Group 05010Team Leader

Walter Strassburg

Chief Engineer

Gabe Marciano

Joe O’Bryant

Iheanyi Umez-Eronini

Taylor ValentineGreg Weimer

Team Mentor

Dr. Jeff Kozak

HMMWV UAV Deployment & Ground Sustainment System

Needs Assessment

Currently, the technology to make an autonomous military weapon such as the DP-5X exists with minor setbacks: Transportation Guidance Communications

Project 05010 will fulfill transportation criteria for the DP-5X.

Initial Scope 12/06/04 Project Requirements

Trailer and launch system must: Transport:

Delicate machinery (300lbs) Maintain safety of crew (2 person) Enable:

Unmanned landing on trailer Waterproof storage of all components

Be shock mounted with tie down system Be operable by low echelon military personnel Have a low cost

Current Requirements

Project Requirements Trailer and launch system must:

Transport: UAV (300lbs) Fuel sufficient for 72 hours of sustained flight (1200lbs) Extra rotor blades for UAV Payload (250lbs and ~$1Million) Crane to support lifting of helicopter and adjustment of engine CG Ramps to load and unload aircraft Additional fluids and UAV support equipment

Maintain safety of crew (2 person) Enable waterproof storage of all components Provide electrical service for UAV and electrical components Have a low cost Be operable by low echelon military personnel

System Design Components

Waterproofing Ramps Boxes Fuel Containers Trailer Type Lift Mechanism Crane Holding Mechanism Attachment Points

Blade Packaging Payload Packaging Power Supply Adapter Power Converter

Module Battery Charging

Module

Preliminary Designs

8 Blades

Payload(s)Crane

Electrical Interface

Canopy

24 Cubic Feet of FuelDistributed Over 4 Corners

DP-5XFCS Tools

And Misc. fluid/gear

Required Load Organization

Feasibility Assessment

15 Subsystems >54 Concepts

Feasibility Assessment Weatherproofing

CANVAS WITH FRAME

SNOWMOBILETYPE

TONNEAUCOVER

Pugh ChartsBaseline Concept:

concept 1 concept 2 concept 3

ATTRIBUTEMetal

Plating

Custom

Tonneau

Cover

Snowmobile

trailer type

price - - -leadtime - x xease of use x x xbreakdown/setup time x + +durability - + +reliability + - -safety - - -weight - - -1

2

3

4

5

TOTAL = -4 -2 -2

Canvas

concept 1 concept 2 concept 3 concept 4

ATTRIBUTERELATIVE

WEIGHT

Metal

Plating

Custom

Tonneau

Cover

Snowmobile

trailer typeCanvas

price 0.00% 3 3 3 4leadtime 28.57% 3 4 4 4ease of use 4.76% 3 3 3 3breakdown/setup time 14.29% 3 4 4 3durability 9.52% 3 2 2 2reliability 9.52% 3 3 2 4safety 19.05% 3 3 3 4weight 14.29% 3 4 4 51

2

3

4

5

Raw Score = 3.00 3.48 3.38 3.76

Normalized Score = 0.80 0.92 0.90 1.00

Comparison of Attributes

Pairwise Comparison: Place an "S" if the row

is more important. Place a "U" if the column is more

important

cost

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cost U U U U U U U 0 0 0 0.0%leadtime S S U S S S 5 1 6 28.6%

ease of use X X X U U 0 1 1 4.8%breakdown/setup time S X X S 2 1 3 14.3%

durability U U U 0 2 2 9.5%reliability X X 0 2 2 9.5%

safety S 1 3 4 19.0%weight 0 3 3 14.3%

Additional 1 (Future Use) 0 0 0 0.0%Additional 2 (Future Use) 0 0 0 0.0%Additional 3 (Future Use) 0 0 0 0.0%Additional 4 (Future Use) 0 0 0 0.0%Additional 5 (Future Use) 0 0 0 0.0%

Column Total 0 1 1 1 2 2 3 3 21 100%

Feasibility Assessment

Ramps Individual Folding Tailgate U-Haul Style Telescoping

Storage Boxes Custom Order Pre-Built New Design

Trailer Deck Flatdeck Extended Flatdeck Partially Enclosed

Fuel Container Custom Bladder Pre-Built Bladder “Jerry Cans” New Design

Lift Mechanisms 4-Bar Scissor Crane Fold-Down Sides

Launch Platform Tri-fold Deck Bi-fold Roof Flat Deck Ground

Crane Manual Manual, Folding Powered, Folding

Holding Mechanisms Latches Ratchet Tie-Down Self Clinching

Tie-Down Rotor Catch Ring

Attachment Points Protruding Clip Recessed D-Ring Clinching Cam

Payload Packaging Cabinets w/foam Floating Net Self-Level

Suspension Blade Packaging

Shelves Foam Block Shredded Foam

DC-DC Converter VTC 1015 VTC 1500 Traco Schaefer Self Designed

12 Volt DC Charger Power Stream Major Power GSL

Electrical Subsystem Overview

Given a HMMWV’s 24V-60A electrical system, provide the ability to: Charge the UAV batteries. Power the computer

station. Power any additional

devices needed to implement system design.

