension) KiteGen Flight Path Tripod

3-Point Chuck   Spring on Base StationRoller Coaster Rail

TrackInflatable Stunt Pad

1 Tether per Control Surface

  Lasso Flight Path   Corn Field

   Feedback Triggered Rocket

Decellerator   Skis

    Kill Propeller Power   Gas Inflated Balloon

   Open Cargo Bay and Drop Line at

Altitude  Air Bags/ Mars Rover

    Tether is a Constant Force Spring  Quadcopter with Drag

Net

   Velcro End of Tether to Release at

Tension 

Porous Net Raised Above Ground

    Two Tethers Which Trade Off Slack        Reverse Zipline    

10/2/2014

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SELECTION CRITERIA

10/2/2014

Simplicity & Effectiveness of Wing Design

Initial Cost

Replacement Part Cost

Weight

Durability

Ease of Manufacturing

Safe Landing

Development Time

Simplicity of Take-Off Method

Tether Stress on Plane

Tether Impulse Mitigation

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CONCEPT GENERATION

Area of Design Devin Maginn Kennedy Zebert Carl

Fuselage Design Football Shape Tear Shape Cylindrical Shape CylindricalBox type with nose cone

Wing DesignMid, High Dihedral, linear taper

Elliptical Wing/ low mount, Asymmetrical Dihedral

Linear Taper/Low Dihedral/Flaps

Flush transition from fuselage to wing/ winglets

High dihedral/ linear taper

Horizontal Tail DesignH shapeLow, Asymmetrical Dihedral Rear Tail/Normal Shape Rear Tail Rear Tail/ Normal

Fuselage Material WoodFoam/ Integrate with Fuse Other Foam/Monocoat EPP with CF rod support Carbon-Fibre

Wing/Tail Material Foam Foam with Monocoat Other Foam/Monocoat EPP or better with Monocoat Foam

On-Board Electronics Yes YesIn-Flight Data Recorder with Software

In-Flight Data Recorder with Software Yes

Plane Take-Off Method Man-powered winch

Propeller with hand launch Prop with hand launch Prop with winch launch Propeller hand launch

Plane-to-Tether Connection

Spool on Plane/ One Point

One Point/Ball and Socket Joint

One Point/Ball and Socket Joint

One Point/Ball and Socket Joint One Point Spool

Prop Location2 Mid Wing Mounted Props Nose Middle Middle (on top of fuselage) Middle

Non-Destructively Achieve Tether Tension

Spool on Board Spring Behind Base hand spool hand spool On-Board Spool

Flight Path Infinity Offset Vertical circle Offset vertical circle Infinity shape Offset Vertical CircleNon-Destructive Landing

Protruding Rod/ Smooth Bottom Parachute Deployment Smooth Bottom Smooth Bottom

Land on Airframe "Smooth"

10/2/2014

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PUGH CHART

10/2/2014

Selection Criteria Maginn Zebert Devin Kennedy Carl Datum (P14462 Bought Plane)Simplicity/Effectiveness of Wing Design + + + + +

Datum

Initial Cost - - - - -Replacement Part Cost + + + + +

Weight - - - - -Durability + + - + +

Ease of Manufacturing - - - - -Safe Landing + + + + +

Develop Time - - - - -Repair Downtime + + + + +

Simplicity of Take-Off Method s - - s sTether Stress on Plane * s s s s s

Tether Impulse Mitigation + s + s +Sum +'s 6 5 5 5 6 Sum -'s 4 5 6 4 4 Sum s's 2 2 1 3 2 Score 2 0 -1 1 2

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PUGH CHART

10/2/2014

Selection Criteria Maginn Zebert Devin Kennedy Carl Datum (P14462 Bought Plane)Simplicity/Effectiveness of Wing Design + - - s

Datum

-Initial Cost + + + + +

Replacement Part Cost + + + + -Weight - + - + +

Durability + - - - -Ease of Manufacturing - s s s +

Safe Landing + s + s -Develop Time - s - + +

Repair Downtime - - - + -Simplicity of Take-Off Method s - - s s

Tether Stress on Plane * - - s - sTether Impulse Mitigation - - s - -

Sum +'s 5 3 3 5 4Sum -'s 6 6 6 3 6Sum s's 1 3 3 4 2

k -1 -3 -3 2 0 -2

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AGENDA

Background Problem Statement Customer Needs Engineering Requirements Week 3 action item review

