FACULTY OF SCIENCE AND TECHNOLOGY
BSc (Hons) Design Engineering
June 2025
S.T.R.E.A.M
by
Harry Meston
REPORT DECLARATION
This Project Report is submitted in partial fulfilment of the requirements for an
Extended Undergraduate degree at Bournemouth University. I declare that this
Project Report is my own work and that it does not contravene any academic offence
as specified in the University’s regulations.
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my Project Report may be held by Bournemouth University normally for a period of 3
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retention period has expired. I am also aware that the University does not guarantee
to retain this Project Report for any length of time (if at all) and that I have been advised
to retain a copy for my future reference.
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In particular any information which identifies a particular individual’s religious or
political beliefs, information relating to their health, ethnicity, criminal history or
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Copyright
The copyright for this report remains with me.
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I agree that this Project Report may be made available as the result of a request for
information under the Freedom of Information Act.
Signed: Harry.M
Name: Harry Meston
Date: 20/05/25
Programme: Design Engineering.
Final Project Report for First Draft.
Surface Testing for Research and Evaluation of Autonomous Machines
Abstract
This report details the research, requirements definition and full design stage of a piece of
equipment to improve efficiency and reduce cost in the unmanned surface vessel design process.
This report dives into the function establishments through market research and quantitative
methods before using these metrics and knowledge to design, develop and optimise a facility that
simulates high water speeds and real working conditions for USVs to close the gap caused
between computer simulation and real life. The objective of this design is to make rapid prototyping
more accessible for the marine industry and accelerate the rate of innovation in this industry.
Acknowledgments
I would like to thank all the individuals and organisations that assisted in the development of this
C:\Users\harry\Documents\Final Year Project Lenovo\DE Project title page 2025.docx
project. Individuals including Dr Nigel Garland and Professor Venkey Dubey for ensuring the
project always remained on target as well as ensuring quality and reliability of engineering
practice. A special thank you for the technician team in the workshops including the electrical
technicians especially.
In addition, I would like to thank my colleagues from mechanical engineering for assistance with
the mechanical features of this project and my father, Rich Meston for assistance with software,
programming and electrical engineering advice and guidance.
Finally, a heartfelt thank you for my family and friends for the love and support personally and
academically through this project process.
Contents
Abstract ................................................................................................................................................ 0
1
2
Introduction .................................................................................................................................... 6
1.1
Aims and Objectives ................................................................................................................ 7
1.2
Intellectual Property Rights ...................................................................................................... 8
1.3
Sustainable Development Goals .............................................................................................. 9
1.4
Design Methodology – Project Plan ........................................................................................... 9
Market Research ........................................................................................................................... 10
2.1
Market Conditions ................................................................................................................. 10
......................................................................................................................................................... 11
2.2
Industry Trends...................................................................................................................... 11
2.3
Regulatory Factors................................................................................................................. 13
2.4
USV Overview ......................................................................................................................... 14
2.5
Standards ............................................................................................................................. 16
2.6
Competitive Products ............................................................................................................ 17
2.6.1.5
3
SWOT of competitors ......................................................................................................... 20
2.7
Pre-made USV Analysis.......................................................................................................... 21
2.8
Market Gaps .......................................................................................................................... 22
2.9
Key failure points on sea drones ............................................................................................. 22
2.10
Customer Needs and Key Customers ..................................................................................... 23
2.10.1
Ideal Customer Profile ................................................................................................... 23
2.10.2
Second Ideal Customer Profile ....................................................................................... 24
Feasibility Study ............................................................................................................................ 24
3.1
Technical Feasibility .............................................................................................................. 24
3.2
Financial Feasibility ............................................................................................................... 26
3.3
Risk Analysis and Mitigation ................................................................................................... 27
3.4
Environmental Conditions ..................................................................................................... 28
3.5
Customer Requirements Map ................................................................................................ 28
4
Product Design Specification – Shortened Copy ............................................................................. 30
5
Early Design Stages ....................................................................................................................... 33
1
5.1
Subfunctions Breakdown – Functions Means Analysis ............................................................ 33
5.2
Concept 1 ............................................................................................................................. 35
5.3
Concept 2 ............................................................................................................................. 36
6
7
5.4
Concept 3 ............................................................................................................................. 37
5.5
Concept 4 ............................................................................................................................. 38
Material Analysis ........................................................................................................................... 40
6.1
Test Tank ............................................................................................................................... 40
6.2
Pipework – Material Suitability Matrix ...................................................................................... 41
Subsystems Design Process .......................................................................................................... 43
7.1
Water Tank ............................................................................................................................ 43
7.2
Hydrodynamic System design ................................................................................................ 48
7.3
Mechanical System Design .................................................................................................... 50
7.4
Water Storage Design............................................................................................................. 53
7.5
Sensor Systems Design ......................................................................................................... 55
7.6
Additional Hardware Design ................................................................................................... 56
7.7
Simulation System Early-Stage Design ................................................................................... 56
7.8
Interface Concept Design ...................................................................................................... 59
7.9
Interface Description ............................................................................................................. 61
7.9.1
Menu ............................................................................................................................. 61
7.9.2
Gauges .......................................................................................................................... 61
7.9.3
Video Stream ................................................................................................................. 61
7.9.4
Sliders ........................................................................................................................... 61
7.9.5
Buttons ......................................................................................................................... 62
7.9.6
Strain Guage status page................................................................................................ 62
7.10
8
9
2
Control System Architecture Design ....................................................................................... 62
7.10.1
Flow control valve system .............................................................................................. 62
7.10.2
Variable Frequency Motor Driver ..................................................................................... 64
7.11
USV Fixing, Inserting and Removing. ....................................................................................... 64
7.12
USV Retention ....................................................................................................................... 66
7.13
Manifold Stress Analysis ........................................................................................................ 68
7.14
Component Selection ............................................................................................................ 70
Optimisation and Simulation ......................................................................................................... 71
8.1
CFD on Manifolds .................................................................................................................. 71
8.2
CFD on Test Tank ................................................................................................................... 74
8.3
Vibration and Resonance Study .............................................................................................. 75
Standards and Legal Compatibility................................................................................................. 77
9.1
Steel Framework Validation .................................................................................................... 77
9.1.1
Force in trusses. ............................................................................................................ 79
9.1.2
Validation of Material choice for purpose. ....................................................................... 80
9.2
10
Safety Systems ...................................................................................................................... 80
Product Regulation Documentation ........................................................................................... 81
10.1
Legal Certification ................................................................................................................. 81
11
Technical Product Specifications ............................................................................................... 82
12
Design for excellence ................................................................................................................ 91
12.1
DFM/DFA............................................................................................................................... 91
12.2
Design for Serviceability. ........................................................................................................ 94
13
14
Cost Analysis ............................................................................................................................ 94
13.1
Materials Cost ....................................................................................................................... 94
13.2
Off-shelf Components ........................................................................................................... 95
13.3
Cost Evaluation ..................................................................................................................... 95
Sustainable Design Analysis ...................................................................................................... 96
Final Design .......................................................................................................................................... 97
15
Next Stages of Design ................................................................................................................ 99
16
Evaluation ............................................................................................................................... 100
17
Recommendations .................................................................................................................. 101
18
References .............................................................................................................................. 101
19
Appendix................................................................................................................................. 103
Gantt Chart for Maritime Drone Test Rig Design Process .................................................................. 105
20
Design Stages ......................................................................................................................... 115
Table of Figures
Figure 1 Initial vision for USV test rig ......................................................................................................... 7
Figure 2 Infographic of Gantt chart made for VIVA 1. ............................................................................... 10
Figure 3 Geo-density map showing locational interest in USV technology. ............................................... 12
Figure 4 Plymouth USV testing site, Plymouth UK .................................................................................... 12
Figure 5 Diagram showing the necessary systems involved with supporting an operational USV. (Zhixiang
Liu, 2016).............................................................................................................................................. 14
Figure 6 Table of flow of functions for an operational USV (Zhixiang Liu, 2016).......................................... 15
Figure 7 Table of properties of different sensor systems and how they are used on USVs. (Zhixiang Liu,
2016) .................................................................................................................................................... 16
Figure 8 Image looking down from the drone supporting assembly. (University of Southampton, 2024) ..... 17
3
Figure 9 Image looking at the Boldrewood Facility from the ground. (University of Southampton, 2024)..... 18
Figure 10 KHL facility. (University of Strathclyde, 2024). .......................................................................... 19
Figure 11 Table showing technical specification of the MAGURA V5 USV. ................................................. 21
Figure 12 HUR made MAGURA V5 USV. (Sutton, 2024) ............................................................................ 22
Figure 13 Initial analysis of functions and their relationship to one another. ............................................. 33
Figure 14 Morphological analysis and breakdown of functions and apparatus, ........................................ 34
Figure 15 Design of composition to fit within cargo container to reduce cost. .......................................... 35
Figure 16 Initial sketch of composition and functions need met. ............................................................. 36
Figure 18 Concept design idea for two stage pump design. ..................................................................... 39
Figure 17 Python program maping the ideal velocity change over the 4.5m length of tank. ........................ 39
Figure 19 Inlet manifold for water into and out of the tank. ...................................................................... 40
Figure 20 Granta edupak analysis on CFRP and GFRP relating price and yield strength. ........................... 41
Figure 21 Pie chart showing weighting of properties against material properties....................................... 42
Figure 22https://steelnavigator.ovako.com/steel-grades/s355/ ............................................................... 43
Figure 23 Image showing proposal for Stream data collection app. .......................................................... 44
Figure 24 Breakdown graph of geometry and their weight and price respectively. ..................................... 44
Figure 25 Proposal sketch for test tank optimisation. .............................................................................. 45
Figure 26 Screenshots from STREAM parabola equator software written for this project to gather data on
ideal hull shapes and tank geometry. ..................................................................................................... 46
Figure 27 table showing plotted results from 35 tested images from STREAM app. ................................... 46
Figure 28 Table showing what this ideal curve will look like. ..................................................................... 46
Figure 29 Screenshot of SolidWorks model of tank design. ..................................................................... 48
Figure 30 Initial design of water exit manifold. ........................................................................................ 51
Figure 31 Selected water pump. ............................................................................................................. 52
Figure 32 Chosen GFRP pre-made water storage tank. ............................................................................ 54
Figure 33 Design of basic splash cover for top of test tank....................................................................... 56
Figure 34 Infographic to show how data will be gathered and data logistics to interface and storage. ........ 59
Figure 35 Web-page GUI prototype to show layout of interface. .............................................................. 61
Figure 36Web-page GUI prototype to show layout of interface specifically strain gauge sensor systems. .. 62
Figure 37 Infographic showing a type of safety system to regulate pressure and water speed. ................... 63
Figure 38 Variable Frequency Driver example ......................................................................................... 63
Figure 39 Initial sketch of movement system for USV into and out of the tank. .......................................... 65
Figure 40 Early simulation on USV retention system. ............................................................................... 66
Figure 41 More developed model of USV retention with thicker material. ................................................. 67
Figure 42 Optimised USV with thicker walls, material and chain loop. ..................................................... 67
Figure 43 Difference in deflection for retention hook. .............................................................................. 68
Figure 44 Factor of safety plot on the inlet manifold. ............................................................................... 69
Figure 45 Factor of safety plot on manifold with support frame. ............................................................... 69
Figure 46 Data sheet for specific motorised gantry with specification. ..................................................... 70
Figure 47 Early CFD simulation on manifold pipe. ................................................................................... 71
Figure 48 Top view of CFD on early pipe design. ...................................................................................... 72
Figure 49 Optimized manifold design with nozzles on. ............................................................................ 73
Figure 50 Graph showing speed for simulation at the pipe split section. .................................................. 74
4
Figure 51 Top view of the tank in the model assembly. ............................................................................. 74
Figure 52 Flow simulation of water entering the tank, interacting with USV dummy and leaving out the rear.
............................................................................................................................................................ 75
Figure 53 Graph showing point where resonance may occur. .................................................................. 76
Figure 54 Early-stage diagram on force acting upon the tank frame. ......................................................... 77
Figure 55 1/6 cut of the steel frame to calculate material and stress properties manually. ........................ 79
Figure 56 Technical Product Specification of the inlet manifold from the pump to the tank. ...................... 82
Figure 57 Image of side profile for tolerance stack. ................................................................................. 84
Figure 58 Technical product specification of steel frame from 120x80x6mm steel frame. ......................... 85
Figure 59 Tank technical specification. ................................................................................................... 87
Figure 60 Chain mount to retain the USV for testing, product specification. ............................................. 89
Figure 61 MBD for pipe that connects from storage tank to inlet pump. .................................................... 91
Figure 62 Chopped strand mat GFRP type, multidirectional fibres bonded in a single layer. (Fiberglass.com,
2022) .................................................................................................................................................... 93
Figure 63 Graphic showing remaining systems to design and improve compared to initial design. ............ 99
Figure 64 Lifecycle assessment report from Granta Edupak. ................................................................... 99
Figure 65 Graph showing projection of market value of USV's ................................................................ 104
Table of Tables
Table 1 Table showing preliminary breakdown of timeline ......................................................................... 8
Table 2 Table showing preliminary view on IPR and risk management ........................................................ 8
Table 3 Table showing UNSDG met in project. .......................................................................................... 9
Table 4 Graph showing timeline of web traffic for USV related terms. ....................................................... 11
Table 5 Showing regulatory bodies that are required to be met during this project. ................................... 13
Table 6 Table showing breakdown of USV sub-systems and their preferable solutions. ............................. 14
Table 7 Table of UK and ISO standards that this project could be required to meet. .................................. 16
Table 8 Table breaking down technical specification of Boldrewood test tank. ......................................... 18
Table 9 Table breaking down technical specification of KHL towing tank. ................................................. 19
Table 10 Table showing key failure points on current USV technology....................................................... 22
Table 11 Table showing academic research type of ideal customer. ......................................................... 23
Table 12 Table showing military based ideal customer profile. ................................................................. 24
Table 13 Table showing initial technical feasibility of STREAM project. ..................................................... 25
Table 14 Table showing initial feasibility technical specifications and metrics. ......................................... 26
Table 15 Table showing requirements as a product of market research and feasibility study. .................... 28
Table 16 Product design specification (Shortened, full in appendix.) ........................................................ 30
Table 17 Experimental type of function solution selection to be sketched. ............................................... 34
Table 18 Table showing evaluation of steel pipework material selection. ................................................. 42
Table 19 Table showing requirements for the test tank. ........................................................................... 43
Table 20 Table showing requirements for the water acceleration at discreet speeds 5-9m/s. .................... 48
Table 21 table showing specification of tank selected for purpose. .......................................................... 49
Table 22 Evaluation of rotational force generation techniques for pump power. ....................................... 50
Table 23 Table of properties required from the torque powering the water pump. ..................................... 51
5
Table 24 Table showing the specification of per-made AC motor. ............................................................. 52
Table 25 Table showing geometrical and dynamic requirements of water storage tank. ............................ 53
Table 26 Calculations to find optimal water storage capacity. ................................................................. 54
Table 27 technical and geometrical specifications of storage tank. ......................................................... 55
Table 28 Table showing the sensors needed for reading, their connection and preferred interface type. .... 55
Table 29 Calculations to show how information will be stored, how much storage is required................... 57
Table 30 Evaluation of interface types. ................................................................................................... 58
Table 31 table showing technical specification of VFD chosen for purpose. ............................................. 63
Table 32 Evaluation table of lift and removal systems. ............................................................................ 65
Table 33 Calculation for requirements of USV logistic apparatus. ............................................................ 70
Table 34 Selected motorised gantry with specification on this project. .................................................... 70
Table 35 Table showing geometry from NASA sub-sonic nozzle design equations for pipe nozzle. ............. 72
Table 36 Structural property and respective equation for configuration in model. ..................................... 78
Table 37Requirements for steel geometry selection. ............................................................................... 78
Table 38 Force direction, type and quantity in each beam section. .......................................................... 80
Table 39 Validation of steel material selection table. ............................................................................... 80
Table 40 Table of safety system breakdown and their respective standards to meet. ................................ 81
Table 41 Legal and standards breakdown and analysis. .......................................................................... 81
Table 42 Table explaining tolerances on inlet manufold. .......................................................................... 83
Table 43 Table explaining tolerances on Steel frame ............................................................................... 86
Table 44 Table explaining tolerances on test tank. ................................................................................... 88
Table 45 Table explaining tolerances on chain mount. ............................................................................. 90
Table 46 DFA decision breakdown and justification................................................................................. 91
Table 47 Draft angle on tank to reduce mould risk and complexity. .......................................................... 92
Table 48 Mould for GFRP layup to create test tank. ................................................................................. 93
Table 49 Design for serviceability decisions and justification table. ......................................................... 94
Table 50 Material cost analysis. ............................................................................................................. 94
Table 51 Off shelf component cost analysis and breakdown. .................................................................. 95
Table 52 Lifecycle assessment............................................................................................................... 96
1 Introduction
Maritime drones are becoming increasingly effective and sought after, especially due to acceleration in demand by the
Ukraine war. It is estimated that by 2050 NATO will have $50BN invested in drone fleets (Porter, 2025). These drones are
proving extremely efficient and effective through practice by Ukraine military. However, these drones are being poorly
designed in the quickest possible ways as the demand is so high and the use of them is new (Clark, 2024). Corners in
production are being cut and the failure rate is high. This is partially due to no time or effective way to test these drones
before they are needed in battle. What I intend to overcome is this design gap for not having sufficient test apparatus
meaning drones are less effective than they could be at lower costs and produced more quickly.