Initial Ideas: Power Inverter Gasoline powered

Generator Combination of DC

input devices and Power Inverter

Electrical Subsystem Design

Provides necessary power connections.

Parts are modular and can be replaced individually.

Safety and ease of use is maintained via plug/play capability.

BI

J H

DI

K

F

(A) NATO Slave Plug

(C)Side of Trailer with Input and Output

connectors

(E)DC to DC Converter

(G) 12V Battery Charger

(M) UAV Battery

(L) Crane

(N) Computer Station

Feasibility Assessment

    Concept 1 Concept 2 Concept 3 Concept 4 Concept 5

Attribute Weight MP VTC1015 || Traco 53622 SP C3822 Self Designed MP VTC1500

Lead Time 40% 4 3 3 1 2

Cost 20% 1 2 2 5 3

Availability from Multiple Distributors 10% 4 2 2 1 2

Ruggedness 20% 3 3 4 1 3

Ease of Integration into Design 10% 3 3 3 5 3

Raw Score   3.1 2.7 2.9 2.2 2.5

Normalized Score   1.00 0.87 0.94 0.71 0.81

    Concept 1 Concept 2 Concept 3

Attribute Weight PST-DU700 MP BCD600 GSL Maximizer

Lead Time 40% 4 3 2

Cost 20% 4 3 2

Availability from Multiple Distributors 10% 2 4 2

Ruggedness 20% 3 3 2

Ease of Integration into Design 10% 4 4 4

Raw Score   3.6 3.2 2.2

Normalized Score   1.00 0.89 0.61

12V DC Battery Charger

24V to 12V DC-DC Converter

Electrical Design Issues

Section Length (ft)

Max Voltage Drop (V)

Current (A)

Resistance/1000 feet (Ω/1000ft)

AWG Actually will Use

B->C->D->E 28 4 200 0.714285714 8 4E->K->C->I 9 1.6 120 1.481481481 11 10G->H->C->J 9 1.6 60 2.962962963 14 14

E->F->G 3 1.6 60 8.888888889 19 14

Problem: Resistance of wires is an issue when transmitting power over long distances.

Solution: Calculate maximum resistance tolerated and choose wires based on that value.

Vibration Analysis of Critical Components

Helicopter and payload must be protected from vibration during high speed transportation over rough terrain

Terrain 65 mph requirement

Defined by the sponsor “Rough terrain” approximation

Sinusoidal Ground Profile 10” amplitude 48” wavelength A fairly conservative estimate

Payload Protection Delicate payload must be protected from accelerations in excess of 2.5 g’s

during transportation Helicopter Protection

Acceleration of helicopter must not exceed 3 g’s No additional vibration isolation needed

Stock trailer suspension meets this requirement

Vibration Analysis of Critical Components

Mathematical Model Calculated/estimated values for trailer tires, springs, dampers System of second order differential equations describing 3 degree

of freedom system under forced oscillation Input into Simulink

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Vibration Analysis of Critical Components

Matlab Simulation

Vibration Analysis of Critical Components

Vibration Analysis of Critical Components

Packaging foam selected for padding material ILD (Indentation Load Deflection) calculated from

desired spring constant Two layers of 3” thick foam to provide adequate travel Sides of payload container will be lined as well A cost effective solution Available from www.foambymail.com

Fuel Tank Selection Tanks need to conform to trailer loading

plan Located under toolboxes Space interrupted by the wheel wells

Tanks must be suitable for military transport Ballistic tolerant Prevent sloshing

Fuel Safe Fuel Bladders Available in custom shapes and sizes Semi-rigid – able to deform slightly to

absorb shock Can be manufactured to military

specs Contain foam baffles to prevent fuel

from sloshing

Integration: Requirements

Trailer Design- Built off of a standard military HMMWV trailer matching the off-road capabilities of the HMMWV itself.

Trailer must carry 1200lbs of JP8 fuel, storage for eight main rotor blades each six feet in length, delicate storage for $1MM payload, UAV with folded tail, 500 lb. crane, electrical ground sustainment equipment, and FCS tools as well as miscellaneous fluids and solider gear. Must be waterproof.