10/2/2014

System Analysis Function Decomposition Areas of Design Solution Brainstorming Selection Criteria Concept Generation Pugh Chart Final System Selection (5 min) Concept Feasibility (15 min) Updated Project Plan System Architecture Risk Assessment

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FINAL SYSTEM SELECTION

10/2/2014

Areas of Design Final SystemFuselage Design Aerodynamically Optimized Rectangular Volume

Wing Design Linear Taper, Fixed Angle of Attack, Dihedral, Flaps

Horizontal Tail Design H-Shaped Tail

Fuselage Material Foam

Wing/Tail Material Carbon Fiber Strip Leading Edge, Foam with Coating

On-Board Electronics (Control Feedback) In-Flight Data Recorder with Software

Plane Take-Off Method Propeller hand launch

Plane-to-Tether Connection One Point/Ball and Socket Joint

Prop Location Nose Cone with folding Prop

Non-Destructively Achieve Tether Tension Hand Spool

Flight Path Offset Vertical Circle

Non-Destructive Landing Land on Airframe "Smooth"

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FINAL SYSTEM SELECTION SKETCH

10/2/2014

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CONCEPT FEASIBILITY - FLAP ANALYSIS

10/2/2014

(1)

(2)

(3)

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CONCEPT FEASIBILITY - FLAP ANALYSIS

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CONCEPT FEASIBILITY - FLAP ANALYSIS

10/2/2014

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CONCEPT FEASIBILITY-WINCH SYSTEM

Means of takeoff since propeller alone is insufficient Pros:

System has off board source of power Cons:

Mechanical-Electrical system is expensive

Alternative Method-Man Powered Pros:

More affordable Cons:

Must exert energy Is it feasible?

Yes! The method is called a Towline Launch.

10/2/2014

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FEASIBILITY STUDY: FOAM MATERIAL

71 Hero 110 Hero 200 Hero EPP-20 EPP-60 EPP-90 EPP-150 EPP-225

Density kg/m3 75 110 205 20 60 90 150 225Tensile Strength MPa 4.10 6.30 12.30 0.26 0.62 0.97 1.37 1.51Tensile Modulus MPa 123.00 189.00 389.00 - - - - -Elongation at Break % 9.50 9.90 10.80 15 14 12 11 9Compressive Strength MPa 1.10 2.50 7.10 0.31 1.07 2.08 5.80 13.50Compressive Modulus MPa 48.00 83.00 180.00 - - - - -Shear Strength MPa 1.30 2.30 5.20 - - - - -Shear Modulus MPa 28.00 50.00 109.00 - - - - -Max Shear Strain % 7.20 7.20 7.20 - - - - -Tear Strength kN/m - - - 1.74 3.25 4.35 5.77 7.33Flexural Strength MPa - - - 0.21 0.72 1.16 1.9 2.95

ROHACELL Expanded PolypropyleneUnitTest Method

10/2/2014

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CONCEPT FEASIBILITY – FOLDING PROPELLER

10/2/2014

Benefit:• Less drag in unpowered flight• More durable in nose first crash• Interfaces with normal RC components

Feasibility Test Plan:1. Test Flight with purchased glider

Due by:1. Week 9

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CONCEPT FEASIBILITY – INFINITY FLIGHT PATH

10/2/2014

*Image from Ampyx Power

Evaluate:• Is this an easier flight path to maintain

Feasibility Test Plan:1. Test Flight with purchased glider2. Test Flight with tethered purchased

gliderDue by:1. Week 92. Week 12

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CONCEPT FEASIBILITY – DIHEDRAL ANALYSIS

10/2/2014

Definition of Dihedral: The angle between a wing and pitch axis

Dihedral Effect Definition: Amount of roll moment produced per degree of sideslip Also influenced by wing sweep, vertical CG

Benefits: Higher dihedral angles generate higher roll moments Stabilizes Plane against crosswinds

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CONCEPT FEASIBILITY – DIHEDRAL ANALYSIS

10/2/2014

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CONCEPT FEASIBILITY – DIHEDRAL ANALYSIS

