Airframe Design

 

Big Project

Project

Project Manager

Big Project

Project

Project Manager

Fixed Wing

Frame

S24: @Alison Thompson

F24: @Evan Janakievski

Task Description

The goal of this task is to design the base frame of the new fixed-wing aircraft, essentially this is the structure which will support all of the main components and allow for different fuselage and wing options to be mounted to it.

We don’t already have a set idea or particular direction for this task, but rather would like to have several people help brainstorm ideas and discuss what makes the most sense for us to move forward with.

Discussions to be had on particular direction for this at mech meetings

Please read:

And attend Fixed Wing Syncs: https://discord.com/events/776618956638388305/1252954173868216404

Constraints

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Constraints

Written By

Append Date

Must have the ability to change out fuselage, tail, and wings

@Alison Thompson

Jun 23, 2024

Permanent mounting location for:

  • Pixhawk 6X

  • PM02D Power Module

  • ELRS Receiver

  • Analog camera

  • Pitot Tube

  • Magnetometer

  • GPS

  • Rangefinder

  • 6S Battery: 4500 mAh LiHV batteries in bay (someone needs to measure these)

I suggest a standard 30.5mm x 30.5mm M3 mounting pattern on the frame so we can account for any location of these components. Some will have specific requirements and their own mounting pattern, ie the Pixhawk but generally we will have cases made for things to comply with the pattern.

Specs and requirements on the components are here: Fixed Wing 2025 | Electronics System Diagram

The focus here is on having the space to mount the components, others will make the cases to allow for this.

@Alison Thompson

Jun 23, 2024

Full airframe needs to be under 5kg, so frame should be <1.5kg with no electronics

@Alison Thompson

Jun 23, 2024

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@Evan Janakievski

link to asana task assigned

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@Thushanth Parameswaran

 

 

@Divit Gawri

 

 

Task Progression/Updates

Author: @Alison Thompson Date: Jun 23, 2024

Initial Ideas

  • 16th wall alumunium frame with some sort of panel in the middle for electronics?

Author: @Alison Thompson Date: Jul 2, 2024

Concept Sketch

 

image-20240703-044605.png

Author: @Thushanth Parameswaran Date: Jul 3, 2024

Source: https://www.boldmethod.com/learn-to-fly/performance/what-effect-does-center-of-gravity-have-on-your-airplane-performance/ , From The Ground up book

Important note:- The distance between CL and CG is exaggerated in drawing below. In real distance be around 3 cm.

When creating a frame, it is important to ensure that the center of Mass is in front of the Center of lift (CL) because we have a net zero moment using the downforce from the horizontal stabilizer. As seen in the Picture below. This means all electronic component needs to be mounted left of the CL. Having the Center Mass close to CL will allow us to have a short tail because Moment = Force x Distance, the moment created by the weight will be less since the distance is small from CL. Remember that CL is not a fixed point, unlike CG. The amount of lift created control is the Angle of Attack (AoA). As AoA increases ( as the aircraft Pitches up) the CL moves forward and moves back as you pitch down the aircraft. At a certain AoA, Max Lift force will be achieved as seen in Image 2 below. it is important to ensure CG is always forward of CL even at Critical Angle of Attack (which is the AoA just right before Stall and AoA where max lift is produced).

 

moment-opposite-direction-20240704-012730.jpg
Image 1

 

 

This is my Concept based on initial research.

 

Author: @Evan Janakievski Date: Jul 28, 2024

Notes from meeting July 25, 2024

  • Adjust how wingspar mounts to frame, use a “crush bar”

  • Use channel as material for wingspar to reduce weight

  • Add motor mount with camera built in attached to it

  • Think about how fuselage will mount to the frame

  • Decrease size of the plate for minimum required to fit all electrical components

  • Extend battery shelf so they are not hanging off

Author: @Alison Thompson Date: Aug 17, 2024

CAD review notes:

 

Looking good! Some suggestions:

  • Look at aluminum circular shaft for the stand offs in the corners of the wing mounting plate instead of the big blocks. You can tap these (think like the PEEK standoffs on Peggy and similar to what you have holding up the batteries)

    • Aluminum > Peek here bc Peek is brittle and shears (saw this w/ peggy peek standoffs that were shattered)

  • I would extend top gusset to the same width of bottom plate (extend farther along wingspar) , and make bottom plate a similar shape (wider to accommodate bolts for stand offs) to cut out some material

 

Author: @Evan Janakievski Date: Sep 8, 2024

  • Following deflection calculations for 1/2” box tube aluminum for 25 N (half of current lift force needed for cruising) and 68 N (calculated for just under half of lift force on take off), decided to update size of box tube to 3/4”

  • Deflection was up to 2 cm

  • Repeating tests (changed 68 N to 80 N for greater safety margin) with 3/4” box tube, deflection decreased to 2 mm

  • Files for sims on PDM in Fixed Wing → Wings

 

Author: @Evan Janakievski Date: Sep 20, 2024

  • Removed electronics (excluding batteries as they are part of the COG calculations) from frame model and will add to main

  • Materials needing to order from EMS

    • 14 x 6 in. - 8 GA (0.1285 in) Aluminum Plate → main plate

    • 11 x 6 in. - 8 GA Aluminum Plate → battery plate

    • 2.125 in x .375 Round Aluminum - X 9 → standoffs

    • 27 in. 3/4 Box Tube Aluminum - X 2 → wing spar

    • 26 in 3/4 Box Tube Aluminum → tail boom

    • 6 x 2 in. - 8GA Aluminum Palte → gussets

 

Author: @Evan Janakievski Date: Nov 3, 2024

  • Adjusted standoffs to be 5/16 in. instead of 3/8 in.

  • Shortened motor mount plates to reduce weight

    • Need to check what max gauge could be bent in student shop

 

Author: @Evan Janakievski Date: Nov 7, 2024

  • Materials needing to order from EMS

    • 14 x 6 in. - 8 GA (0.1285 in) Aluminum Plate → main plate

    • 11 x 3.25 in. - 8 GA Aluminum Plate → battery plate

    • 2.125 in x 5/16 Round Aluminum - X 9 → standoffs

    • 27 in. 3/4 Box Tube Aluminum - X 2 → wing spar

    • 26 in 3/4 Box Tube Aluminum → tail boom

    • 6 x 2 in. - 8GA Aluminum Plate → gussets

    • 3 x 2.25 14 GA Aluminum Plate X 2 → motor mounts