Major issue is carrying all required loads while remaining within the trailer’s rated load capacity of 3000 lbs.

Standard military LTT-FE HMMWV off-road trailer from Silver Eagle Inc.

Integration: Fuel Storage

Fuel containers are simple sheeted steel framework with custom manufactured bladders within, specifically designed to provide required volume while keeping CG low and weight distributed.

Standard trailer deck does not extend to the outer corners of its frame. This area is required for all loads to be contained on the unit.

Issues: Many parts require extensive welding and accurate cutting. Steel is durable and military tough, however it is also very heavy reducing the amount of cargo the trailer will be able to carry.

Integration: Payload, Blades, Tools…

Storage boxes designed according to volume required per contained load, as well as symmetric, structural design for future launch/landing platform to be added at a latter date.

Payload boxes in the front of the unit were not able to be made square due to the turning radius of the crane’s power pack. Payload boxes are top loading for vertical lifting access.

Blade storage box consists of a side loading 84” long compartment with a single shelf integrating a divider/cushion system.

The two door compartment tool box on the opposite side will provide storage for and operation of the system’s electrical requirements, FCS tools, miscellaneous fluids, and solider supplies.

Integration: Crane The Crane serves as a winch to raise and lower the UAV up/down a ramp, lift the payload into place for

assembly, and adjust engine location for CG optimization. It is also able to lift the entire UAV to a future platform height.

The Crane mounts on a 12” x 12” flat mounting plate at the front of the trailer.

The mounting plane was raised and strengthened to provide the necessary area for mounting the crane and reduce torsional stresses induced on the trailer tongue frame by distributing the load.

Integration: Weatherproofing

A simple tube supported canvas cover bungee corded to the trailer frame will keep the UAV dry and serve as protection from the elements.

The canvas and tube frame is completely removable allowing two men to quickly unload and prepare the UAV for launch.

8 Blades

Payload(s)Crane

Electrical Interface

Canopy

24 Cubic Feet of FuelDistributed Over 4 Corners

DP-5XFCS Tools

And Misc. fluid/gear

Required Load Organization

Stress Analysis of Major Structural Areas

Cube dimensions = 22’’ x 33’’ x 15’’ Cube Volume = 10,890 in3

Density of JP8 fuel of 6.7 labs/gal 1 gallon = 231 in3 Overall concentrated Force = 315.8lbs Max. Stress = 15,245 lb/in2

Max. deflection = 4.55 x 10-3 in. Max. allowable stress = 100,000 lb/in2

Stress Analysis of Major Structural Areas

The weight of the fuel, as well as an additional 1,000lbs. (1600lbs.)

Trailer must be operational in rough terrain with bumps causing a force of up to three times that of gravity, therefore this entire load is multiplied by 3g.

Load is distributed. Max deflection = .0106 inches

Budget Trailer Crane Tool boxes Ramps Fuel bladders Tie downs Steel tubing Electrical wiring Electrical connectors Foam padding Travel Office supplies Miscellaneous Total

Final Purchase PricesItem Quantity Vender Price ($)

Structural steel square tubing 60 in. Metal Supermarkets $44.00

Structural steel plate 7'' x 24'' Metal Supermarkets $45.00

Structural steel square tubing 100 ft. Metal Supermarkets $225.00

Structural steel square tubing 105'' Metal Supermarkets $85.00

Structural steel square tubing 52 in. Metal Supermarkets $60.00

Structural steel sheet 53 sq. ft. Metal Supermarkets $240.00

Structural aluminum round tubing 46 feet Metal Supermarkets $368.00

Structural aluminum plate 75 sq. in. Metal Supermarkets $28.00

Structural aluminum round tubing 40 in. Metal Supermarkets $304.00

Structural steel angle 10 ft. Metal Supermarkets $24.00

Electric/Hydraulic Mast Crane Venturo Manufacturing Inc. $5,275.00

Base Trailer Silver Eagle Manufacturing Co. $11,332.00

Custom steel boxes for payloads, blades and miscellaneous storage.