6
My initial vision is a test chamber which can simulate high speed water, winds, temperature changes etc to match that of
what these drones will be operated in as well as measuring factors such as efficiency, lifespan, service, runtimes and other
factors that cannot be definitively concluded with the use of computer simulation to help optimise their use and despite
AI advancements, they will never fully be able to simulate this (BPS.Space, 2024).
Other uses for drones where this technology will have value: hull inspections, operational support, detection, monitoring,
privacy assurance, biological and geographical research, pollution monitoring and antenna calibration.
All these industries are using an ever-growing number of drones for these purposes and besides a support boat only when
the drone is fully functional, no small scale, rapid tests can be done. With this design the process of designing and
manufacturing can be accelerated and iterated more quickly and effectively.
Figure 1 Initial vision for USV test rig
1.1 Aims and Objectives
I aim to gather suitable market research from primary sources such as local yacht organisations, UAV manufacturers and
developers as well as metrics relating to working conditions and how best this can and be used to simulate weather and
sea conditions.
Due to this design having many complex sub-systems such as water pump, jets, monitoring devices etc, each system will
have a short amount of design time before moving onto the next stage with time allowed for iterations in the design and
loopbacks. I intend to design each system using standard components, pumps etc where possible as these can produce
large datasheets with values and test results. If possible, I can create a small-scale prototype to show concept conveying
the working mechanism of the water flow, monitoring etc.
7
In terms of project milestones, my project will be presented at the industrial review night before any stages of physical
development. By this stage I will have focused heavily on creating a product design specification as well as detailed
component drawings. This stage as well as the VIVAs will be a point of specification review and iterative changes in the
feedback loop before beginning any final design.
Table 1 Table showing preliminary breakdown of timeline
Task/Phase
1. Project Initiation
2. Proposal Development
3. Research Phase
4. Design Phase
5. Prototyping
6. Festival of Design Engineering (FODE)
Start Date
Sept 23, 2024
Sept 30, 2024
Sept 30, 2024
Dec 26, 2024
May 28, 2025
June 16, 2025
End Date
Sept 30, 2024
Oct 11, 2024
Dec 25, 2024
May 27, 2025
June 15, 2025
June 30, 2025
Developing this high-speed environment requires technical challenges to overcome. One primary challenge being the
difficulty to create even flow that accurately mimics the real world, hydrodynamic movement of water and its interface
with a boat hull. Additionally, ensuring this can be sustained for minutes or hours at a time to gather meaningful and
accurate results from the test. Gathering precise feedback and data is directly the value created for the customer and
therefore is critical. Important parameters such as speed, strain, efficiency and drag are key properties that must be
measured.
1.2 Intellectual Property Rights – Preliminary View
For an initial view on the subject, no partnerships for IPR’s are initiated in this domain, therefore any developed work will
be owned by myself – in a non-secure by legal administrative way. In terms of physical design, mechanical systems and
unique integrations of control systems and electronics will – upon a developed concept – need looking into for the correct
IPR’s and ownership. This applies for any firmware that is created and when other developers’ libraries are included such
as pre-existing sensor libraries in Arduino IDE.
Another subject relating to this is the drive for these drones for military purposes. Being a competitor for funding by the
government for example for military use, this will initially require the secrecy that most military developments require.
However, this project Is not for that purpose specifically and can be developed without such requirements. The project
will adhere to national and international intellectual property laws and regulations, including maritime-specific standards,
to ensure the apparatus meets global compliance requirements.
Table 2 Table showing preliminary view on IPR and risk management
Risk
Cyber
Security
Intellectual
Property
Solution
Data
Management
Research and data from external companies given require limitations in this project development.
Mitigation: All sensitive data will be only visible to me (the developer) and to the assignment marker.
Any published copies will have censored information on report, studies and summary of overall
project.
8
Virus/hacking of relevant computers used. Mitigation: ensuring that all drives are named, filed and
encrypted/decrypted before and after use.
Ideas that are confidential becoming known. Mitigation: ensure no sharing data or ideas before any
milestone in the project to ensure all ideas are my own and kept that way.
1.3 Sustainable Development Goals
Alignment with UNSDG’s is critical to this project as it directly addresses customer value and morality.
Below is a breakdown of the three goals this project will align with and how. (UnitedNations SDG , n.d.)
Table 3 Table showing UNSDG met in project.
Goal Number
Description
Use in this project
This project will drive technological
advancements and innovation in
hydrodynamics and autonomous vehicle
development.
This facility encourages low cost USV
testing for research, development
and academic purposes. This can
accelerate innovation rapidly in this
field of technology.
This project enables the creation of more
efficient and sustainable marine
autonomous technology which can be
used for purposes regarding research and
sustainability practices in the ocean.
This project can directly support
environmental monitoring drones,
improving efficiency, lowering cost
and increasing the deployment rate
to research and educate on subsurface life.
This facility can promote the
development of security drones, to
ensures the seas are safer and more
secure from threats. With more
developed and reliable systems at a
lower cost, the demand will
increase.
This project promotes technological
solutions that can enhance country
security or defence. The development of
precise and effective USV’s can ensure
these can carry out missions more
effectively and quickly.
1.4 Design Methodology – Project Plan
This project will be broken down into three stages. Stage one will be requirements analysis and creating a
PDS to effectively create a solution to the problem. This market research will consist of a short literature
review on current USV systems and their architecture. There will also be an analysis of competitive
hydrodynamic testing technologies which will be used to gather quantitative research on their
specifications and technologies used.
Stage two will be development of ideas and creation of a final design with iteration and evaluation
included. The design methodology my project will remain adherent to is the systems engineering design
method (Science Direct, 2015). Reasoning for this comes from the complex and multi-systemic nature of
the project and following this design method freely will allow me to effectively coordinate systems and
evaluate them at the most appropriate points.
Stage three will be embodiment of the final design and creating proof of concept and display features for
FODE (Festival of Design and Engineering) as well as creating and optimising firmware for the systems and
entire project evaluation.
9
For a more detailed view of the project initial and final Gantt chart, see to the appendix at the end of the
report.
Figure 2 Infographic of Gantt chart made for VIVA 1.
2 Market Research
2.1 Market Conditions
The global market for unmanned surface vehicles (USV’s) is expected to reach 1.71B USD growing at a
CAGR of 10.8% (The Business Research Company, 2024). One of the driving factors for this expansion is
the pull of the market by the demand for marine research, energy and defence. Cost effective technologies
are being encouraged by companies such as Ocean Infinity (Ocean Infinity, 2024) who are employing
commercial use of offshore drone technology which indicates market growth in the sector.
10
2.2 Industry Trends
Intrest in USV related terminology
Number of Searches, 10,000s
120
100
80
60
40
0
02/02/2…
15/03/2…
26/04/2…
07/06/2…
19/07/2…
30/08/2…
11/10/2…
22/11/2…
03/01/2…
14/02/2…
28/03/2…
09/05/2…
20/06/2…
01/08/2…
12/09/2…
24/10/2…
05/12/2…
16/01/2…
27/02/2…
10/04/2…
22/05/2…
03/07/2…
14/08/2…
25/09/2…
06/11/2…
18/12/2…
29/01/2…
12/03/2…
23/04/2…
04/06/2…
16/07/2…
27/08/2…
08/10/2…
19/11/2…
31/12/2…
11/02/2…
24/03/2…
05/05/2…
16/06/2…
28/07/2…
08/09/2…
20/10/2…
01/12/2…
12/01/2…
20
Descrete time periods
Table 4 Graph showing timeline of web traffic for USV related terms.
The growth anticipated in this market is partially down to rising number of threats and risks associated with
marine security. This can include military and social risk such as robbery, smuggling and piracy as well as
geographical and environmental security and research. In July 2023, COC1 reported 65 incidents relating to
these matters, an increase of nearly tenfold. Investment in USV market has been increasing approximately
9% on average since 2021 (Association for Uncrewed Vehicle Systems, 2022). With regards to
technological trends in the industry, it was reported that Sefine Shipyard-Aselsan unveiled an inaugural
unmanned surface vehicle with warfare capabilities regarding electronic warfare, naval warfare in both
water bodies and open sea environments (The Business Research Company, 2024). In the west, US based
Ocean Power Technology acquired Marine Advanced Robotics allowing for more advanced autonomous
capabilities.
North America, in 2023, was the region with the largest demand for unmanned surface vehicles (The
Business Research Company, 2024). The defence sector within this global market share was the most
prominent sector regarding investment for these drones. In Europe, market portrays proportionally similar
drive and applications with an “increasing demand for maritime security in the European waters” says
hydro-international (Tapken, 2018).
1
Chamber of Commerce USA.
11
The largest group, according to hydro-international (Tapken, 2018), regarding USV technology is the AsiaPacific region (37%) with Europe and US being 27% and 26% respectively.
Figure 3 Geo-density map showing locational interest in USV technology.
This project is in accordance with the necessary requirements for use in the UK. The focus will be with
ensuring compliance with local authority and bodies regarding security, data protection and safety
standards. The project will be driven by research on the preference, trends and requirements of local
organisations. Accessibility to information will be critical to ensuring reliability and competency of the
project. Feedback from stakeholders will be included to refine and develop and will be used to assess
success.
After discussion with a professional who visited the industrial review night display, it was discovered that
the city of Plymouth in the south coast of England (Devon) has large push for USV technology. This
industry in this location has been pushed for development in collaboration by the university of Plymouth.
The USV under development is the Cetus in collaboration with L3 Harris. For this reason, there would be –
in this location – a high demand for apparatus for evaluation of the performance of this hardware. Next in
Figure 4 Plymouth USV testing site, Plymouth UK
12
this project, I will create specification on the conditions that apply to this apparatus for implementation in
this specific area.
2.3 Regulatory Factors
Below is a table describing the relevant regulatory bodies a sea drone test rig in the UK will need to comply
with/receive approval from.
Table 5 Showing regulatory bodies that are required to be met during this project.
Regulatory
Body
Maritime
Safety
Regulations
Environmental
Regulations
Safety
Regulations
Autonomous
Vehicle
Regulations
Battery and
Energy Storage
Test Site
Approval
13
Regulations
Requirements
Maritime Coastguard
Agency
May need to comply with safety, navigation rules,
collision avoidance etc in UK waters. Report position
AIS compliance.
Protecting marine ecosystems.
Marine and Coastal
Access 2009
Marine Pollution
(MARPOL) Regulations
Environmental Impact
Agency (EIA)
Health and Safety
Executive
Health and Safety at work
1974
Remote Piloted Systems
Regulations (RPAS)
Automated and
Autonomous Vehicles
(AAV’S)
Control of Substance
Hazardous to health
(COSHH)
Marine Management
Organisation (MMO)
Port Authorities
Reduce marine pollution.
Assessment of total environmental impacts
Human operator safety.
Employee health and safety.
Regulations regarding controlling personnel of drone.
May reach water based autonomous systems.
Might not need - includes operating, testing and safety
standards.
Regards lithium-ion or other substances - storage,
usage and disposal.
Regulates use of UK sea and coast. Seek approval
before operating near protected zones.
Regards commercial ports or harbours and ensure no
interference with port activities.
2.4 USV Overview
Figure 5 Diagram showing the necessary systems involved with supporting an operational USV.
(Zhixiang Liu, 2016)
Table 6 Table showing breakdown of USV sub-systems and their preferable solutions.
Hull Materials
Rigid Inflatable – For military purposes, greater
endurance and higher payload capacity.
Twin Hull – flexible uses and easily configurable.
Kayak – easy and cheap to modify, commonly
used for hobby, low scale manufacture.
Propulsion
Steering
Rudder
Water Jets
Rotating water Jets
Rudder
For autonomous vehicles with full self-piloting and minimal human interference, there is typically wired
onboard communication, wireless to ground station communication architecture (Zhixiang Liu, 2016).
There are some levels of data collection and closed loop systems occurring onboard the device with
telemetry sent to the ground station. This data can be IMU, GPS, camera, radar, lidar, sonar and
temperature or humidity readings in real time. The ground stations are typically offshore facilities
(stationary) or vehicular local boats supporting the USV from afar. These are used to send commands and
14
data between the USV and GS (Zhixiang Liu, 2016). These can be given definitive communication such as
engage commands. This project will be focusing on specifically battery operated drones using electric
motors or jets for propulsion.
