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164 Pages·2005·8.36 MB·English

by  Zebb Prime

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ii
Executive Summary
This project is a continuation of the 2004 University of Adelaide Mechanical Engineering
final year VTOL project, which aimed to develop a controlled and stable VTOL model
aircraft based on the F-35 Joint Strike Fighter. Last year’s project group was unable to
complete the project for several reasons, primarily because of the poor performance of the
internal combustion engines. Due to advances in electric motor and battery technology,
the use of electric motors in now a feasible option and has been chosen for this year’s
project. An investigation was performed to re-evaluate the most suitable aircraft upon
which to base this year’s design. This research identified that the V-22 Osprey was the
most suitable platform. The primary advantage in using the V-22 Osprey as opposed to
the F-35 was the higher thrust to weight ratio achievable using propellers.
Severaldesignswereconsideredduringtheconceptevolution, witheachconceptcompared
with the design requirements. The final concept which met all requirements was then
modelled in SolidEdge where further details were considered. The design consists of an
Aluminium chassis with rotating wing arms controlled by servo motors allowing for tilt-
rotor operation. Control simplifications use this wing arm rotation along with a rear
tail-fan to directly control all three rotational degrees of freedom.
Thrust providing components were selected to best satisfy the constraints of cost, weight
andpower. Ultimatelytwo-bladefixed-pitchpropellerswerechosentobemountedradially
to brushless motors via a planetary gearbox. These motors are controlled using an
electronic speed controller and powered by on-board Lithium Polymer batteries. Using
softwarebasedpropellertheorythesecomponentswereshowntoproduceadequatethrust.
To facilitate the creation of an appropriate control system using the physical
characteristics of the model aircraft, a mathematical representation of the system
was obtained by following several closely related examples. Using this mathematical
representation a state space controller was developed using a Reduced-Order Observer
and tuned using LQR Optimal Control. Another control technique, Proportional Integral
Derivative (PID) control, was also used as a controller for the aircraft. While the PID
iii
controllerwaslesscapablethanthestatespacecontroller, itwasmucheasiertoimplement
and tune.
The controllers were initially built in Matlab Simulink, which creates C code that is
cross-compiledanddownloadedtoadSPACEDS-1104rapidprototypingcontrolplatform.
This allowed for the easy implementation and tuning of these control systems. However
this control platform is an undesirable final solution to control the aircraft due to its
size and cost, so the control system was migrated to the on-board MiniDRAGON+
microcontroller. This microcontroller was specifically programmed to interface with all of
the control peripherals, including a standard remote control and receiver which was used
to control the model.
The model aircraft was attached to a gimble to allow the tuning of the control systems
while in a tethered and safe configuration. However due to problems associated with
this gimble the tuning was not successfully completed. The model was then moved to a
semi-tethered configuration, where it was removed from the gimble but still tethered via
the wiring loom which allowed relatively free movement within a fixed range. During this
semi-tethered stage of controller tuning a gearbox shaft failed which prevented progress
towards the project goals of controlled and stable hover.
The project was set back due to the late procurement of vital components and several
mechanical failures. While this contributed to the project goals of controlled and stable
hover being incomplete, the design was shown to be able to provide enough thrust to
achieve hover and sufficiently controllable to achieve these goals. Furthermore due to the
significant work undertaken in integration and control embedding the model is a solid
control platform for future work.
iv
Acknowledgements
The VTOL group would like to thank everybody who has assisted with the project.
OurprojectsupervisorDr. BenCazzolatohasprovidedvaluableassistanceinthisproject.
Both his technical advice and general experience have been very useful for us. We thank
Benforcontinuouslyallocatingusintohisexceedinglydemandingscheduleandappreciate
his time spent with us.
The Sir Ross and Sir Keith Smith Fund for providing the financial support which has
made this project possible.
Mr. Tim Newman, our industrial associate has provided us with advice and product
sourcing based on practical knowledge and experience with aeronautical engineering and
model aircraft.
Within the School of Mechanical Engineering Mr. Richard Pateman and Mr. Steven
Kloeden from the workshop and Mr. Silvio De Ieso from Electronics and Instrumentation
have been extremely helpful throughout the project, providing advice and assisting us
despite our constant pestering. Dr. Frank Wornle has also provided valuable help
with the microcontrollers and provided advice regarding the use of his real-time target
for embedded control. Postgraduate student Mr. Rohin Woods also helped in the
development of a Virtual Reality model.
Finally the group would also like to thank our family and friends for supporting us
throughout the project.
v
vi
Disclaimer
We, the authors, state that the material contained within is entirely our work unless
otherwise stated.
Zebb Prime Allan Stabile
Michael Smith Jesse Sherwood
vii
viii
Contents
Executive Summary iii
Acknowledgements v
Disclaimer vii
List of Figures xv
List of Tables xviii
1 Introduction 1
1.1 Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Significance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Literature Review 4
2.1 Key Findings of the 2004 Report . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Existing VTOL Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.1 F-35B Joint Strike Fighter . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.2 V-22 Osprey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.3 Experimental Craft . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Previous Tilt-Rotor VTOL RC Aircraft . . . . . . . . . . . . . . . . . . . . 9
2.4 Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ix
Contents Contents
3 Concept Evaluation 13
3.1 F-35 Joint Strike Fighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.1 Ducted Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.2 Basic Feasibility Calculation . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Osprey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.1 RC Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.2 Basic Feasibility Calculations . . . . . . . . . . . . . . . . . . . . . 17
3.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Mechanical Design 19
4.1 Control Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.1 Yaw Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.2 Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.3 Roll Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.4 Translation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Frame Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.1 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2 Tilt Rotor Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.3 Final Tilt-Rotor Design . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.4 Frame Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.5 Final Frame Design . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3 Propulsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3.1 Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.2 Propeller Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3.3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
x