UAV Engine Test StandUAV Engine Test StandFinal Presentation
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Craig Koehne Richelle Raquet(Systems Engineer)
Brent Minchew
(Design Engineer)
Steven TrollingerBrent Minchew(Team Lead)
Steven Trollinger(Chief Engineer)
ASE 463Q – Design and Test of Aerospace StructuresSpring 2008
Department of Aerospace Engineering and Engineering MechanicsThe University of Texas at Austin
Austin, Texas 78712
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Presentation Outline
Introduction and Team OrganizationIntroduction and Team OrganizationBackgroundUAV Classifications and Engine OperationUAV Classifications and Engine OperationEngine CriteriaC t D i d I t tiCurrent Design and IntegrationFuel and Water SystemsHardware and SensorsSafety and Cost Analysis
2
Future Design Goals(Steven)
Introduction
Purpose: Design an engine test stand toPurpose: Design an engine test stand to ascertain the performance of small to medium UAV engines operating with various fuel typesUAV engines operating with various fuel types
Project sponsor: AF Research Lab Small UAS Research and Evaluation (SURE)( )
3 (Steven)
Team Organization
Brent Minchew(Team Lead)
Steven Trollinger(Chief Engineer)
Richelle Raquet(Design Engineer)
Craig Koehne(Systems Engineer)
Structural Design
Engine Requirements
Sensor and Hardware
Design
StevenBrent
RichelleBrent
CraigSteven
4 (Steven)
Background
UAVs are extensively used for reconnaissanceUAVs are extensively used for reconnaissance, search and rescue, and weapons delivery
Different UAVs require different fuels
Fuel supply dictates area of operations
5 (Brent)
Background
Currently-used alternative fuelsCurrently-used alternative fuels– Ethanol
• Manufactured from plants or biomass• Manufactured from plants or biomass• Readily mixes with gasoline• Approx. 99 octanepp
– Coal to liquid• Coal is turned to gas, then gas is turned to a liquid g g q
through Fischer-Tropsch process• Produces high amounts of CO2
ll f bl f l d d l i l
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• Small amounts of usable fuel produced relative to coal used
(Brent)
Background
Currently-used alternative fuels (cont )Currently-used alternative fuels (cont.)– Liquid natural gas
• Natural gas liquefied via Fischer-Tropsch process• Natural gas liquefied via Fischer-Tropsch process• Can produce gasoline, diesel, and jet fuel
Alternative fuels in the militaryAlternative fuels in the military– Air Force has flown B-52 on mixture of JP-8 and
liquid natural gasliquid natural gas – Air Force considering investing in coal to liquid
fuel industry
7
fuel industry
(Brent)
UAV Classifications
Classification by range/altitude:Classification by range/altitude:Type Altitude [m] Range [km]
Handheld 600 2Handheld 600 2
Close 1500 10
NATO 3,000 50
Tactical 5,500 160
Medium altitude, long endurance (MALE)
<9,000 2000+(MALE)
High altitude, long endurance(HALE)
9,000+ Indefinite, withrefueling
8 (Richelle)
Hypersonic 15,200 200+
UAV Size Variation
PredatorAZIMUT 2001
Hermes 1500
Orbiter Mini UAV
9
NASA X-43A-LSOrbiter Mini UAV
(Richelle)
Engine Operation
Five main types of UAV enginesFive main types of UAV engines– Two stroke – Rotary (Wankel)– Four stroke – TurbopropFour stroke Turboprop– Diesel
Each varies in:Each varies in:– Size and weight – Flight time– Fuel requirements – Power outputq p– Maintainability – Rebuild capability– Lifespan – Cost
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(Richelle)
Engine Operation
Two Stroke EnginesTwo Stroke Engines– Excellent power-to-weight ratios– Relatively inexpensiveRelatively inexpensive– High vibration and noise levels– Typically methanol or gasoline powered yp y g p
Four Stroke Engines– Most fuel efficient of gasoline enginesg g– Lower vibration and noise levels than two stroke– Most operate on heavy fuels
11
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(Richelle)
Engine Operation
Rotary (Wankel) EnginesRotary (Wankel) Engines– Combine rotating cylinder with rotary valve in
single component (RCV)– Reduces component count; less complex assembly– Operate with gasoline, methanol, diesel, and JP8
12 (Richelle)
Sample UAV Engines
E i E i W i ht M S d A li tiEngine Model
Engine Type
Weight[kg]
Max power output [hp]
Speed [RPM]
Application
Sachs SF 350
Two stroke
26 6800 Pioneer
LimbachL550E
Two stroke
16 50 7500
Rotax 912 S/S
Fourk
58 78 5500 PredatorULS/S stroke
Rotax 582 Mod 99
Four stroke
64 65 6500
UEL Rotary 29 52 6000 HermesUEL AR801R
Rotary 29 52 6000 Hermes
UEL AR-741
Rotary 24 38 7800 Shadow
13 (Richelle)
Effects of Fuel Variationon Engine Operationon Engine Operation
Required fuel-air ratios for operationRequired fuel air ratios for operation
Detonation due to the use of a lower octane fuelDetonation due to the use of a lower octane fuel
Increase in exhaust particulates and other ppollutants
Need for additional maintenance
14 (Richelle)
Engine Criteria
Fuels / premixFuels / premix– Methanol mixture known as “glow fuel”
• methanol, nitromethane (5 – 15%), and synthetic castor ( ) yoil lubricant (16% at a minimum).