Figure 6 Table of flow of functions for an operational USV (Zhixiang Liu, 2016)
2.4.1.1 Conventional Sensor Architecture.
Being fully autonomous, there are sensor limitations. For example, there is a specific level of state
estimations that take place when the device can only read for example, position and orientation. The
determination of velocity and acceleration require reconstruction. For example, the typically used IMU or
GPS sensors provide position, orientation and velocity readouts – however are largely affected by errors in
cumulative drift being a water vehicle, environmental noise and sensor function errors (Jamal Ansary,
2022). These can be reduced by using multi-sensor-fusion. These can include a basic sensor architecture
for example the one stated above with the gaps in the system filled by additional hardware either wired in
or working sequentially with time stamp and post, data collection synchronization (Zhixiang Liu, 2016).
15
Figure 7 Table of properties of different sensor systems and how they are used on USVs. (Zhixiang Liu, 2016)
These can use the low-rate transmission or data collection (GPS) and high-rate sensor data collection
(sonar) together to have accurate readings at any moment in time (Jamal Ansary, 2022).
2.5 Standards
Below is an initial view on the British and international standard this facility will need to comply with. Also
included are possible assistive standards that could aid development such as the mid-sea ocean steel
work standards that could assist calculations required for materials and structures with exposure to
constant salt water.
Table 7 Table of UK and ISO standards that this project could be required to meet.
General
General Safety and
Design
Mechanical Systems
Hydrodynamic
Systems
Title
ISO 12100:2010, BS EN ISO 138491:2015, ISO 13850:2015 – Safety of
machinery
ISO 11161:2007 - Integrated
manufacturing systems
ISO 9763:2004 – Water Quality.
ISO 8068:2014 - Water Jet Technology
ISO 2631-1:1997 – Mechanical
Vibration and Shock
ISO 14222:2017 – Small craft marine
propulsion
16
Purpose
Overall safety or machinery in use.
Guidelines for risk assessment and
overall evaluation
Outlines safety requirements for
integrated systems.
Assessment of microbial quality of
recreational water, if operate near
natural body of water.
Useful for specifying water jet
equipment. Terminology and
definitions of values.
Exposure of human body to
vibrations when machinery is in
use.
Propulsion system compliant with
health and safety regulations
Electrical and Control
Systems
Testing and Sensors
Environmental
Considerations
Structural and
Mechanical Integrity
Marine Shoreline
Equipment
IEC 61508 – Functional of
electrical/electronic/programmable
systems.
ISO 26262:2018 – Autonomous
control systems
ISO 9001:2015, ISO 17025:2017 –
Quality management systems and
general requirement for testing
competence.
ISO 14001:2015, ISO 14064-1:2018 –
Environmental Management systems
and greenhouse gasses.
ISO 19901-1:2015, BS 5950-1:2000 –
Petroleum and Natural Gasses
structure and Steelwork in building.
ISO 13686:2001 – Small Craft, Ropes
and Mooring systems.
BS EN 1993-1-1 – Steel structures.
Ensures electronic control systems
are safe and preventing failures.
Mainly used for road vehicles –
could apply where autonomy is
implemented.
Testing of sensor equipment and
calibration of systems – ensures
meet precise standards.
Possible impacts of device on
environment, criterial for managing
responsibilities.
Use for design work – applies to oil
rig construction and standards for
exposure to water/ weather.
Restraint of drone in rig - ensuring
all load bearing systems are correct
rating.
Ensures all structures can
withstand normal and abnormal
operating environments. Ensures
safe and functional.
2.6 Competitive Products
Due to the recent increase in demand for a USV related market, no facilities for testing specifically
unmanned vehicles are available for public knowledge. Despite this, there are facilities for testing and
research of similar products.
2.6.1.1 Boldrewood Towing Tank
This facility is owned by the university of Southampton and is considered the “largest towing tank in the
UK” (University of Southampton, 2024). This facility supports use by research and commercial bodies.
Figure 8 Image looking down from the drone supporting assembly. (University of Southampton, 2024)
17
2.6.1.2 Technical Specification: Boldrewood
Table 8 Table breaking down technical specification of Boldrewood test tank.
2.6.1.3 Kelvin Hydrodynamics Laboratory
Value
Quantity
Length
128M
Width
6M
Depth
3.5M
Frame Material
Aluminium
Maximum Speed
10M/S
Drag Range
0-150,500,1000N
Figure
9
Image
looking
at
the
Boldrewood
Facility
from
the
ground.
(University of Southampton, 2024)
Side Force Range
0-150,500,1000N
Roll Movement
0-30Nm
Yaw Movement
0-40Nm
Pitch Range
+/-18 Degrees
Roll Range
+/-45 Degrees
Heave
Free
Wave Maker
12 elements HR Wallingford Wavemaker
Capabilities
Short and long crest random wave generation at
normal and oblique angle
Communication
Video Streaming
Other Systems
LA Vision underwater PIV, Above and below
motion capture, open water for propeller
testing, Dantec LDA, suitable for mooring tests.
This facility is based in Glasgow, Scotland. This facility is for experimental research purposes on floating
turbine platforms, wave energy converter efficiency and floating structure real life simulations (University
of Strathclyde, 2024). Other applications include ship resistance, unsteady motion, damage resilience,
vortex vibrations, evaluation of surface-piercing and submerged bodies, wave impact studies and
renewable energy device performance.
18
Figure 10 KHL facility. (University of Strathclyde, 2024).
2.6.1.4 Technical Specification: KHL
Table 9 Table breaking down technical specification of KHL towing tank.
Value
Length
Width
Depth
Wave Maker
Communication
Test Vessel size
Wave properties
Other Properties
19
Quantity
76M
4.6M
2.5M
Variable water depth computer-controlled four
flap absorbing wavemaker.
PC based data acquisition control, up to 64 inputs
and 20 outputs for up to 60Khz sample rate.
<4M
0.5M
Up to 25 wave probes, 3-axis fluid velocity
measurement PIV system. Above and under water
video systems.
2.6.1.5 SWOT of competitors
Boldrewood SWOT
1.1.1.2 Strengths
Large Scale tank and wide range of waves
can be created
High-fidelity capabilities, PIV system, force
transducers and motion tracking
Versatility for research, wave-ship
interactions, fluid structure interaction.
1.1.1.1 Opportunities
Advancements in autonomy and ai-based
research
Sustainability factors in technology
development
Increased industry defence collaboration
20
1.1.1.4 Weaknesses
Cannot completely simulate open sea
turbulence.
High cost of build and operating and
maintaining.
Restricted accessibility.
1.1.1.3 Threats
Emerging competition and alternative testing
facilities
Environmental Regulatory Constraints
Economy and policy risk and uncertainty.
KHL Swot
1.1.1.7 Strengths
Deep tank and highly configurable wave making
system.
High precision testing equipment includes wave
probes and motion capture.
Strong offshore sustainability capabilities
1.1.1.5 Weaknesses
Scaling limitations and limited deepwater
simulation capabilities.
Energy intensive operations due to advanced
wavemaker.
Restricted access to public.
1.1.1.6 Opportunities
Expansion for autonomous and AI systems
1.1.1.8 Threats
Hybrid modelling using CFD and AI
Growing reliance on CFD and LES using AI
Sustainability research for improve
environmental cost.
Competition from global facilities
Political and economic uncertainty,
Increased defence spending collaboration.
2.7 Pre-made USV Analysis
Figure 11 Table showing technical specification of the MAGURA V5 USV.
This device was designed and developed by HUR in Ukraine. This device was purposed for surveillance,
reconnaissance, patrolling and attack. This drone is capable of speeds of up to 78km/h and can last up to
60 hours making it the first of its kind to effectively be used in carrying out its intended purposes.
21
Specification
Length
Gross weight
Operating range
Range of operation
Range
Payload
Cruising speed
Maximum speed
Navigation methods
Video transmission
Cryptographic protection
Cost of production
Value
5.5 m
< 1000 kg
up to 400 km
up to 800 km
up to 60 hours
up to 200 kg, at least one R-73 air-to-air missile
41 km/h
42 kt (78 km/h)
automatic GNSS, inertial, visual
up to three HD video streams
256-bit encryption
about US$273,000
Figure 12 HUR made MAGURA V5 USV. (Sutton, 2024)
2.8 Market Gaps
As a conclusion from the SWOT analysis above, some emerging market gaps appear in the weaknesses of
the pre-existing similar products.
High Cost: Due to the extremely high initial costs of these facilities, they require high cost-per-test. Hence
independent entities who wish to use the facilities are required to wait significant time and spend a
significant sum of money.
Advancements of AI: The advancements of AI can predict more and more accurate simulations without
hardware requirements. There is less need for high-cost test facilities.
There is a gap in the market caused by the large pull of demand for autonomous small vessels – this is not
being adequate met with the correct research and development equipment at a low cost. Part of the
attraction to the USV industry as opposed to manned vessels is the low price. One large aspect of the
development process is the cost of correct test facilities and otherwise, cheap drones are produced
without being tested properly.
2.9 Key failure points on sea drones
Table 10 Table showing key failure points on current USV technology.
Failure Point
Thrust Malfunction
Hull Integrity
22
Description
For some model, thrust can provide
translational force as well as
rotation and steering (Haolin Liu,
n.d.).
Key structural components of the
devices can be eroded, thawed or
damaged due to rapid small
collisions (Macdonald, 2024).
Cause
Causes for such malfunctions can be
due to debris in the open water and
incorrect knowledge of wear and tear on
components.
Incorrect knowledge of specifications of
drones. Structural inflexibility and not
temperature tested at extreme
temperatures.
Unpredictable Sea
Conditions
Energy Management
Software Bugs
Poor Maintenance
When there is not enough research
into design limits, operators are not
aware of where the drones can
operate (Porter, 2024).
This relates to the transfer of energy
from the battery to necessary
components and how much is sent
where at what time (GAO Tek, 2024).
Errors in control or autonomous
algorithms either caused by
engineer error or incorrect sensor or
actuator coordination (BPlan, 2025).
This refers to the understanding of
the technicians of the systems and
how regularly to service parts.
Too cold sea or weather conditions for
hardware, electronic components and
battery usage.
This is caused by manufacturer not
being fully aware of limitations in design
and improvements to allow for device
flexibility.
This is caused by incorrect or
insufficient testing in the device and the
operator or manufacturer not being
aware of design limits.
Limits in run times before manufacture.
Deployment is still considered a testing
stage.
2.10 Customer Needs and Key Customers
2.10.1
Ideal Customer Profile
Table 11 Table showing academic research type of ideal customer.
Feature
Description
Justification
Organisation
Academic and Research
Institutions.
Position
Marine engineering robotics lab
directors. Oceanographic
research groups. Autonomy
research centres.
£100,000-500,000
Innovative design ideas for systems and
physical design of such devices have strong
investment.
Implement of system for testing and
evaluation would concern heads of
departments and authorities figures to decide
to pursue investment
Lower budget than military purposes – no
direct financial benefit however cost of
maintenance will be less due to less running
hours.
Students’ post-graduation could benefit from
having rapid prototyping facilities that are
more common in the UK. Research can be
encouraged in such platforms.
Financial
Considerations
Facility Uses
Other interests
23
Rapid testing of experimental
ideas for hull design and
propulsion systems.
Refinement of mathematical
models relating to CFD and AI in
design.
Such institutions have close
sustainability needs and goals.
Government spending in the UK strongly
supports R&D in academic research
laboratories. There is significant
encouragement for research and
development in USV.
2.10.2
Second Ideal Customer Profile
Table 12 Table showing military based ideal customer profile.
Feature
Description
Justification
Organisation
Defence and military research
labs or contractors. (Including
national coastguard).
Unmanned systems offices,
testing and evaluation
departments. Program
managers, procurement officer.
£1 million over lifetime.
Largest customer basis for USV technology.
Position
Financial
Considerations
Facility Uses
Other interests
Testing prototypes in early
design stage
Testing completed systems for
evaluation and design limits
testing.
Gathering research for next
generation of devices.
Reduction in government
spending due to public opinion.
Increase in sustainability
awareness to improve public
opinion.
Implement of system for testing and
evaluation would concern heads of
departments and authorities figures to decide
to pursue investment
Evidence from the Japanese defence budget –
allocation of £110 million for trial of USV test
equipment.
The purpose of this project is to create a
system that can streamline the development
of these systems. All stages of development
will need to be considered for this project.
The public are becoming more aware of
military and defence budget requirements aswell as the inefficiency related to the industry.
Such services will need to add to this
philosophy of reduction in effort, time and
cost.
3 Feasibility Study
3.1 Technical Feasibility
To outline the technical requirements for this project, properties such as dimensions, forces, electrical
requirements and other quantitative features will be mapped.
24
Table 13 Table showing initial technical feasibility of STREAM project.
Property
Dimensions
Description
The average size for USV’s for military and research
is between 1-4m in length by consistently 1m in
width and a depth of 1m. Given that not all this
depth will be submerged (typically 30-40% below
the surface (Boating World, 2025)), the full depth
of the drone in a water body will not be required. To
be correctly tested, the drone will need extra
space to allow for rotation, roll and steering as well
as small forward and back movements.
Forces
Key force requirements will come from the mass of
the water bodies asserted on the ground and any
supporting structure. Tanks that hold this will need
to be able to withstand safely and with little
maintenance.
The main power draw will come from the pumps
used for the hydrodynamic tests. The electrical
sensor and monitoring systems will also
contribute to the overall energy consumption. The
mixture of fluid (water) and electrical components
will need to be closely monitored and ensure
safety.
The typical speed for military USV is 50 knots. This
equates to 25m/s. However, with research taken
from automobile dynos, to gather accurate test
results from a dynamic run, the typical dyno test is
limited to 100mph as this is where the majority of
service life will stay. This is approximately 66% of
the average cars top speed and therefore speeds
of only 16m/s to match this ratio.
Electrical
Requirements
Fluid Flow
Requirements
Allowing 1m of padding for each
dimension in the total frame size.
Allow for an average size. Larger
facilities can be created with
more room and smaller can be
created at smaller cost with the
same functionality. For this
project, the average dimensions
of a sea drone will be used at 3m
length, 1m wide and
Calculations required for mass
of water flow and ensure with a
SF2 of 0.6. Ensure is suitable for
environmental conditions.
Reduce direct contact with
electrical components and
hydrodynamic. Carefully
consider the electrical/water and
waterproofing standards
documents.
Pumps and water jets to be able
to recreate dynamic fluid
simulation of speeds close to
16m/s. This will need to run for a
set amount of time to achieve
accurate results.
Water will need to be supplied to
match this rate.
This table below is an initial map of values and metrics associated with a facility of this size to
accommodate a drone of median dimensions. The cost is plotted also at a median for the components or
estimate of length of material.