4 Maintainer Corp. $4,800.00

Miscellaneous hardware 1 Fastenal $5,000.00

Recessed tie down anchors 6 Erickson Manufacturing $52.74

Ramps 3 AZTrucks, Inc. $300.00

Nato Slave Plug 1 Pending $40.00

#4 AWG Wire 60 ft. B & C Specialty Products Inc $168.00

#10 AWG Wire 25 ft. B & C Specialty Products Inc $12.00

#14 AWG Wire 40 ft. B & C Specialty Products Inc $10.80

24VDC-12VDC Converter 1 Schaefer Power $3,675.00

12VDC Battery Charger 1 PowerStream $115.00

Wire Connectors 8 Anderson Power Products $174.16

16-14 AWG Spade Terminals (100 pack) 4 Grainger $12.47

Insulated Battery Clamps (10 pack) 6 Ace Hardware $35.01

Total Cost $32,425.18

Future Work Schedule Finalize design optimization Review final design with sponsor

May require an additional visit Acquire materials for construction Begin product construction Finish construction Testing and evaluation Write CDR

ID Task Name Duration Start Finish Predecessors

1 Senior Design II 55 days Mon 3/7/05 Fri 5/20/05

2 DPI Approval 1 day Mon 3/7/05 Mon 3/7/05

3 Final Design Modifications 10 days Tue 3/8/05 Mon 3/21/05 2

4 Design Analysis for Optimization21 days Fri 3/11/05 Fri 4/8/05

5 Trailer Procurement 5 days Tue 3/8/05 Mon 3/14/05 2

6 Structural Steel Procurement 5 days Wed 3/9/05 Tue 3/15/05

7 Fuel Bladder Procurement 7 days Mon 3/14/05 Tue 3/22/05

8 Payload & Accessory Boxes Procurement7 days Wed 3/9/05 Thu 3/17/05

9 DC-DC Converter Procurement 7 days Wed 3/9/05 Thu 3/17/05

10 12-V Charger Procurement 7 days Wed 3/9/05 Thu 3/17/05

11 Wiring & Connector Procurement7 days Wed 3/9/05 Thu 3/17/05

12 Crane Procurement 7 days Fri 3/11/05 Mon 3/21/05

13 Fuel Systems Equipment Procurement7 days Wed 3/23/05 Thu 3/31/05 7

14 Vibration Isolation Material Procurement7 days Wed 3/9/05 Thu 3/17/05

15 Tie Down Procurement 7 days Wed 3/9/05 Thu 3/17/05

16 Tie Down Anchor Procurement 7 days Wed 3/9/05 Thu 3/17/05

17 Canvas Procurement 7 days Mon 3/14/05 Tue 3/22/05

18 Ramps Procurement 7 days Mon 3/14/05 Tue 3/22/05

19 Structural Steel Frame Assembly15 days Wed 3/16/05 Tue 4/5/05 6

20 Fuel Bladder Installation 10 days Wed 3/30/05 Tue 4/12/05 19FS-5 days

21 Payload & Accessory Boxes Assembly & Installation10 days Wed 4/6/05 Tue 4/19/05 20FS-5 days

22 DC-DC Converter Wiring & Installation5 days Wed 4/13/05 Tue 4/19/05 21FS-5 days

23 12-V Charger Wiring & Installation1 day? Wed 4/13/05 Wed 4/13/05 21FS-5 days

24 Connector Wiring & Installation30 days Fri 3/18/05 Thu 4/28/05 11,21FS-25 days

25 Electrical Distribution Center Final Wiring10 days Wed 4/13/05 Tue 4/26/05 21FS-5 days

26 Crane Installation 5 days Wed 3/30/05 Tue 4/5/05 19FS-5 days

27 Crane Wiring 2 days Wed 4/6/05 Thu 4/7/05 26

28 Fuel Systems Equipment Plumbing & Tie In8 days Wed 4/6/05 Fri 4/15/05 20FS-5 days

29 Vibration Isolation Material Installation8 days Fri 4/15/05 Tue 4/26/05 21FS-3 days

30 Tie Down Anchor Installation 3 days Fri 4/22/05 Tue 4/26/05

31 Canvas Fitted and Installed 4 days Wed 4/20/05 Mon 4/25/05 21

32 Ramps Testing & Storage Compartment Modification5 days Mon 4/18/05 Fri 4/22/05 21FS-2 days

33 Final Inspections 7 days Mon 4/25/05 Tue 5/3/05

34 Painting 3 days Fri 5/6/05 Tue 5/10/05

35 Test Run at DPI 3 days Wed 5/18/05 Fri 5/20/05

36 Modifications as Necessary 25 days Mon 4/11/05 Fri 5/13/05

37 Final Design Analysis 50 days? Mon 3/7/05 Fri 5/13/05

38 Poster Creation 3 days Wed 5/11/05 Fri 5/13/05

39 Website Creation 15 days Mon 5/2/05 Fri 5/20/05

40 CDR Writeup and Presentation21 days Fri 4/22/05 Fri 5/20/05

M T W T F S S M T W T F S S M T W T F S S M T W T FMar 6, '05 Mar 13, '05 Mar 20, '05 Mar 27, '05

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