– Gas and oil mixtures at ratios of 40:1 to 50:1Ci il d j f l– Civil grade jet fuels
• Jet A-1, Jet A, and Jet BMilitary grade jet fuels– Military grade jet fuels
• JP-4, JP-5, JP-8, and JP-10– Diesel
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Diesel
(Richelle)
Engine Criteria
Ignition systemsIgnition systems– Electric ignition systems
Injection system versus carburetor– Injection system versus carburetorCooling– Cooling fins– Ambient air or bypass air– Liquid systems
16 (Richelle)
Current Design
StructureStructure– Truss Design
• Airflow• Airflow• Wiring• Structural Analysisy• Multiple Engine Sizes
– Engine Mounting bracketg g• Multiple engines• Mounting patterns
17
• Teeth design
(Steven)
Current Design
CurrentCurrent– Material
• Steel• Steel– Cost – Availability– Workability
• Aluminum 7075-T6– CostCost – Availability– Dissimilar metal
M hi bilit
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– Machineability
(Steven)
Current Design
DynamometerDynamometer– Radiator support
Pump Placement– Pump Placement– Dynamometer Frame
19 (Steven)
Integration
20 (Steven)
Integration
O2 SensorO2 Sensor– Cannon Plug connectors
Th lThermocouples– Junction Connections– Large Wires (Alumel-Chromel)– Temperature Range– DVM guard Terminal Block w/barrier strips
21 (Steven)
Integration
Pressure Sensor AnemometerPressure Sensor– Intake Manifold
12 gauge wires
Anemometer– Intake Pipe
RS 232– 12 gauge wires– Solder Connections
D
– RS-232Manometer
Dynamometer– 5 pin cannon plug
– Intake Pipe– RS-232
22 (Steven)
Fuel Delivery
Fuel delivery systemFuel delivery system
23 (Brent)
Fuel Delivery
Needle ValvesNeedle Valves– Provide precise metering of fuel
Act as shutoffs for respective tank– Act as shutoffs for respective tankInline Pump– Used to pressurize mixing unit and supply fuel to
engine fuel pumpH ll 12 927– Holley 12-927
– Electric– 255 PPH @ 15 psi
24 (Brent)
Fuel Delivery
SnubberSnubber– Mitigates pressure fluctuations
Help prevent damage to engine fuel system– Help prevent damage to engine fuel system
E Sh t ff V lEmergency Shutoff Valve– Solenoid valve– Spring-loaded closed – energized open
25 (Brent)
Fuel Delivery
Mixing UnitOut
Mixing Unit– Volume = 32 in3
Separates water and heavyIn
– Separates water and heavyparticulates
Out
In
26
Out
(Brent)
Dynamometer Mount
2 Axis adjustment2 Axis adjustmentRigid mount during
ioperationVertical Adjustment
(H lf t i )
27 (Brent)Horizontal Adjustment
(Half-symmetry view)
Water Supply
Purpose: Recirculate and cool water for pdynamometerComponents:Components:– Electric Pump
• Max flow = 26 gpmMax flow 26 gpm• Cast iron housing
– RadiatorRadiator• 2-Core Aluminum
– Electric Fan• Dual 12 in. fan system
28 (Brent)
Hardware and Sensors
Dynamometery– Kahn Series 101-080
• Max Hp of 450• Max Speed of 14,000 RPM• Max Torque 250 ft.lb• Dry Weight 50 lbs
– Uses water brake to provide constant load– Load control and calibration system
29 (Craig)
Hardware and Sensors
Dynamometer Operating RangeDynamometer Operating RangeRotax 912 ULS/S
(Predator)
Rotax 582 Mod 99
UEL AR801RUEL AR801R
Limbach L550E
UEL AR 741UEL AR-741(Shadow)
Sachs SF 350
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(Pioneer)
(Craig)
Hardware and Sensors
DynamometerDynamometer Breakdown
Perforated Disc (1)Perforated Disc (1)Drive Shaft (2) Trunnion Bearings (7)Load cell fixed on thetorque armPower absorbed is function of water level and speedMax power when rotor chambersare filled with waterare filled with water
31 (Craig)
Hardware and Sensors
Remote Throttle Control– Adjusts RPM, torque, or manifold pressure
– Dynesystems DTC-1 Digital Throttle Controller