10/2/2014

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CONCEPT FEASIBILITY – DIHEDRAL ANALYSIS

10/2/2014

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AGENDA

Background Underlying Mission Problem Statement & Deliverables Customer Needs & Engineering Requirements Week 3 action item review

10/2/2014

System Analysis Functional Decomposition Areas of Design Solution Brainstorming Selection Criteria Concept Generation Pugh Chart Final System Selection Concept Feasibility Test Plan Updated Project Plan (2 min) System Architecture (2 min) Risk Assessment (2 min)

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UPDATED PROJECT PLAN

SYST

EM DES

IGN REV

IEW

SUBSY

STEM

S DES

IGN REVIEW

DETAILE

D DES

IGN REVIEW

FINAL D

DR

Deliverables Deliverable Stage Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11Computer Simulator 1 1 1 1Aero Team's Trainer 1 1 1 1

1 1 1 1

1 1

1 1

Revise and Refine 1 1Concept Generation 1 1Critical Tech Analysis 1 1

Morph Chart Framework 1 1Alternative List 1 1Concept Selection 1 1Assess CapabilitiesRevisit Requirements

Systems Design Preperation

Funtiaonl Decomposition

Benchmark Existing RC Plane Parts

Existing Systems Benchmarking Table

Edge Site Upkeep and Review

Flight Experience

SYST

EM DESIG

N REVIEW

SUBSY

STEM

S DES

IGN REVIEW

DETAILE

D DESIGN REVIEW

FINAL D

DR

Section Deliverables Deliverable Stage Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11 Week 12 Week 13 Week 14 Week 15Computer Simulator 1 1 1 1 1Aero Team's Trainer 1 1 1 1 1 1

1 1 1 1 1 1

1 1

1 1

Revise and Refine 1 1Concept Generation 1 1Critical Tech Analysis 1 1

Morph Chart Framework 1 1Alternative List 1 1Concept Selection 1 1Assess CapabilitiesRevisit Requirements

Elevator Speech 1 1Feasbility Posters 1 1Invite SDR Attendees 1 1Solidify SD (see below) 1 1

SDR Action Items 1 1Test Plan 1 1Peer Reviews 1 1 1 1 1

Critical Interfaces 1 1Specs 1 1Sub- Decomposition 1 1Proof of Concept 1 1

Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1

Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1

Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1Preliminary Design 1 1Final Design 1 1 1

Preliminary Benchmark 1 1Final Code 1 1 1Preliminary Benchmark 1 1Final Code 1 1 1Preliminary Benchmark 1 1Final Code 1 1 1

List 1 1 1

MSD Project Process

Subsystem Design

Post SDR

Sytem Design

Systems Design Preperation

Funtiaonl Decomposition

Benchmark Existing RC Plane Parts

Existing Systems Benchmarking Table

Edge Site Upkeep and Review

Flight Experience

Wing Design

Aero and Structual Design

Controls

Bridal System

Simulation Code

Fuselage Design

On Plane Hardware

Tail Design

Propeller Design

Rudder Design

Structural Integrity

Control Surfaces

Electric Motor

Speed Controler

Linear Acuator Controls

Micro Controler Design

RC Design

Controls Algorithm

Maintenance Documentation

Tether Material

Base System Integration

Kinematic Simulation (MATLAB)

Aerodynamic Simulation (CFD)

Structual Analysis (ANSIS)

Replaceable Parts List

10/2/2014

SYSTEM ARCHITECTURE

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Glider Fuselage

Base Station

Wings

Ailerons

Horizontal Tail

Vertical Tail

RudderElevators

On-Board Feedback System

TetherRemote Control

On Board Control

Electronics

Propeller

Motor

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RISK ASSESSMENT

10/2/2014

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RISK ASSESSMENT (CONT.)

10/2/2014

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SOURCES

10/2/2014

Feasibility Study: Foam Material http://

www.rohacell.com/sites/dc/Downloadcenter/Evonik/Product/ROHACELL/product-information/ROHACELL%20HERO%20Product%20Information.pdf

http://www.sonoco.com/UserFiles/sonoco/Documents/Tegrant%20EPP%20Design%20Guide%20April%202012.pdf

http://en.wikipedia.org/wiki/Dihedral_(aeronautics)