Design, Fabrication, and Characterization of a Gun-Launched Deployable-Wing Unmanned Aerial

89 Pages·2017·2.83 MB·English

by  Timothy Schutter

Lehigh University
Lehigh Preserve
Theses and Dissertations
2016
Design, Fabrication, and Characterization of a Gun-
Launched Deployable-Wing Unmanned Aerial
System
Timothy Schutter
Lehigh University
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Recommended Citation
Schutter, Timothy, "Design, Fabrication, and Characterization of a Gun-Launched Deployable-Wing Unmanned Aerial System"
(2016).Theses and Dissertations. 2796.
http://preserve.lehigh.edu/etd/2796
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Design, Fabrication, and Characterization of a
Gun-Launched Deployable-Wing Unmanned Aerial System

By
Timothy Schutter

A Thesis
Presented to the Graduate and Research Committee
of Lehigh University
in Candidacy for the Degree of
Master of Science

in
Mechanical Engineering

Lehigh University
September 2016
© 2016
Timothy J. Schutter
All Rights Reserved
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This thesis is accepted and approved in partial fulfillment of the requirements for
the Master of Science.

_________________________
Date

_____________________________________
Keith W. Moored, Thesis Advisor

_____________________________________
Terry J. Hart, Co-Advisor

_____________________________________
D. Gary Harlow, Chairperson
Department of Mechanical Engineering and Mechanics
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Acknowledgements
I would like to thank Keith Moored and Terry Hart for the opportunity to work on this
project for a Master’s Thesis. They have helped me grow as a designer and
experimentalist and I greatly appreciate their insight and support in this process.
I would like to thank Scott Larson for his early work on this project and help when
passing the work on to me. Additionally, I would like to thank Jacob Patterson and Zack
Rambo for their insight on UAVs and their help with conducting flight tests.
Lastly, I would like to thank my family. Thank you to my parents for supporting my
education and having my back when I was struggling. The work ethic and curiosity you
have given me has been instrumental in shaping who I am. Also, to my brother and sister,
thank you for picking me up when I was down and always being excited for me.

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Table of Contents
Table of Figures ................................................................................................................ vii
List of Tables ...................................................................................................................... x
Abstract ............................................................................................................................... 1
1. Requirements ............................................................................................................... 2
1.2 Literature Review ...................................................................................................... 2
2. Design .......................................................................................................................... 8
2.1 Initial Design ............................................................................................................. 8
2.2 Packing the GLUAS into a Mortar Shell ................................................................ 11
3. Analysis of Aerodynamic Characteristics ................................................................. 12
3.1 Lift and Drag ........................................................................................................... 12
3.2 Flight testing ............................................................................................................ 32
4. Performance ............................................................................................................... 33
4.1 Range and Endurance .............................................................................................. 33
4.2 Propulsion................................................................................................................ 38
4.3 Control Surfaces ...................................................................................................... 39
5. System Level Design ................................................................................................. 42
5.1 Evolution of CAD Model ........................................................................................ 42
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5.2 Physical Properties of Model4 ................................................................................ 57
5.3 Wing Folding Mechanism ....................................................................................... 61
5.4 Elevon Control Mechanism ..................................................................................... 63
5.5 Power and Video Systems ....................................................................................... 64
5.6 Guidance, Navigation and Control .......................................................................... 68
6. Field Testing .............................................................................................................. 68
6.1 Carrier Plane ............................................................................................................ 68
6.2 60mm GLUAS Flights ............................................................................................ 69
6.3 Understanding of issues .......................................................................................... 71
7. Future Work ............................................................................................................... 71
7.1 Carrier Launch/Gun Launch.................................................................................... 72
7.2 Wind Tunnel PIV Testing ....................................................................................... 74
7.3 Morphing Wings ................................................................................................ 75
8. References ................................................................................................................. 76

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Table of Figures
Figure 1: GLUAS Model 1 with 3D printed fuselage and aluminum wings .................... 10
Figure 2: GLUAS packaged in mortar shell ..................................................................... 11
Figure 3: AeroLab sting balance shown with 40mm GLUAS model ............................... 14
Figure 4: 40mm Model in Wind Tunnel at 10 degrees and 13.4 m/s ............................... 15
Figure 5: 𝐶𝐿,𝐶𝐷 as a function of angle of attack for 40 mm GLUAS with separating wing
sections ...................................................................................................................... 16
Figure 6: 𝐶𝐿3/2/𝐶𝐷 and 𝐶𝐿/𝐶𝐷 as functions of angle of attach for 40mm GLUAS with
separating wing sections ............................................................................................ 17
Figure 7: (a) Continuous wing. (b) Separating wing. ....................................................... 20
Figure 8: 𝐶𝐿 as a function of 𝛼 comparison of five-section continuous and separating wings
................................................................................................................................... 21
Figure 9: 𝐶𝐷 as a function of 𝛼 comparison of five-section continuous and separating wings
................................................................................................................................... 23
Figure 10: 𝐶𝐿3/2/𝐶𝐷 as a function of 𝛼 comparison of five-section continuous and
separating wings ........................................................................................................ 24
Figure 11: 𝐶𝐿𝐶𝐷 as a function of 𝛼 comparison of five-section continuous and separating
wings .......................................................................................................................... 26
Figure 12: 𝐶𝐿 as a function of 𝛼 comparison of five and seven-section separating wings
................................................................................................................................... 28
Figure 13: 𝐶𝐷 as a function of 𝛼 comparison of five and seven-section separating wings
................................................................................................................................... 29
Figure 14: 𝐶𝐿3/2 /𝐶𝐷 as a function of 𝛼 comparison of five and seven-section separating
wings .......................................................................................................................... 30
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Figure 15: 𝐶𝐿/𝐶𝐷 as a function of 𝛼 comparison of five and seven-section separating wings
................................................................................................................................... 31
Figure 16: Test plane 3:1 scale of the 40mm model ......................................................... 33
Figure 17: Battery mass as a function of range for constant structural weight ................ 36
Figure 18: Battery mass as a function of endurance for constant structural weight ......... 37
Figure 19: Elevon torque on servos as a function of elevon deflection angle relative to body
................................................................................................................................... 41
Figure 20: 40mm UAV Showing Wing Sections ............................................................. 43
Figure 21: Geared Wing Sections and Catch Mechanism ................................................ 44
Figure 22: 40mm UAV with Tail Deployed ..................................................................... 45
Figure 23: Profile of Model2 ............................................................................................ 46
Figure 24: Model2 showing wing structure ...................................................................... 47
Figure 25: Model3 with extended wing sections .............................................................. 48
Figure 26: Profile of Model3 showing vertical stabilizer and collapsed wings ................ 48
Figure 27: Open wings with elevon horns and control rods ............................................. 49
Figure 28: Cut view of servos and torsional springs ........................................................ 50
Figure 29: Electrical components in the top half of Model3 ............................................ 51
Figure 30: Model3 assembled ........................................................................................... 52
Figure 31: Model4 with inverted servos and new connecting rod placement .................. 53
Figure 32: Model4 with wings and tail deployed ............................................................. 54
Figure 33: Assembled Model4 ready to fly (model inverted in picture) .......................... 55
Figure 34: Overlapping wing sections for packaging ....................................................... 59
Figure 35: Elevon with connecting rod and servo ............................................................ 64
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Figure 36: Packaging of video and electrical power components .................................... 66
Figure 37: Ground Station ................................................................................................ 67
Figure 38: UAV Mounted to Bottom of Carrier Plane ..................................................... 73

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