2
SF – Significant Figure, to which the dynamic flow systems will be designed to meet.
25
Table 14 Table showing initial feasibility technical specifications and metrics.
Feature
Length
Highes Chose Unit
t
n Value
1.5
5
3 M
Width
0.5
1.5
1 M
Initial Dimensions
of Test area
Length
Height
1
1
1 M
Width
2.5 M
2000
Paddin
g
0.5
1
0.75 M
Height
0.9 M
2000
Water
Speed
Flow
CSA
Flow
rate
Numbe
r of Jets
used
Flow
rate per
jet
Mass
Flow
rate
Lowest
5.15
25.91
Estimate Cost
Value
Unit
s
4.5 M
Total 2D area
11.25 M^2
16 M/s
Total Volume
10.125 M^3
2.25 M^2
Total Volume
10125 L
36 M^3/
s
2
Mass
50000 Mass
0
Estimat
e Cost
3000
10094.62 KG
5
11.2613 T
18 M^3/
s
35892 M^3/
s
Water usage for
60 seconds of
runtime
In Tonnes
2153520 M^3
2153.52 T
See appendix for an initial map of the electrical requirements taking average energy considerations of
similar products. The mention of power regen is including in the design a system of slowing down the
accelerated water and using the kinetic energy of this water that is no longer needed to power an electrical
regen system to recuperate some of the power. This can reduce operational cost.
3.2 Financial Feasibility
Sensor systems
26
Propulsion
Force on body
Temperature
Power Drawl
Speed
Drag
Barometric Pressure
Humidity
State of charge (SOC)
Battery temperature
Hull Strain
Vibration
Tilt or Capsize
Initial Estimate BOM
Initial Estimate Cost for hours run
Hall effect for RPM
Load Cell
Thermistor
Power Meter
Dopler Property Log
RPM
N
Degrees
W
?
1000
2000
200
1000
10000
Barometers
Hygrometers
V and I sensors.
Battery Man System
Load Cell
Accelerometers
IMU Sensor for roll.
PA
?
V/Amps
Various
N
M/s, Degrees
Degrees
500
250
1000
1000
5000
2000
5000
535950
32404.1
3.3 Risk Analysis and Mitigation
The facility will involve a combination of hydrodynamic testing apparatus such as the water jets as well as
electrical systems for co-ordination and sensing. Due to this being an industrial apparatus, it could be
rated with up to 415 volts, three phase power supply. One major risk is the exposure of these systems with
the hydrodynamic test facility. This could result in serious malfunction involving working personnel. This
design must be ensured to produced safe operation in all states. How this could be done is through
waterproof housings for all the high voltage equipment as-well as well-maintained seals and sealant to
insulate the two dynamic mediums. Regular maintenance and calibration of these systems can be
implemented to ensure all systems are checked and up to date.
Another risk is the forces that act on the drone in testing. In accordance with my project proposal vision for
my design, there will be required a drone fastened to the frame so the water can pass through the design
for accurate testing. This water will be travelling at significant speed, and measures will have to be taken to
ensure there is contingency, and safety measured for this. The rig could also include real-time monitoring
to detect excessive strain on the frame itself and provide feedback on the frame. In addition, the
continuous exposure of individual components to turbulent and high-speed waters may involve erosion to
critical equipment so measures will need to be taken to ensure that this is not fatal to the safety of staff or
equipment.
Due to the large scale of this facility, there will need to be such government re-enforced measures for
safety such as power cutoffs, controlled access and structural integrity assessments regularly. A machine
that could be beneficial to government and military bodies could produce valuable and confidential
information that will need to be taken into consideration when designing and planning.
27
3.4 Environmental Conditions
This facility differs from previously designed facilities in being smaller and more cost/material effective –
carbon footprint and damage to the environment are specifically important however as there is a strong
market pull for products that can suite this classification. Overall impact of the facility must be kept to a
minimum through measures such as material selection, physical size and impact on the surrounding land
as-well as water supply and discharge from facility.
This facility involves speeding water to real world conditions to test USV hulls and internal systems – this
water will need to be gathered to supply the jets and then once test is complete, discharged into either a
cycle back to an original tank or discharged into a near man-made or natural body of water. If released into
the natural body of water, it will need to meet the parameters required by governing bodies to ensure no
chemicals offensive materials are reassessed with it.
Energy usage in this facility will increase its overall effect on the environment over its lifetime – solutions for
recycling energy or minimising facility power consumption must be taken to improve customer value and
overall CO2 footprint
3.5 Customer Requirements Map
Table 15 Table showing requirements as a product of market research and feasibility study.
Requirements
Table
Specification
Functionality
Performance
Reliability
Safety
Accuracy
Efficiency
Innovative
Maintenance
28
Point
Requirements
1
1.1 Must be able to accurately test device at 60% of median device top speed
for time sufficient to gather accurate data.
1.2 Must be able to run the test on the USV for 30 mins to 1 hour up to 4 times a
day. Must use majority off shelf components
for quick and efficient replenishment of parts and understanding of part
reliability ratings.
1.3 Must be compliant with safety standards to ensure electrical and
hydrodynamic interface safety - IEC 61508, ISO 26262:2018,
ISO 8068:2014 ISO 12100:2010, BS EN ISO 13849-1:2015, ISO 13850:2015
1.4 Must be able to recreate at least 85% of the normal working conditions of
up to 30m/s water speed and take accurate results
with measurements from equipment with accuracy of +/-2%
1.5 Measures to be taken to reduce running cost per test. Measures to be taken
to reduce initial cost of facility. Measures to be taken to
reduce total water consumption.
1.6 Be able to accommodate AI infrastructure on the USV and when collecting
data points from measurement apparatus.
1.7 Where possible, use off shelf components from reliable manufacturers
with comprehensive datasheets. Regular but minimal
maintenance.
Materials
Size
Scope
1.8 Ensure all materials are - corrosion resistant, waterproof, non-absorbent,
safe and sustainable.
1.9 Facility must be able to accommodate for median size USV with
dimensions of 3x1x1m
2
Production
Type
Purchase Cost
2.1 To be suitable for small batch production - 10-20 units.
Maintenance
Cost
Availability
2.3 No more than £1k per day in operational cost including energy
consumption, water consumption and operational staff.
2.4 Minimal turnaround time between tests. Effective removal of USV and
preparing for next test. To be run 5 weekdays, 36 weeks a year
- 180 days annually.
2.5 Make use of pre-fabrication, site construction to take less than two months
and prefab construction to take between 3-6 months. Total time from 5-8
months.
Construction
Time
Market
Coherence
USP
Target Market
Compliance
and
Regulatory
Future Trends
2.2 Between 1-1.5 million over entire lifetime
3
3.1 Ensure fast turnaround and rapid test to reduce cost of test and waiting
time. Ensure all costs are kept as minimal. Ensure rapid delivery
and operational timeframe.
3.2 Only for UK sale and use for research, defence and commercial
applications.
3.3 Be adherent to UK standards for electrical, autonomous, hydrodynamic
and locational regulatory bodies (coast guard and council).
Adaptability
Allow for AI infrastructure. Allow for infrastructure to test autonomy levels
of vehicles and simulate navigational working conditions.
3.5 Customer had need to test own/colocation USV technology. Own facilities
for manufacturing and development with workshops and
repair facilities with proximity. Sustainable power infrastructure.
3.6 Allow for configurability in performance, dimensions and energy usage.
Support and
Training
Sustainability
3.7 Electrical Systems technician, hydrodynamic systems technician and data
and systems performance technician.
4
Durability
4.1 Must be able to run for 180 days annually with maintenance checks 3
monthly. Ensure calibration for systems and alert for systems
malfunction.
4.2 Parts and components from sustainable sources and material selection
with renewable and safe materials prioritised.
4.3 Must be able to recycle water consumption and access water from
sustainable sources. Electricity consumption reduces and where
possible from renewable sources
Customer
Infrastructure
Lifetime
Operation
29
3.4
Waste
Reduction
4.4 Easily powered off and automatic standby mode. Monitors of water and
energy consumption. Reuse water for multiple tests. Use energy
regen technology. Ensure all components are energy efficient. Include
access to renewable energy.
End of Life
4.5 Use recyclable materials e.g. metals, long life plastics where needed and
no adhesives or non-reusable joints. Easy disassembly and
material segregation. Minimalize effect on physical area and surrounding
area.
4 Product Design Specification – Shortened Copy
Table 16 Product design specification (Shortened, full in appendix.)
Product Design Specification
Requirements
PDS Value
Value
Performance
-1
Geometric
(G)
Objective
(G)1.01
1.1
(G)1.02
1.1
(G)1.03
1.1
Allow for
sufficient
movement of
drone
Fit average size
of USV (length)
Fit average size
of USV (width)
1.1
Fit average size
of USV (Depth)
(G)1.04
Metric
Test area padding of 0.51m
Test area will be
between 4 and 5m long
Test area will be
between 2 and 3m wide
Test area will be
between 1.5 and 2m
wide
Value
Unit
0.5<x<1
m
4<x<5
m
2<x<3
m
1.5<x<2
m
25
m/s
30
m^3/s
1000
Tonnes
Dynamic(D)
(D) 1.16
1.4
(D) 1.17
1.4
(D) 1.18
1.4
30
Simulate water
moving at 60%
of average USV
top speed
Sufficient water
us supplied to
pumps
Water must be
held and
supplied as
requested by
pumps
Water will flow at up to
25m/s
Flow rate can reach 50
meters cubed per
second
1000 tonnes of water on
hold for each test
(D) 1.19
1.4
(D) 1.22
4.3
Test must last
for sufficient
Test must run for no
time
more than 1 hour
Be suitable for use with natural water
accounting for salt and PH differences
1
Hour
Scope - 2
Market Coherence - 3
3.01
3.2, 1.3
Only for UK
sale and use
3.02
1.3
Only for UK
sale and use
3.03
1.3
Only for UK
sale and use
3.04
1.3
Only for UK
sale and use
3.05
1.3
Only for UK
sale and use
3.06
1.3
Only for UK
sale and use
3.07
1.3
Only for UK
sale and use
3.08
1.3
Only for UK
sale and use
3.09
3.1
31
1.3
Only for UK
sale and use
1.3
Only for UK
sale and use
Ensure all safety
standards in the UK are
met
Ensure that all
integrated systems are
safe and meet the
relevant standards
Ensure all water jet
technology is coherent
with the UK standards
Ensure all water jet
technology is coherent
with the UK standards
Ensure all standards for
vibration and
mechanical oscillation
are complied with
All propulsion systems
integrated systems are
in accordance with UK
standards
All electrical systems
are commissioned and
signed off - complying
with UK standards
Autonomous system
control is up to UK
standards
Electrical systems are
checked and
commissioned and
operate under UK
standards and law
Environmental
standards are met
including gasses and
waste produced
ISO
12100:2010,
BS EN ISO
138491:2015, ISO
13850:2015 N/A
ISO
11161:2007
N/A
ISO
9763:2004
N/A
ISO
8068:2014
N/A
ISO 26311:1997
N/A
ISO
14222:2017
N/A
IEC 61508
N/A
ISO
26262:2018
N/A
ISO
9001:2015,
ISO
17025:2017 N/A
ISO
14001:2015,
ISO 140641:2018
N/A
3.11
1.3
Only for UK
sale and use
3.12
1.3
Only for UK
sale and use
1.3
Only for UK
sale and use
3.13
3.14
3.15
Steel work is in
accordance with UK
standards for sea
mounted steel
framework construction
Fastening systems of
USV are sufficient with
UK marine standards
Steel structures in
facility framework are in
accordance with UK
standards.
ISO 199011:2015, BS
59501:2000
N/A
ISO
13686:2001
N/A
BS EN 19931-1
N/A
Be able to regen 20-40
percent of power per run
20 to 40
Percent
Include Standby more
for apparatus
N/A
N/A
Use test area water for
plumbing, heating and
personal facilities
N/A
N/A
Draw water from rain,
nearby bodies of water
and discharge
responsibly
10 to 20
Percent
Sustainability - 4
4.02
4.4
4.04
4.4
4.05
4.06
4.07
4.08
4.09
4.4
4.4
4.4
Be able to run
from renewable
energy source
Be able to
utilise regen
power
capabilities
Be able to
reduce energy
use where
possible
Use water from
test tank area
for facility
utilities
Harness
naturally
occurring water
to reduce water
grid
consumption
Allow for power from
210v UK mains or 450v
UK industrial mains with
green power linkage
Safety - 5
All electricity
components be
waterproof to IP67
5.02
5.03
32
1.3
Control station
to be placed
close to test
area
UK
waterproofing
standards
IP67
5.07
1.3
5.08
1.3
5.09
5.1
1.3
Use treated
steel or plastic
to ensure no
water
contamination
Include ladder
access to all
components
Pipes to be
enclosed in
building
N/A
N/A
N/A
N/A
N/A
N/A
5 Early Design Stages
5.1 Subfunctions Breakdown – Functions Means Analysis
This chart displays the features contributing to the successful simulation of high-speed water environment
in the tank. This next section will break down each function into functions and means to begin allocating
components and systems to each function.
Figure 13 Initial analysis of functions and their relationship to one another.
33
Figure 14 Morphological analysis and breakdown of functions and apparatus,
Experimenting with different combinations of functions and means.
Table 17 Experimental type of function solution selection to be sketched.
Column1
General
Layout FM
Table
PDS Point
1.01, 1.02,
1.03, 1.04
Column2
General Layout FM
Table
Column3
Column4
Column5
Column6
Function
Fit median size USV
Means
Steel
Framework
Fit in cargo
contained
Aluminium
Frame
(D) 1.16
Simulate water moving
at 60% of average USV
top speed
Sufficient water us
supplied to pumps
Gravity
Water Jets
Steel Reenforced
concrete
Cavitation
tunnel
Take water
from natural
body
Tank above
pumps
Collect Rain
Mains Water
Hybrid of all
three
Tank
underground
Tank level
with pumps
Crane to lift
from above
Ethernet
based data
transmission
Opening at
rear
Fiber-optic
communicati
on
Opening at
side
Tethered
Data Links
On-demand
from water
body
Opening at
front
Serial
Communicati
on
(D) 1.17
(D) 1.18
2.03
7.01-7.2
34
Water must be held and
supplied as requested
by pumps
Move USV in and out
rapidly
Receive data in live time
from the USV
Tow Tank
7.01-7.2
Human Interface
Direct PC
SCADA
7.01-7.2
Interface live data from
USV
Data storage
Slow water after test
Analog
Interface
Local Storage
Turbine
Database
Logging
Cloud Storage
Pump up
vertical tube
7.01-7.2
3, 4, 5,
Cloud
Dashboard
LabView
Hybrid
Eject water
below
surface
Custom GUI
Offline storage
Extract bottom
water surface
This is a function means table regarding the overall composition and functionality of the facility. Different
functions for different systems and ways of achieving will be designed and evaluated in the next section to
achieve the most optimised design for the specific requirements.
