2006-2007 MAE 461/462

Machine Design Project

Michael Coleman
Will Goodrum
Marc Heisel
Mark Hopke
Arthur Orton
Johan Yavari
Luke Scruby
OUTLINE
„ Introduction
„ Controls
„ Lift & Skirt
„ Thrust
„ Chassis
„ Conclusion
INTRODUCTION: HISTORY
„ 2005/2006 →
hovercraft selected
‰ Built, some issues
‰ Truncated timetable TIFF
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‰ Flew, some issues

„ 2006/2007 →
hovercraft continued IMAGE: http://www.hovpod.com/images/images.html

‰ Concept only
‰ Major revisions
PROJECT CEO:
CEO: Will
Will
Goodrum
Goodrum
COO:
COO: Jonathan
Jonathan
Kassoff
Kassoff
CFO:
CFO: Johan
Johan
Yavari
Yavari
ORGANIZATION CTO:
CTO: Trevor
Trevor CIO:
CIO: Mike
Mike
Wesolowski
Wesolowski Coleman
Coleman

Chassis
Chassis Controls
Controls Lift
Lift Thrust
Thrust

Marc
Marc Heisel
Heisel Mike
Mike Coleman
Coleman Brady
Brady Bolton
Bolton Dave
Dave Adelman
Adelman

Johan Eric
Eric Zettervall
Zettervall
Johan Yavari
Yavari Will
Will Goodrum
Goodrum Jon
Jon Kassoff
Kassoff
Ryan
Ryan O’Grady
O’Grady
Luke
Luke Scruby
Scruby Mike
Mike Jones
Jones Arthur
Arthur Orton
Orton
Mark
Mark Hopke
Hopke
Josh
Josh Heim
Heim James
James Clarke
Clarke Drew Trevor
Trevor Wesolowski
Wesolowski
Drew Michelotti
Michelotti

Alex Matt
Matt Federici
Federici
Alex Sohn
Sohn Nate
Nate Grady
Grady Evan
Evan Van
Van Ness
Ness
CONTROLS: CONCEPT & ANALYSIS

„ Allow for complete fly-by-wire

„ Provide safety features to
pilot and bystanders
„ Interface with all other
groups’ components
„ Redundancies in event of
component failure
„ Provide an easy to use
console
CONTROLS: CONCEPT & ANALYSIS

„ Use modeling to
determine forces,
torques, and velocity
CONTROLS: DESIGN & TESTING

„ Select pre-designed
components, when
possible

„ Design components
according to model
CONTROLS: DESIGN & TESTING

„ Testing includes
verification of metrics of
performance and
specifications
„ Primarily bench testing of
system
„ Functionality testing after
installed
„ Electrical system tests for
fuses and kill switches
LIFT & SKIRT: CONCEPT &
ANALYSIS
„ Anything flat plate will hover
‰ Skirt provides functionality
„ Three primary types of skirts
‰ Bag
‰ Bag and Finger Skirt
‰ Jupes
„ Selected a bag skirt design
‰ Considered terrain
‰ Craft’s purpose
Image Source: http://www.australianhovercraft.com/design_skirts.htm
LIFT & SKIRT: CONCEPT &
ANALYSIS
„ Fan generates 4.5 in water pressure rise
„ Required craft profile confirmed
‰ Chamfered corners
‰ Bottom edge chamfered
‰ Lift Fan and engine placement
„ Finalized total craft weight
(750lbs)
LIFT & SKIRT: DESIGN &
CONSTRUCTION
„ Skirt
‰ 18 oz vinyl coated nylon
‰ Sewing outsourced
‰ Installed by wrapping around ½ inch tubing
„ Lift fan
‰ Engine placement
‰ Support structure
‰ Fan duct
LIFT & SKIRT: LIFT FAN ASSEMBLY
LIFT & SKIRT: DESIGN &
CONSTRUCTION
„ Orifices
‰ Paper and Pencil vs. Cosmos Flow Works
‰ Lift fan opening = 10% of lift fan shroud

‰ Twenty 3.5 inch

diameter orifices
LIFT & SKIRT:

„ Fuel system – integrated design

THRUST: CONCEPT & ANALYSIS
Final 2005-2006 Design

„ 42” diameter, 36” pitch

propeller
„ 10 HP engine
„ Belt drive
„ Square steel tubing
and plywood frame
„ Fiberglass rudders
THRUST: CONCEPT & ANALYSIS
PROPULSION
„ Must meet hill climb spec, maximum speed spec

„ Propeller vs. ducted fan

Propeller Analysis 40

35

„ Propeller Selector 30

Shaft Power (HP)

software 25
800 mm
20 900 mm

„ Propeller theory and 15

1000 mm

equations 10

Ducted Fan Analysis 0

5 10 15 20 25 30 35 40 45 50

„ Fan theory and curves Velocity (mph)

THRUST: CONCEPT & ANALYSIS

STEERING:
„ Must meet turning rate
specification
„ Rudders vs. vectored thrust
„ Flat plate vs. airfoil rudders

Analysis:
„ FloWorks CFD
„ Varied rudder height, length,
airfoil shape
„ Observed lateral force produced,
resulting angular acceleration
THRUST: DESIGN &
CONSTRUCTION
Propulsion
„ Ducted fan selected

Rudder
„ Flat plate selected

„ 36 inches tall (diameter of duct)

„ 24 inches long
THRUST: CONCEPT & ANALYSIS

„ Modular design
„ Contains thrust
mechanism
„ Contains steering control
surfaces

Interfaces with
„ Chassis mounts

„ Controls for manipulation

of control surfaces
THRUST: DESIGN &
CONSTRUCTION
Final Design
„ 26 HP Rotax 277

„ 36” fan

„ Glass duct

„ Flat plate rudders

„ Steel frame

„ Wooden ribs
CHASSIS: CONCEPT & ANALYSIS
Final 2005-2006 Design

•Square Steel Tubing with ½” plywood deck

•407 lbs
•5.5’ x 12.5’
CHASSIS: CONCEPT & ANALYSIS

Fall 2006 Proposed Design

Geometric Constraints
 CHASSIS: CONCEPT & ANALYSIS
•¼” plywood bulkheads
•5.2mm plywood deck
•1”x3” pine stringers

•17 oz 45-45-chop fiber

•Polyester resin
•Wax surface coat
CHASSIS: CONCEPT & ANALYSIS
CONCLUSION
QUESTIONS?