– Analog Reference Input: 0 to 10VDC = 0 to 10,000 units
maximum (adjustable)
– Failsafe secures to the closed position– Failsafe secures to the closed position
– Operates on code similar to BASIC
32 (Craig)
Hardware and Sensors
O2 Sensors– Gives air-fuel ratio (A/F), oxygen content (O2)– Lambda Sensor LSU 4.9 in combination
with ES430 Lambda Module– Temp. Range up to 930°C
Thermocouples– Entry Temperature and Exhaust Temperature– 5TC Ready-Made Insulated Thermocouple– Temperature Range from 0 ˚C to 750 ˚C
Accuracy of 2 2°C
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– Accuracy of 2.2°C
(Craig)
Hardware and Sensors
Pressure SensorsPressure Sensors– Necessary to calculate air density, determine the engine's air mass flow
rate, and appropriate fuel flowd ili– MPX4115A Integrated Silicon Pressure Sensors
– Maximum error of 1.5 % – Temperature operating range of -40 to 125 °C.
Ambient Temperature and Humidity– Thermo-Hydrometer RH411– Displays constant values of ambient temperature and humidity – Humidity
• Accuracy of 3% with a range of 2 – 98 %
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– Tempeature• Accuracy of 0.5°C and range of -17 to 48 °C
(Craig)
Hardware and Sensors
Flow Sensors - AirFlow Sensors - Air– Hot wire anemometer
• Measures precise air velocity, and usingMeasures precise air velocity, and usingpipe area, calculates air flow.
• Extech Instruments 407119 AnemometerFl R f 0 t 36 000 3/ i• Flow Range of 0 to 36,000 m3/min
– Digital Manometer• Determines pressure which can use to findDetermines pressure, which can use to find
velocity and then using the area of the pipe, we can calculate air mass flow.L S i HM28 H dh ld Di it l M t• Love SeriesHM28 Handheld Digital Manometer
• Redundancy 35 (Craig)
Hardware and Sensors
Flow Sensors - FuelFlow Sensors - Fuel– Turbine flow sensor that measures
the flow of hydrocarbon fuels. – instruMART SF45-A– Measure Flow: 0.3 to 80.0 GPH
DAQ SystemDAQ System– National Instruments CompactDAQ system– Used to obtain and record the data measured from sensors– Provides signal conditioning – Real-time processing
Send data to Labview for analysis
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– Send data to Labview for analysis. – 32 Channels
(Craig)
Safety
Remote throttle control fails to closed positionRemote throttle control fails to closed position
Emergency shut-off valve automatically closes g y ywith loss of power
E i h t t d t llEngine exhaust routed externally
Approved fuel tanks and storage containersApproved fuel tanks and storage containers
Operators work in separate room from unit using remote control
37 (Craig)
Cost AnalysisSensors -
Dynamometer $35 000– Dynamometer - $35,000– DAQ - $1,800– 02 Sensor - $33002 Sensor $330
Structure and Wiring– Structure & Fabrication ~$1,000– Wiring ~$500
Fuel and Water System – $1,050Total Cost of UAV Engine Test Stand ~$41,000
38 (Craig)
Future Design Goals
Additional DesignAdditional Design
– Engine cooling system
– LabView/BASIC codes
E i t l d– Experimental procedure
– Possible design modifications for alternative experiments (e.g. propeller efficiency)
Improve safety equipment and procedures
39
Improve safety equipment and procedures
(Brent)
Conclusion
Discussed goal of project and potential fuelsDiscussed goal of project and potential fuels
Outlined UAV engine types and the possible effects of different fuels on performance
Discussed current design and sensorsDiscussed current design and sensors
Gave cost analysis and scheduley
Listed some future design activities
40 (Brent)
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