5.2 Concept 1
Below is a string of concept ideas all relating to the shipping container idea. Components and systems are
not described – only the general composition of the sub-systems fitting inside the rectangular box.
Figure 15 Design of composition to fit within cargo container to reduce cost.
35
5.3 Concept 2
Figure 16 Initial sketch of composition and functions need met.
This design above is describing the offshore design where the test rig takes advantage of the natural water
body as its water source – this allows for more water storage and a more streamline and efficient design.
36
5.4 Concept 3
This image is a combination of means dedicated to reducing overall power and water consumption. It
utilises a closed water loop system and partial water acceleration due to gravity through mounting the
water tanks above the test area. The tank area itself is closed with an open top allowing for crane outside
the area for lowering and removing the USV from the test area.
1
2
3
4
5
6
37
This design includes a tank mounted above the tank – using gravity to create lower threshold
pressure for the pump to function. This could allow a higher output spec pump.
This tank is held with a steel frame, could prove unstable when mounted outdoors. The steel would
need to be fastened correctly to ensure all movement in winds etc, is relative to the tank to avoid
fracture in the connecting water pipes.
This design includes two separate pumps for each leg of the manifold coming from the vertical tank.
Each pump would be controlled identically with the ability to throttle independently.
The main test tank is positioned in the body of water off the coast. This would ensure a pressure
equilibrium with the test tank and balance forces when designing further. The outside of the tank is
structural steel frame.
The rear of the tank could slow down the water using a regenerative braking system. The kinetic
energy from the water transferred to electrical energy to power the pumps.
The USV could be moved using a simple shop lift separately mounted to the ground to reduce cost
and complexity of design.
5.5 Concept 4
This system is dedicated to reducing electronic control and components and ensuring analogue function
and control. The control room is larger. There is only one tank and still two pump configurations for manual
control. There is a hinge in the side of the test area for removal and placement. The water level in the test
area is at the height of the water outside the test area – when the hinge opens, water is allowed in and out
to level the test chamber and fill the tanks.
1
2
3
4
38
This design houses the tank level with the test tank. The outlet for the water is at the base to
achieve the inlet pressure for the tanks.
This is a two-pump design. There is a pump for either inlet manifold. This allows for accurate
control over the inlet speed of water.
The test tank is a steel frame design, with an opening out the side of the tank to release and
insert the USV test subject.
The water tank and control room here are designed to fit inside a cargo container. This is to
reduce cost for the design and surface of land to position this facility on.
Figure 18 Concept design idea for two stage pump design.
Figure 17 Python program maping the ideal velocity change over the 4.5m length of tank.
This design shows the composition of positioning the test tank between two pumps. These two pumps are
connected at opposing functional directions. The first tank accelerates water into the tank which
immediately begins slowing down when turbulent like flow is created as shown in the graph idea, when this
water with one pump design would begin slowing down to 0.31m/s, the low pressure in the second pump
begins to assert a force on the flowing water again which accelerates again into the second pump.
Recommendations – Ensure that the pumps can withstand the high flow rate and velocity. Prove that there
will be enough low pressure to influence the moving water into the tank.
39
Figure 19 Inlet manifold for water into and out of the tank.
This design is an early idea of the delivery method from the pump exit to the tank. The design is a manifold
with three hollow pipe sections that ensure as laminar flow as possible to the inlet of the tank. This could
be married with a nozzle or flat exit to mimic the hydrodynamic movement of USV working conditions. The
join to the pump exact geometry will need to be derived from the pump chosen after further calculations.
Recommendations – Find optimal curvature amount of exit pipe sections into the tank. Find optimal
geometry for water flow to maintain speed while spreading out. Ensure pipe joins to pump and tank are
suitable to reduce leakage. Specify material chosen.
6 Material Analysis
6.1 Test Tank
GFRP3 is the primary material choice of the test tank. This is mainly due to its unique moulding ability to be
layered, and vacuum moulded to form complicated shapes. Another key property is the resistance to
varying levels of salt in the water it can withstand corrosion which lowers the specification of water
3
GFRP - Glass fiber reinforced polymer.
40
required to circulate this system. The mechanical properties of high mechanical strength and yield stress
as well as being slightly flexible when compared to other non-composites to provide dampening when in
the system with two pumps oscillating. Despite requiring labour cost to make such a part – the batch
production expectation of the facility is more closely suited to a mould less manufacturing process with no
costly die.
Figure 20 Granta Edupak analysis on CFRP and GFRP relating price and yield strength.
This graph shows the difference in cost VS the yield strength of carbon fibre composite and glass fibre
composite. Due to this project highlighting optimisation and cost reduction, the carbon fibre composite is
disqualified from the material selection as the cost does not outweigh the mass reduction.
6.2 Pipework – Material Suitability Matrix
This table is a breakdown of the top three most common steel used for pipe flow with un-controlled water.
The main factors that will decide the suitability are those that align with the design brief of lowering cost,
ease of manufacture and ease of acquisition.
41
Table 18 Table showing evaluation of steel pipework material selection.
Material Selection for water
pipes
Property
ASTM A53 Grade B
EN 10255
Stainless Steel 304
Material Type
Carbon Steel
Carbon Steel
Austenitic Stainless Steel
Common Use
Water, Steam, Air
pipelines
Water Gas, Fire,
protection
Drinking water and corrosive
fluids.
Corrosion Resistance
1
1
3
Yield Strength
3
1
2
Weldability
2
2
3
Galvanisation
1
1
3
Cost
3
2
1
Common at 500mm Dia
3
3
0
Standards
ATSM A53 / A500
Suitability Results
EN 10255
13
ASTM A312 / EN 1.4301
10
12
SUITABILITY RESULTS
Stainless Steel
34%
ASTM 53 Grade
B
37%
EN10255
29%
Figure 21 Pie chart showing weighting of properties against material properties.
The results of this material selection are that the ASTM A53 Grade B steel is the best suited for the purpose
and at the lowest available cost. This is a low budget carbon steel with excellent yield strength in alignment
with its purpose as well as good weldability for ease of assembly. The corrosion resistance is relatively low
however for this application the variation in PH from any water is negligible when using steel pipework.
42
The pipework will be made from one type of steel to reduce manufacturing suppliers and assembly
complexity. This will reduce overall cost.
The steel frame supporting the tank will be made from S355J2 rectangular hollow section. The dimensions
of which are calculated in the section further in this report. The material is chosen for its high strength and
easy weldability and is commonly used for high load bearing applications. S355J2 is a non-alloy structural
grade that complies with EN10025. Due to the frame possibly being located outside for its lifetime – this
steel is optimal as it supports structural integrity under cold conditions and impact resistance from the
environment.
Figure 22https://steelnavigator.ovako.com/steel-grades/s355/
These steel sections are produced to delivery following these processes: hot-rolled, annealing,
normalised, quenched and tempered
7 Subsystems Design Process
7.1 Water Tank
To find the optimal Tank design, the parameters and cost were calculated for tanks of different shapes all
with properties to match the PDS.
Table 19 Table showing requirements for the test tank.
Shape
Unit
Rectangle
Square
Length 1
Length 2
Perimeter
Area
Volume
Water Fill Cost
Frame Calculations
Length Steel Frame
Estimate Cost
Total Weight
M
M
M
M^2
M^3
£
4.5
2.5
14
11.25
10.125
19.95233
4.5
4.5
18
9
8.1
15.96186
14.13
15.89625
14.306625
28.19263523
2.25
3.75
14.35
19.90625
17.915625
35.30453063
M
£
Kg
11.09025
609.9638
166.3538
16.94925
932.2088
254.2388
13.96220625
767.9213438
209.4330938
14.81675625
814.9215938
222.2513438
43
Circle
Curved
Rectangle
2.25
This produced the following graph of estimated cost and weight for each shape.
COST AND WEIGHT OF EACH SHAPE TANK
Estimate Cost £
1000
Total Weight Kg
932.20875
VALUE
800
600
767.9213438
814.9215938
609.96375
400
200
166.35375
254.23875
209.4330938
222.2513438
CIRCLE
CURVED RECTANGLE
0
RECTANGLE
SQUARE
SHAPE
Figure 24 Breakdown graph of geometry and their weight and price respectively.
Figure 23 Image showing proposal for Stream data collection app.
From this, the decision was made to opt for a rectangular tank with dimensions of 2.5x4.5x0.9m deep. By
using a smaller depth In the test chamber, the water usage can be significantly reduced and therefore
energy consumption and overall efficiency can be increased. Using a shallow tank shaped to the median
shape of a boat hull under water instead of a rectangle can reduce the cross-sectional area the water
needs to flow across to simulate high speed water flow.
44
The tank will simulate the flow of the USV in water – this water is only required at the interface with the USV
and not needed in the corners as shown below.
Figure 25 Proposal sketch for test tank optimisation.
In order to effectively remove this empty space and improve efficiency of the water flow, data was required
on the shapes of boat hulls. A python program was developed to complete this task quickly and accurately
for a large dataset of pictures of USV hulls. The program would utilise the MATLAB python development
library (MathWorks, 2015)and some GUI libraries to allow a graphical overlay on the graph. A X^2 parabola
was drawn on top of the image and sliders were used to change values of A and C (In form Ax^2+Bx+C – B)
was not required as this changes the Horizontal intercept, and the image would be centred. The user is
then allowed to select any image and open it within the application. The sliders are manipulated to find the
best fit parabola and then the “Record data” button when the values are timestamped and recorded to a
.txt file where they can be imported into excel for graphical display.
45
This tool was used to test 60 images for their best fitting parabola and co-efficient for A value for the shape
of their hull. The results are displayed below.
Figure 26 Screenshots from STREAM parabola equator software written for this
project to gather data on ideal hull shapes and tank geometry.
From this graph, it was selected that an X^2 co-efficient of 0.17 would be slightly larger than the median to
allow for a small extra movement of the USV and more area for the water to flow – while reducing volume of
the test chamber.
This was then plotted in a graph shown below.Figure 28 Table showing what this ideal curve will look like.
A Co-efficient Value
A-Value
0.2
0.15
0.1
0.05
0
0
10
20
30
40
Image Tested (Random)
Figure 27 table showing plotted results from 35 tested images from STREAM app.
46
This body in the centre of the Y=0.9, X=+/-1.25 (test area width of 2.5) and f(x)=0.117x^2 parabola from the
python program results – gives the chosen cross-sectional area of the test area – the geometry of which is
calculated below.
Area between parabola and Y=0 line for positive values of X:
1.25
𝐿𝑖𝑚𝑖𝑡𝑠 @ 0, 1.25. ∫
0.17𝑑𝑥
0
0.17 ∙
𝐿𝑖𝑚𝑖𝑡 @ 𝑥 = 1.25,
𝑥 3 0.17𝑥 3
=
3
3
0.17(1.25)3
= 0.1107. 𝑁𝑜 𝑛𝑒𝑒𝑑 𝑡𝑜 𝑓𝑖𝑛𝑑 @ 𝑥 = 0.
3
𝐴𝑟𝑒𝑎 = 0.1107𝑚 𝑓𝑜𝑟 𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒 𝑣𝑎𝑙𝑢𝑒𝑠 𝑜𝑓 𝑋.
𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑖𝑠 2 ∙ 0.1107 ∴ 𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑓𝑜𝑟 𝑠𝑢𝑏𝑟𝑎𝑐𝑡𝑒𝑑 𝑝𝑎𝑟𝑡 𝑖𝑠 0.2214.
Total CSA of tank:
𝐵 ∙ 𝐻 = 𝐴 ∴ 2.5 ∙ 0.9 = 2.25𝑚 2
𝑆𝑢𝑏𝑟𝑎𝑐𝑡 𝑝𝑟𝑒𝑣𝑖𝑜𝑢𝑠 𝑎𝑟𝑒𝑎 = 2.25 − 0.2214 = 2.02𝑚 2 .
𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑖𝑠 2.02𝑚 𝑐𝑜𝑚𝑝𝑎𝑟𝑒𝑑 𝑤𝑖𝑡ℎ 2.25 ~ 10% 𝑣𝑜𝑙𝑢𝑚𝑒 𝑟𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛.
Below is a SolidWorks model of this optimised tank design.
47
Figure 29 Screenshot of SolidWorks model of tank design.
7.2 Hydrodynamic System design
To accelerate the water, I considered using one pump at one end to push water into the tank and one pump
at the other to create a low-pressure zone and pull the water. This could mean the test area could be
doubled with the same tank type and performance.
The decision was made to use a centrifugal pump as they are more suited for continuous and high flow rate
design implications and have more reliable output pressure and velocity performance curves.
To figure out the specifications of the pump I required, I used the following excel document.
Table 20 Table showing requirements for the water acceleration at discreet speeds 5-9m/s.
Pump Requirements:
Pump Into Tank
Flow Velocity
Ref.
Unit
Vo
m/s
5
6
7
8
9
Total Head
Ht
m
0.5
0.5
0.5
0.5
0.5
Total Pressure
Pt
Pa
4905
4905
4905
4905
4905
CSA Tank CSA
CSA
m^2
1.02
1.02
1.02
1.02
1.02
Volumetric Flow Rate
Q
m^3/s
5.1
6.12
7.14
8.16
9.18
48
Proportion of tank
flow required
Volumetric Flow Rate
into tank
Volumetric Flow Rate/
min
Volumetric Flow Rate/
hour
Individ Pipe Flow Rate
Q
Q/min
0.2
0.2
0.2
0.2
0.2
m^3/s
1.02
1.224
1.428
1.632
1.836
m^3/min
61.2
73.44
85.68
97.92
110.16
m^3/hour
3672
4406.4
5140.8
5875.2
6609.6
0.34
0.408
0.476
0.544
0.612
Q/min
Due to the relatively massive flow rate at 9m/s, and the limit of pumps on the market, the water will be
accelerate after the pump by a factor of 2 using Bernoulli’s and the continuity equation. By reducing the
exit nozzle of into the tank by a factor of 2.
𝐶𝑜𝑛𝑡𝑖𝑛𝑢𝑖𝑡𝑦 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛: 𝐴1 ∙ 𝑉1 = 𝐴2 ∙ 𝑉2
𝐴2 =
𝐴1
𝐴1
, 𝑆𝑢𝑏𝑠𝑡𝑖𝑡𝑢𝑡𝑖𝑛𝑔 𝑔𝑖𝑣𝑒𝑠, 𝐴1 ∙ 𝑉1 =
∙ 𝑉2
2
2
𝑆𝑖𝑚𝑝𝑙𝑖𝑓𝑦𝑖𝑛𝑔 𝑔𝑖𝑣𝑒𝑠, 𝑉2 = 2𝑉1, ℎ𝑒𝑛𝑐𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑖𝑠 𝑖𝑛𝑐𝑟𝑒𝑎𝑠𝑒𝑑 𝑏𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 2.
This will ensure that at a constant flow rate, the velocity will increase by 2 times allowing the volume flow
rate at 9m/s to be ½ of the value in this table at 3304.5m^3/hour
This pump is the BABA400D centrifugal pump. (Tapflo, 2023) see Appendix F.
Table 21 table showing specification of tank selected for purpose.
Max Flow
Max Flow
Max Flow
Max Head
Outlet Dia
Solid Handle Capacity
Max Speed
PTO
Weight
PTO Dia
Angular Velocity
Torque
Max Allow Torque capacity
Cost
49
m^3/h
m^3/min
m^3/sec
m
mm
mm
Rpm
kW
kg
mm
rad/s
Nm
Mpa
£
3000 DN
50
0.833333333
2.316
500
100
1000
125
3500
34.93
104.6666667
1193.659282
142.57
65K
7.3 Mechanical System Design
This pump requires a torque to control the water flow, to find the type of apparatus used to create this
rotational motion, multiple possible solutions where evaluated.
Pros
Cons
Electric Motor
- Very high efficiency
- Precise and easy to
throttle
- Low maintenance
- Instant installation
-
Requires
infrastructure
Requires electricity
Can be expensive
when waterproofing
is required.
Outcomes For this purpose, the
electrical motor provides the
most efficiency and
reliability for the least cost
and independence from
external factors such as
temperature, vibration and
water. This is especially
important in AC induction
motor where the magnetic
fields are oscillated to move
the rotating component and
waterproofing is less critical
to its use.
Internal Combustion
- High power
density
- Portability is high
-
Low efficiency
Complex control
High
maintenance
- Heavy
- High operational
cost.
For this purpose, as a
monitoring system – the
vibration and heat that is
created from an ICD
driven pump does not
counteract the highpower density and
relatively low startup
cost, This vibration and
heat from the engine
can cause data
disruption and decrease
the reliability of the
machine.
Hydraulic Pump
- Smooth torque
output
- Very practical
- Low environmental
impact
- Very reliable
- Requires
infrastructure
- Initial cost is high
- Can produce noise
and vibration
This system for driving the
water tank, despite its
smooth output and
relatively high-power
density, requires the even
more water flow and
storage for infrastructure.
To reduce build and
operational complexity of
this facility – it becomes
more reasonable to not
include hydraulics in the
pump mechanism.
Table 22 Evaluation of rotational force generation techniques for pump power.
7.3.1.1 Pump – Tank Interface Design
This pump has exit properties of diameter 500mm. It has input properties of 3x 30mm diameter input
pipes. For this to create high pressure at one end of the tank and low pressure at the other, there will need
to be a manifold converting pump exit to three nozzles, then sucking one nozzle into three input holes. This
is shown below.
50
Figure 30 Initial design of water exit manifold.
This is an early design for this component, specifying geometrical limits and requirements. This will require
simulation and optimisation in geometry, manufacturing method and integration in the design. This is
completed later in the report.
7.3.1.2 Transmission Calculations
To find the optimal specs for the AC motor to power the pumps, we take the data from the pump
datasheets and work backwards. Below is the specs from the pump’s datasheet.
Table 23 Table of properties required from the torque powering the water pump.
Property
Max Flow
Max Flow
Max Flow
Max Head
Outlet Dia
Solid Handle Capacity
Max Speed
PTO
Weight
PTO Dia
Angular Velocity
Torque
Max Allow Torque capacity
Cost
51
Unit
m^3/h
m^3/min
m^3/sec
m
mm
mm
Rpm
kW
kg
mm
rad/s
Nm
Mpa
Value
3000
50
0.833333333
2.316
500
100
1000
125
3500
34.93
104.6666667
1193.659282
142.57
65K
The calculation for torque is below,
𝑃𝑜𝑤𝑒𝑟 = 𝑇𝑜𝑟𝑞𝑢𝑒 ∙ 𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦,
𝜔=
∴
𝑃
= 𝜏
𝜔
2∙𝜔
2 ∙ 1000
125,000
,=
= 104.67. ∴ 𝜏 =
= 1194𝑁𝑚
60
60
104.67
Figure 31 Selected water pump.
This is the AC electric motor chosen to drive both centrifugal pumps. The specifications are below.
Table 24 Table showing the specification of per-made AC motor.
Attribute
Motor Type
Value
3 Phase 132kW 6 Pole Cast Iron Motor
Mount Type
B3 / Foot
Rotation Speed
980 / 1176 RPM
IP Rating
IP55 (IEC 60034-5)
Efficiency Class
IE3 High Efficiency
Insulation Class
F
Temperature Rise Class
B
Duty Type
Continuous duty: S1
Torque Output
1286.3 Nm
Max Current (Delta)
243.55 A
Max Current (Star)
140.61 A
52
Efficiency at 100% Load
95.40%
Efficiency at 75% Load
95.70%
Bearing (DE)
NU319 C3
Bearing (NDE)
6319 C3
Cable Glands
2 x M63 x 1.5
Thermal Protection
PTC 140 Degrees
There will not need a gearbox between the two as the rpm and torque of the motor is sufficient with a
overpower margin. The rpm can be electronically controlled to not exceed the maximum RPM of the pump,
and the extra cost is not worth gearbox development. However, the interface will require a shaft with a
couple.
7.4 Water Storage Design
The hydrodynamic water movement will be created by two pumps. One will push the water into the tank,
the other will suck water from the other end of the tank. To calculate the water required to be stored, first
must be calculated the time taken for water to leave the test-tank, travel back to the storage tank and back
into the pump.
Table 25 Table showing geometrical and dynamic requirements of water storage tank.
Re-circulation Calcs
Length
m
Total pipe Distance
Pipe Dia
Pipe Area
Flow Rate
Velocity
Time Taken to return water
m
m
m^3
m^3/Hour
m^2
s
4.5
13.5
0.5
0.19625
0.833333333
4.246284501
3.17925
This would then be used to calculate the extra volume needed to provide water for this down time.
53
Table 26 Calculations to find optimal water storage capacity.
Required Run Time
Time to cover and
hold water for
Water Used In this
time
s
3600
3600
3600
3600
3600
3.17925
3.17925
3.17925
3.17925
3.17925
m^3 3.242835 3.891402 4.539969 5.188536 5.837103
Continuity
multiplier
0.1
Extra time
s
72
72
72
72
72
Extra Water
m^3
73.44
88.128
102.816
117.504
132.192
Tank Capacity
m^3
0
0
0
600
700
0
0
0
600000
700000
Tank Capacity L
From this set of calculations, it is decided that the tank be ran at 8m/s for an hour would require 6x10^5
m^3 of water, or 9m/2 for an hour with 7x10^5 m^3 of water. A tank with this much storage is significantly
higher cost that makes the part of this project to reduce cost not possible. Instead, it Is unlikely the test will
be run at 9m/s for this amount of time continuously therefore at 9m/s we will reduce the run time to only 30
mins and ensure that the tank is ample for this. This considers acceleration and deceleration of the tank.
The tank would have to store enough water for 10% of a 1hr run, using recirculation to provide the rest. The
capacity would need to be >550,000l. See Appendix Fi.
Figure 32 Chosen GFRP pre-made water storage tank.
54
Table 27 technical and geometrical specifications of storage tank.
Category
Details
Tank Capacity
615,984 Litres
Tank Diameter
16590mm (54ft)
Overall Height
3040mm (10ft)
Outlet BSP(M) Sizes
1", 2", 3", 4"
Gate Valve BSP(F)
Available in 1", 2", 3", 4"
Copper Float Valve Set
Available in 0.5", 0.75", 1", 1.25", 1.5", 2"
Pre Drilled Inlets
Available in 1", 2", 3", 4"
Outlet Position & Number
Decided by customer
7.5 Sensor Systems Design
Table 28 Table showing the sensors needed for reading, their connection and preferred interface type.
Sensor System
Sensor Type
Description
Force Guage
Measure thrust performance from
propulsion system
Load Cell
Measures strain on parts of USV hull
and predict fracture.
Data Received
Digital Date Received
Connection Interface
USB
Guage
ADC to
USB
Guage
ADC to
USB
USB
Guage
Voltage Meter
Measure temperature of water in
system.
Measure power drawn by entire facility
Analog Voltage - can be
put through ADC to
digital output
Analog resistance
change
Analog Value
Amp Meter
Measure power drawn by entire facility
Analog Value
USB
Camera
Video stream
USB
Barometer
Capture normal to the USV and view
turbulence and water interaction with
USV in real time
Measures pressure in pipework
Pa (digital pressure)
I2C
Hygrometer
Measures air humidity in USV
Percentage reading
USB
Battery
Thermistor
Battery
Voltage
Battery Amps
Measures temperature of USV battery
Degrees C readout
USB
Load
guage
Percentage
Guage
Guage
Measures voltage USV power is running
on
Measures Amps drawn by USV onboard
battery
Voltage reading
USB
Guage
Current reading
USB
Guage
Thermistor
55
Analog and
digital
guage
Analog and
digital
guage
Stream
Accelerometer Measures vibrations and movements
inside USV
IMU Sensor
Measure rotation and vibration
onboard USV
Speed and axis
vibrations occurring
Digital Multi-axis
USB
I2C/UART
Graphic
Display
Graphic
Display
7.6 Additional Hardware Design
Figure 33 Design of basic splash cover for top of test tank.
This design is of a splash cover which curves up and into the centre of the tank. This is made from a simple
and hollow – non-structural plastic to be lightweight and simple to form. This component’s purpose is to
catch water splashes from turbulent flow or water jet collisions and act as a safety feature to protect the
electrical systems and personnel. This plastic cover is non-load bearing and will be supported with a steel
frame that must be sufficiently waterproof.
7.7 Simulation System Early-Stage Design
The simulation system is the umbrella term given to the GUI or control panel that controls and monitors the
device. This included the metrics received from the device and the control of water speed and following
systems. The requirement for this specific system is listed below.
56
Table 29 Calculations to show how information will be stored, how much storage is required.
Data storage requirements
Sample Rate
Number of Sensors
Data type
Logging duration
Format
Bytes Per second
Per test
Gig per Test
Camera Data
Camer Per Test
Total Per Test Total
Total GB per test
Tests per day
Days to hold storage
Total storage Capacity
Metric
Unit
100
Hz
18
No.
4
Bytes
60
Mins
Binary/Compressed
7200 Bytes
25920000 Bytes
25.92 GB
1 Byte/Sec
3600
25923600
25.9236 GB
8 Hours
7 Days
1451.722 GB
Float
1.5 TB
These calculations are to deduce the on-site storage requirements for 7 days’ worth of data at up to 1 hour
per test and max 8 tests per day. Once this 7-day period is over the client of the facility can export the data
collected with timestamped sensor readings in binary format to their personal storage. The policy of
holding 7 days maximum worth of data is to reduce and streamline the cost of the facility and ensure
customer usage is kept to a minimum impact to the hardware.
This was used to calculate the other requirements.
Requirements
Metrics
Units
Real time data
2<x<4
GHz
Data storage
1.5 TB
Be reliable
8 Hours/Day
Be easy to use and interface
7 Days training
Be Allow for inputs
Ethernet
Allow for outputs
Ethernet
57
Clock Speed of System
Table 30 Evaluation of interface types.
Interface
LabVIEW
Methods
Description Graphical programming
environment that’s
widely
used for engineering
tests for data acquisition,
control and real time
monitoring.
Python Interface
Web-based GUI
Matab App
Designer
Use python on Linux,
Using web-based Using the MATLAB
windows, raspberry pi
languages (HTML, user interface and
hardware and
Java,
downloadable
run python programs
CSS) to
program to
with the use of different
communicate
interface, measure
interface libraries.
with a backend
and monitor the
server
systems and
to display data.
results.
Positive
Large number of
Flexible and
Large number of
Quick to model,
hardware compatibility,
configurable, streamline different methods powerful plotting
plug and play
sensor integration with
for creating
and interface,
capabilities. Drag and
CAN and ethernet
and languages.
extremely reliable
drop GUI, real time and
connection. High
Python can cover and used in large
reliable data acquisition
hardware flexibility.
backend
numbers.
and storage.
Easy to plot with
development
external reliable
with large
libraries.
libraries and
support.
Can run on local
server.
Negative
Being a commercial
Basic and non-fluid GUI, Very complex
Not very open
software, initial costs can Manua setup and
stack compared
source or scalable,
be high.
lengthy sync
to other options,
not as flexible
Ecosystem is closed and
process to thread the
requires network
or configurable.
not as flexible with noninputs and outputs into
setup, more risk
NI hardware,
the system
included
not coding friendly and
reliably.
being web-based,
only works on
frontend learning
windows/Linux.
curve.
This is an evaluation of the most suitable interface methods using different platforms and configuration
types.
The outcome from this evaluation is that the most suitable option for the facility is using a web-based
interface which communicates with a local API using a combination of JSON and HTML language. The
reasoning behind this and its suitability for this project is the configurability of the system to comply with
specific companies developing their USV and for different purposes. With a database that collects the
relevant sensor readings from the test USV being accessed and controlled by a configurable GUI and
58
multiple GUI for different test purpose. This only requires the development of the API that stores the data
from the test and allows the customer to develop their own “dashboard”.
Figure 34 Infographic to show how data will be gathered and data logistics to interface and storage.
However, for the demonstrator, this system will convey the speed of the water and its control. For this
system – a scale representation running off no more than 12v – a Arduino interface with HTML embedded
and is most suitable as configurability and cost is lowest and can be done with minimal help and extra time
for this project.
7.8 Interface Concept Design
Requirements – below is a table of the individual sensors on the USV and their connection type with their
preferred interface type for the web-based GUI. This is a very early-stage design and not a part of the
system that will be completed in this report. Instead, it will be a relative black box for the system to come in
production or pre-production stage.
59
Sensor System
Sensor Type
Description
Data Received
Connection
Interface
Force Guage
Measure thrust
performance from
propulsion system
Measures strain
on parts of USV
hull and predict
fracture.
Measure
temperature of
water in system.
Measure power
drawn by entire
facility
Measure power
drawn by entire
facility
Capture normal to
the USV and view
turbulence and
water interaction
with USV in real
time
Measures
pressure in
pipework
Measures air
humidity in USV
Measures
temperature of
USV battery
Measures voltage
USV power is
running on
Measures Amps
drawn by USV
onboard battery
Measures
vibrations and
movements inside
USV
Measure rotation
and vibration
onboard USV
Digital Date
Received
USB
Guage
Analog Voltage can be put
through ADC to
digital output
Analog resistance
change
ADC to USB
Guage
ADC to USB
Guage
Analog Value
USB
Analog and digital gauge
Analog Value
USB
Analog and digital
gauge
Video stream
USB
Stream
Pa (digital
pressure)
I2C
Load gauge
Percentage
reading
Degrees C readout
USB
Percentage Guage
USB
Guage
Voltage reading
USB
Guage
Current reading
USB
Guage
Speed and axis
vibrations
occurring
USB
Graphic Display
Digital multi-axis
I2C/UART
Graphic Display
Load Cell
Thermistor
Voltage Meter
Amp Meter
Camera
Barometer
Hygrometer
Battery
Thermistor
Battery Voltage
Battery Amps
Accelerometer
IMU Sensor
60
Figure 35 Web-page GUI prototype to show layout of interface.
This is used to create an example interface with readouts from these sensor systems and control of the
whole system including the two motors.
7.9 Interface Description
7.9.1 Menu
This menu has 4 sub-menus including full gauge view, a full camera view from different angles (Appendix
ref), and a side USV graphic with the strain gauge positions. These can be clicked-through or be open on
different monitors of the system.
7.9.2 Gauges
These gauges here show values regarding on-board USV properties. They are giving a live readout with data
from the API that runs on the local machines and provides data to this interface. These can be percentage
or a value between maximum and minimum. Alongside is digital values.
7.9.3 Video Stream
These video streams are from the cameras mounted perpendicular to the USV in the water. They provide
high FPS recordings of the water interacting with the USV hull and can be used for AI image
training/monitoring to predict failure.
7.9.4 Sliders
These sliders are to control the motors which control the pump and the water speed. These can be
controlled digitally or manually on the site. They can be synchronized to ensure the water leaving the tank
61
matches the water volume entering or can be used one at a time for filling/emptying the tank. They have
readouts of water flow rate and speeds along with system calibration for these values.
7.9.5 Buttons
These buttons provide more control to the system allowing valves to be turned on and off and can be used
to control systems on the USV such as total power, navigation and radar systems and lights etc for more
reliable testing.
Figure 36Web-page GUI prototype to show layout of interface specifically strain gauge sensor systems.
7.9.6 Strain Guage status page
This page displays a graphic of the USV with green/red points where the strain gauges on the hull are
positioned. The colour can change from red to yellow and then red depending on how strained the gauge is
and how likely fracture is. With a mouse hover over, these will display values for each strain gauge and
percentages of total strain.
7.10 Control System Architecture Design
The pump is driven from an AC motor. This motor will be connected to the pump via the shaft on the pump
that originally allows for tractor drive train torque force. However, in this instance due to the specification
requirements for high configurability and low cost, will be driven from an electric motor.
Being an AC motor, it is built around the architecture of a motor with a stator around the outside with
multiple coils of wires that can be charged and discharge according to a set frequency. This frequency can
be manipulated to control the rate at which the rotator in the motor rotates and is magnetically attracted to
the next coil. – hence the motor will create torque. To control this motor as per the design specifications, a
fine control on the motor speed is required. There are two ways which we can vary the speed for the
hydrodynamic flow system.
7.10.1
Flow control valve system
This system requires a valve after the pump and can be opened and closed to reduce the flow rate and
slow down the water flow after the pump. This requires no extra infrastructure controlling the pump as the
62
speed control is a separate system that reduces the water flow after the pump and re-routes it back to the
storage tank.
Figure 37 Infographic showing a type of safety system to regulate pressure and water speed.
The downside of using this system is that calibration requires iteration and physical intervention and
therefore more room for operator error and maintenance. This increases complexity and operational cost.
Figure 38 Variable Frequency Driver
example
Table 31 table showing technical specification of VFD chosen for purpose.
63
7.10.2
Variable Frequency Motor Driver
Power Range
0.55 kW to 250 kW (0.75 hp to 400 hp)
Voltage Variants
Control Units
200V, 400V, and 690V
Various options including CU230P-2, CU240E-2, and CU250S-2, each
offering different functionalities such as standard control, extended
safety features, and advanced positioning capabilities
Power Modules
Options like PM240-2 and PM250, designed for specific applications
and offering features such as regenerative feedback capability
FSA to FSGX, accommodating different power and size requirements
Frame Sizes
Safety Integrated
Functions
Includes features like Safe Torque Off (STO), Safe Stop 1 (SS1), Safely
Limited Speed (SLS), Safe Speed Monitor (SSM), and Safe Direction
(SDI)
Communication Interfaces Supports PROFINET, PROFIBUS, Ethernet/IP, and Modbus TCP/IP for
seamless integration into various automation environments
Ambient Temperature
Typically, 0 to +50°C without derating; specific ranges may vary
Range
depending on the configuration and options selected
Protection Class
IP20 standard; higher protection classes available with additional
enclosures or specific configurations
This system of pump control uses a module that can interfere with the output frequency and control finely
with a simple interface for controlling the pump speed. This works by taking the mains voltage, in this case
using UK 240v at 50Hz AC supply, and converts to DC using a rectifier, DC bus and inverter. This outputs a
frequency and can be controlled by operator to vary the frequency on the output and can be used to speed
up or slow down the AC motor receiving the voltages. See appendix J, K.
For this application, minimalizing cost and efficiency, using the DC motor controlled by a VFD is more
practical despite its higher initial cost than using flow control systems, see appendix L and M. The VFD
chosen for this application must meet the 6-phase input for the AC motor chosen as well as the operating
voltage between 240-650v. With low-cost in mind, a suitable VFD is as follows.
7.11USV Fixing, Inserting and Removing.
In order too safely and quickly remove and insert the USV into the test area, there is a need for a lift system
that can lift and move the USV into the tank.
64
Figure 39 Initial sketch of movement system for USV into and out of the tank.
There are two suitable systems for this task.
Table 32 Evaluation table of lift and removal systems.
Point
Description
Image
65
Motorised Gantry
Using a supported beam with rail
functionality – as well as a
kinetic actuation that allows a
module to move laterally across
the rail and back.
Crane
Using a crane on wheels/pivot to
pick and place the USV in and
out of the tank.
Positive
Negative
Quick and safe, does not require
manual movement other than
connection. Exactly same
movement repeatedly. Can carry
larger loads.
Expensive installation, electrical
actuation in contact with water
is a risk. Requires mounting and
takes up larger space.
Cheap and simple to use and
install. Flexible movement and
positioning. Requires no
infrastructure in the facility.
If manually operated – risk of
injury. Non-repeatable
positioning may lead to
inaccurate placement in the
tank. Baseplate and roller might
need adjustment for USV load.
Despite the larger initial cost, using a Gantry system will produce more accurate results and at a quicker
removal and placement speed. The electric control system gives more configurability and less risk in
manual movement with the correct waterproofing. The design of a simple and efficient facility aligns more
closely with a motorised gantry system rather than a manual shop crane.
7.12USV Retention
The USV will need to be tested for high speeds and therefore will require suitable restraint in order for it to
not move in the tank when full thrust is engaged.
Figure 40 Early simulation on USV retention system.
66
This is a first stage design on a bracket to hold the USV with a standard chain loop to be mounted to the
frame at the corners (4x 1 on each corner). This design is made from titanium as the part is only small the
extra cost can be justified, and the high tensile strength is required. However, this part undergoes plastic
deformation at the FEA limit which is the top speed force to a SF of 1.5.
Figure 41 More developed model of USV retention with thicker material.
After increasing the thickness of the material used for this component, the stress distribution is reduced.
There is still large stress concentration at the base of the attachment ring, however. This was improved by
thickening this ring.
Figure 42 Optimised USV with thicker walls, material and chain loop.
67
Here the ring is double the thickness as the values of stress are reduced 10x. There is still stress
concentration however to the safety factor of 2 this entire part is suitable for use.
Figure 43 Difference in deflection for retention hook.
Here is a comparison of the optimised design for displacement reduction for this component. Despite the
top of the component still holding marginal deflection, the part as a whole is much better fit for purpose.
Deflection across object for USV retention.
6.00E+00
5.00E+00
4.00E+00
3.00E+00
2.00E+00
1.00E+00
0.00E+00
0
50
100
150
200
Optimised Design
250
300
350
400
450
500
Initial Design
This graph shows from front to back of the part, the deflection for each meshed node for the FEA study. The
initial design has much higher peaks with a higher frequency of peaks throughout. The optimised design
has much lower peaks and only one significant peak around node 200. This has far less density of extreme
nodes however than the other part.
7.13 Manifold Stress Analysis
One weak point on the frame is the join with the pump and the tank. These need tight positional tolerance
to ensure alignment and therefore displacement must be removed. This simulation below is a FOS plot
conducted using the finite element method. The constraints here are the load constraints assuming
uniform distribution of load under gravity from the weight of the manifold itself. The dynamic pressure from
water here is assumed negligible. This is a point for further development on the facility. This study
68
highlighted large stress concentrations allowing for the development of a frame to support the UDL
throughout the manifold.
Figure 44 Factor of safety plot on the inlet manifold.
Figure 45 Factor of safety plot on manifold with support frame.
This re-design met the required FOS of 3 that was decided upon for this component. There are significantly
less frequent and smaller stress concentrations that align with the thickest parts of the inlet manifold and
therefore the least likely to deform. This frame is positioned against the pump and tank frame – two large
and highly supported sections to allow effective load distribution.
69
7.14 Additional Component Selection
Table 33 Calculation for requirements of USV logistic apparatus.
Motorised
Gantry
requirements
Load
Metric
Unit
Distance
Reason
1400 KG
USV mass to safety factor 0.6
5 m
Tank width + attach to control
building + excess space for
load.
To be controlled by GUI or
manual control panel from
control cabin
To fit between test tank and
storage tank
Control
Electrical control
N/a
Optimisation
Least amount of space
N/a
Table 34 Selected motorised gantry with
specification on this project.
For this application, the most suited pre-made solution is to use this gantry system below.
This has the technical specifications below.
Figure 46 Data sheet for specific motorised gantry with specification.
With a 1600Kg lift limit it is suitable for the 1400Kg application of a medium to large USV. The span Is up to
5m (second collum) with a total mass of the system of 369Kg.
70
8 Optimisation and Simulation
8.1 CFD on Manifolds
Figure 47 Early CFD simulation on manifold pipe.
This simulation was created on SolidWorks using lid features on the openings of the manifold. The
boundary conditions consist of an inlet velocity of 9m/s in the -Z direction with three mass flow outlets in
the -Z direction. The pressure the outlet velocity would meet is equivalent to the water pressure of 0.5m
below surface – this is assumed at 5047 Pa.
71
Figure 48 Top view of CFD on early pipe design.
Here is an initial pipe flow CFD on the pipework for the inlet manifold. The conditions required and the
success metrics here are 9m/s exit speed from the three pipes. There must be as low turbulence and high
pressure as possible to ensure the water leaves laminarly and at as close to 9m/s as possible.
This photo above shows room in the pipe where water does not reach – the water is taking the path of least
resistance, and this does not match the geometry of the initial pipe design. Aswell, the water is
significantly slowing down when exiting the pipe to almost stationary. 4
With a pipe curvature re-design, the new pipe produced more suited results with the geometry matching
closer the path of least resistance. In addition, the new design incorporates a nozzle onto the end with a
reduction of 0.5m to 0.22m. This was calculated using the nozzle calculations for sub-sonic flow from
NASA website.
Table 35 Table showing geometry from NASA sub-sonic nozzle design equations for pipe nozzle.
Nozzle Diameter
Each
Nozzle Area Each
0.1525
0.1525
0.1525
0.1525
0.1525
0.018256156
0.018256156
0.018256156
0.018256156
0.018256156
Individual Pipe Dia
0.219073875
0.219073875
0.219073875
0.219073875
0.219073875
As shown in this flow simulation below, increased the velocity to 9m/s before leaving the end of the pipe on
all three of the outlet pipes. The CFD configuration and boundary conditions remain the same as the initial
72
test. The nozzle has ensured that the water velocity is increased to the desired velocity at 5047 Pa of
pressure in the test tank.
Figure 49 Optimized manifold design with nozzles on.
To validate this CFD model, a simplified analytical comparison was made using Bernoulli’s equation for
ideal fluid flow. Under the assumptions of internal water pressure and external pressure in the tank, as well
as the fluid being incompressible – the theoretical velocity was calculated. When compared, they
produced results within 8% deviation of this simulation. With this at worst case scenario, the outlet speed
is still acceptably above 9m/s.
73
Velocity Without Nozzle Optimisation
1.2
VELOCITY
1
0.8
0.6
0.4
0.2
1
5
9
13
17
21
25
29
33
37
41
45
49
53
57
61
65
69
73
77
81
85
89
93
97
101
105
109
113
117
121
125
129
133
137
141
0
POINT
Series1
Series2
Figure 50 Graph showing speed for simulation at the pipe split section.
This graph shows the speed changing in the centre of the manifold, when the single large stream splits into
three streams. Although not completely optimal, there is an increase in water velocity in this turbulent
section of the tube.
8.2 CFD on Test Tank
Figure 51 Top view of the tank in the model assembly.
74
This plan view shows the top of the tank with the triple inlet pipe section with a single larger exit manifold.
The water will flow from right to left, leaving the triple manifold at 9m/s to then leave with the same flow
rate with the section pipe with diameter 3x larger. The enclosure is not sealed and therefore the pressure
on the water will be atmospheric. Due to the tank curvature optimisation, the tank is only 0.9m at its
deepest and therefore there is a small pressure differential between top and bottom of the tank. This
further improves the properties of the water leaving the triple manifold section.
The CFD was configured with an ambient pressure lit on top of the tank, three inlets with a 9m/s velocity
and a mass flow outlet at the rear of the tank. With these conditions inputted to CFD software, the results
are as shown below,
Figure 52 Flow simulation of water entering the tank, interacting with USV dummy and leaving out the rear.
In appendix O and this image above, this simulation includes a dummy body of a typical USV design to
simulate how the water interacts with the curved surfaces. There is the fast continuous flow of water into
the tank with the inlet manifolds. The water slows down as it approaches halfway along the tank; it then
begins being drawn towards the low-pressure zone where the exit manifold is and begins speeding up to
leave the tank. Despite the water slowing down significantly when it leaves the three-exit pipe manifold
sections, the water speed is relatively consistent throughout the entire tank with small pockets of
turbulence. This tank could benefit from a redesign with larger fillets on the corners to reduce the size of
the turbulence pockets. These pockets could create low pressure zones and pull the USV around the tank
due to this chaotic force in the tank. There is also wasted space that could cause unnecessary turbulence
towards the back of the tank. This could benefit from a curvature redesign also.
8.3 Vibration and Resonance Study
For a pre-liminary study on vibration and assessment of working performance, basic calculations were
completed to validate the suitability.
75
The main structure and points of vibration will originate from the two AC motors spinning at up to 1000rpm.
These are mounted at 90 degrees to one another.
𝐹𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 =
𝑅𝑃𝑀
1000
, ∴ 𝐹𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 =
, 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 16.67 𝐻𝑧.
60
60
These motors will bring a periodic dynamic force and moment to the system including the steel support
frame that will be loaded. Using Euler-Bernoulli beam theory for the first natural order of cantilever beam,
we can predict natural frequency below.
𝑓𝑛 ≈
1.8752 𝐸𝐼
√
2𝜋𝑙 2 𝜌𝐴
Using the values calculated in the steel beam calculations for E, I and density,
𝐸𝐼 (255𝑥109 )(374𝑥10−12 ) 4.732𝑚 2
=
=
.
𝜌𝐴
7850𝑥2.568𝑥10−3
𝑠2
Substituting this into the Euler-Bernoulli theory formula,
𝑓𝑛 =
3.156
∙ 4.732 ≈ 0.85𝐻𝑧.
2𝜋 ∙ (1.2)2
This predicts there will not likely be resonance occurring in the system at 1000rpm. The motor frequency at
this speed of 16.67Hz is far off the 0.85Hz natural frequency of the system.
Figure 53 Graph showing point where resonance may occur.
The X-axis of this graph is RPM, and the Y axis is frequency plot. The blue line is the natural frequency of the
system. When the lines intercept there is more risk of resonance at an RPM equivalent to 51. To overcome
76
this in the design, a system could be implemented to begin the motors separately unto the threshold clear
of 51 RPM to reduce change of dramatic vibration and possibly damage or unsafety.
For more validation of this however the next stages would be to use ANSYS to perform a CAD simulation of
the vibration in the system.
9 Standards and Legal Compatibility
9.1 Steel Framework Validation
In order to find the optimal steel tube dimensions, the load on the beam, bending moment, deflection limit
and elasticity modulus must be found. These calculations will start with the load on top.
Figure 54 Early-stage diagram on force acting upon the tank frame.
The tank is containing water at any given time equal too:
𝑇𝑜𝑡𝑎𝑙 𝑡𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 ∙ 𝑔 = 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡𝑎𝑛𝑘. (2.02 ∙ 4.5) ∙ 1000 ∙ 9.81 = 89172.9𝑁. 89𝐾𝑁.
There are three individual beams that take the load of the tank with mounting points to maximise the
surface area and stability of the interface with the tank and the steel frame.
𝑀𝑎𝑠𝑠 𝑜𝑛 𝑖𝑛𝑑𝑖𝑣𝑖𝑑𝑢𝑎𝑙 𝑠𝑡𝑒𝑒𝑙 𝑏𝑒𝑎𝑚 = 𝑡𝑜𝑡𝑎𝑙
𝑚𝑎𝑠𝑠
. = 30𝐾𝑁.
3
Due to the steel frame being three repeated frames joined by joining beams, the calculation of one profile
will match with the division of weight across the three beams.
The geometric properties of this frame are as follows.
77
Table 36 Structural property and respective equation for configuration in model.
Length
Force
4.5m
30000
Deflection on UDL Beam
5𝑊𝐿3
384𝐸𝐼
Stress formula
𝐵𝑀
𝑊𝐸𝐼
BM
𝑊𝐿
4
As dictated by BS2573, the limit of deflection for the beam is given for a beam supported at two sides as.
𝐷𝑒𝑓𝐿𝑖𝑚𝑖𝑡 = 𝐿/200
The limit of deflection therefore for a 4.5m length beam is 0.0225m.
This is then used to find the second moment of area in the equation for deflection on UDL beam.
𝐷𝑒𝑓𝐿𝑖𝑚 =
𝑅𝑒𝑎𝑟𝑟𝑎𝑛𝑔𝑒𝑑. 𝐼 =
5𝑊𝐿3
384𝐸𝐼
5𝑊𝐿3
384𝐷𝑒𝑓𝐿𝑖𝑚 ∙ 𝐸
Plugging in the values with E being from the steel with a young’s modulus of 205x10^9 GPa.
𝐼=
5(30000)(4.5)3
= 374𝑚𝑚 4 .
(384)(205𝑥10^9)
For the bending moment and elastic modulus – the max stress of the beam needs to be found.
𝑌𝑒𝑖𝑙𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 = 355 (35552 𝑠𝑡𝑒𝑒𝑙 ). 𝑆𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = 0.6. 𝑇𝑜𝑡𝑎𝑙 𝑏𝑒𝑎𝑚 𝑠𝑡𝑒𝑠𝑠 = 213𝑀𝑃𝑎.
𝐹𝑜𝑟 𝑢𝑛𝑖𝑓𝑜𝑟𝑚 𝑙𝑜𝑎𝑑𝑒𝑑 𝑏𝑒𝑎𝑚, 𝑡ℎ𝑒 𝑓𝑜𝑟𝑚𝑢𝑙𝑎 𝑓𝑜𝑟 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡 𝑖𝑠
𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒 𝐵𝑀 =
𝑊𝐿
.
8
(30000)(4.5)
.
8
This bending moment can be used to find the elastic modulus.
𝑊𝑒𝑙 =
𝐵𝑀
= 7.93𝑥 10−6 𝑚 3 . 𝐶𝑜𝑛𝑣𝑒𝑟𝑡𝑒𝑑 𝑡𝑜 7.93𝑐𝑚 3
𝜎
Table 37Requirements for steel geometry selection.
Weight requirements
Wel
Second moment of area
78
Lowest possible
7.93𝑐𝑚 3
374𝑚𝑚 4
From table B.3, in EN 10210-2:2006. The optimal beam has the properties as follows.
Height
120
Width
80
Mass
14.7
Wall thickness
5
9.1.1 Force in trusses.
Figure 55 1/6 cut of the steel frame to calculate material and stress
properties manually.
This diagram is labelling the points A through D for the joints in the steel frame. This will be used to
calculate the geometry of the repeated beam section.
Type
Section
Metric
Length
AB
2.25
Length
DC
2.25
Length
AD
0.472
Length
BC
0.472
Length
AC
2.229
Angle
DCB
12°
To begin calculating the forces in the beams – the load and its properties must be established. The total
load of 90,000N is split into 3 sections and for this example is split again in half.
The total weight on this member shown is 1/6 of the total mass of 90,000N therefore 15,000N
𝐹𝑜𝑟𝑐𝑒 𝑎𝑐𝑡𝑖𝑛𝑔 𝑎𝑠 𝑈𝐷𝐿. 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑓𝑟𝑜𝑚 𝑐𝑒𝑛𝑡𝑒𝑟 𝑡𝑜 𝑈𝐷𝐿 𝑚𝑜𝑑𝑒𝑙 𝑖𝑠
79
4.5
= 1.125𝑚
4
The beam CD is laying parallel to the floor fixed at either end to the ground. The moments on points CD are
0. To find the reactive force – the following calculations where evaluated.
𝑀𝑂𝑐 = 0. 𝑅𝑑 − 2.25 − 15000 ∙ 1.125 = 7500𝑁
This can be used to calculate now joint by joint force calculations and their respective force properties.
Calculations done by hand can be found in the appendix figure X.
These produced the following results.
Table 38 Force direction, type and quantity in each beam section.
Member
AB
AD
BD
CD
Force (N)
38,579
39,308
7500
38,579
Property
Tension
Compression
Compression
Tension
9.1.2 Validation of Material choice for purpose.
The buckling stress of the steel members was calculated using the Euler buckling formula.
𝑃𝑐𝑟 =
𝜋 2 𝐸𝐼
.
(𝐾𝐿)2
Using this formula in excel to calculate the values for each member produced this table.
Table 39 Validation of steel material selection table.
Steel Truss
Validation
Membe Length Force
I(mm^4) Eulers
Area
Material Yield Strength
Stress in Beam
r
(mm^2)
(MPa)
(MPa)
AB
2.25
38576
374
Tension
1900
355
20.30315789
AC
2.3 393088
374
46.6
1900
355
206.8884211
BD
0.472
7500
374
1107
1900
355
3.947368421
CD
2.25
38576
374
Tension
1900
355
20.30315789
This validates that steel rectangular beams of geometry 120x80x5mm is suitable for this application to
support the test tank.
9.2 Safety Systems
With an entirely cloud based control system design many risks occur, Including cyber-attacks and general
instability in a wireless connection. To meet safety guidelines, safety precautions must be included on the
system itself and hardwired.
80
Table 40 Table of safety system breakdown and their respective standards to meet.
Safety Systems
Feature
Description
Regulatory Bodies Met
Kill Switch
Local switch that’s easily accessible to cut all motion and
electrical power.
Manual Override Allow local - hardwired control in case of network failure for key
functions
Physical
Guardrails, non-slip surfaces and signage conveying warnings for
Barriers and
water and moving machinery
Signage
Alarms
Visual and audible alarms for conveying emergency and exits.
BS EN ISO 13850:2015
Lighting
BS 5266-1:2016
Electrical Safety
CCTV
Water Detection
Sensors.
Visibility running from separate power source for emergency
situations
Residual current device and correct earthing as well as correct IP
rated devices
Real time video monitoring separate from web Gui system for
verification
Automatic emergency cutoff in case of water leakage.
BS EN 60204-1:2018
HSE workplace safety
Regulations 1992
BS 5266-1:2016
BS 7671:2018 - IET
wiring Regulations
Data Protection act
2018- GDPR
BS EN 61508
10 Product Regulation Documentation
For the design of this facility, to bridge the gap from design to real creation the concept must be approved
by the MCA (Maritime Coastguard Agency), IMO (International Maritime Organisation) and EPA
(Environmental Protection Agency). This is legal and to ensure that the waterborne equipment,
international laws similar for outside of country use, Aswell as minimal environmental impacts from
material choice to disassembly and recycling at end of life.
10.1Legal Certification
Table 41 Legal and standards breakdown and analysis.
Mechanical and Electrical
Testing and Commissioning
Protocols
Environmental
81
CE/UKCA Marking to non-premade components. To confirm
compliance with UK electromagnetic compatibility regulations.
LVD (Low voltage Directive). Ensures electrical and mechanical
safety.
RAMS – risk assessment and method statement. Pinch points,
drowning risks, electrocution, emergency stop and maintenance
inspection.
Factory acceptance Testing and Site Acceptance to verify
functionality before and after installation.
Leaks and failsafe tests – behaviour and procedures in case of
emergency.
Instrument calibration – ensure results are suitable and reliable for
its purpose.
Noise and vibration test limits.
Disposal of materials – used water disposal.
Testing could affect use of AI autonomy and saturate training for AI
with incorrect data for AI USV or if using system for AI benefits.
For this facility to be operational, these certificates or tests must be completed. This may involve redesign
or added safety components for features such as failsafe. The next stages for this design process are this
legal compliance – this will need to be completed on the design before assembly begins.
10.1.1.1.1 IPR Statement
This project includes forms of original IP. This includes mechanical system of the USV test tank and its
assembly and mounting systems. Also control systems used to monitor and automate testing as well as
GUI design are products of this project. These are all unique and original to this project and can be
vulnerable to exploitation. The IP of this project solely relies with me (Harry Meston) being a university
project and including no external industrial partners.
11 Technical Product Specifications
All specifications are to BS8888 standards with regards to BS EN ISO 1101 to ensure geometric tolerances
and limit declaration.
Figure 56 Technical Product Specification of the inlet manifold from the pump to the tank.
82
Functional Limits
Feature
1- Interface with the single inlet pipe to the
tank.
2- Outlet geometry to interface the test tank
and align bolt holes.
3- Distance between the inlet and outlet pipe.
Analysis
This geometric tolerance on the end face allows for
0.5mm total deviation from an envelope plane that lies
parallel to datum A. This ensures that after
manufacture, the face interfacing with the tank will be
sufficiently parallel to ensure gasket fit and no water
leakage.
This detail is from the flange that connects to the inlet
water pump. There are 6x 8mm diameter clearance
bolt holes that position the bolts to hold the gasket
inside the join from pump to pipe. This geometry is
with respect to BS EN 10922-1 for flange and bolts for
pipes and fittings.
This detail addresses the alignment the distance from
the centrelines of the three inlet pipes. They have a
total tolerance of 0.97mm from the datum being the
centre line of the centre pipe. This ensures they will fit
the inlet holes in the test tank. These welds must be in
accordance with BS EN 10253-2:2007 for welding and
pipe fittings.
Table 42 Table explaining tolerances on inlet manufold.
From one end of the pipe to the other, there are three linear tolerances that dictate the total distance from
the test tank to the pump.
83
Figure 57 Image of side profile for tolerance stack.
Given the tolerance allowance on these three dimensions of the TPS above, the tolerances where stacked
and analysed.
Main body allowance = +/- 1.5mm
Flange x2 =+/-0.5mm
𝑁𝑜𝑚𝑖𝑛𝑎𝑙 𝐿𝑒𝑛𝑔𝑡ℎ = 30𝑚𝑚 + 30𝑚𝑚 + 1695.027 = 1755.027
Worst Case
0.5 + 1.5 + 0.5 = +/−2.5𝑚𝑚
𝑇𝑜𝑡𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ 𝑤𝑜𝑟𝑠𝑒 𝑐𝑎𝑠𝑒 = 1752.527 ≤ 𝐿𝑤 ≤ 1757.527
To complete a statistical analysis on this, the assumption is of the manufactured parts being nominally
distributed using root-sum of squares method.
𝑇𝑡𝑜𝑡𝑎𝑙𝑅𝑆𝑆 = √1.52 +0.52 +0.52 = +/−1.658𝑚𝑚.
The mean of this distribution is 1755.027mm with the value ϭ (standard deviation) is 1.658mm from this.
This however reflects natural probabilities of deviation for high-volume.
84
Figure 58 Technical product specification of steel frame from 120x80x6mm steel frame.
85
Table 43 Table explaining tolerances on Steel frame
Functional Limits
Detail
1- Flatness of the top surface to ensure
water is perfectly level and force
distribution is linear.
2- Height from the ground to control
positioning relative to pipe of tank.
Analysis
This feature dictates that the top steel pane will
exist within 0.5mm of parallel identical plane to
the datum A (contact with the floor). This
ensures that the tank will be kept at maximum
of 0.005 degrees. Which is suitable for the tank
on top to not cause force irregularity.
This feature is the hole positions for the
attachment beams for the tank. These holes are
10mm clearance diameter with a tight
tolerance on the bolts due to the vibrations this
component will take. The energy will need to be
efficiently transferred from the tank to the
frame and not into the bolts.
This part is the side beams and their parallel to
the opposite side of the beams. This must be
within 0.5mm to ensure there is no component
of the force acting sideways and it is efficiently
transferred into compression in the steel beam
vertically.
This specification is in accordance with BS EN 1993-1-1:2005 for the design of steel structures. The
geometry is calculated using data from BS EN 10210-1 and further data from BS 2573 for the general rules
for designs of cranes.
86
Figure 59 Tank technical specification.
Verification and development for this tank are from BS EN 13706:2018 – GFRP plastic tank designs.
87
Table 44 Table explaining tolerances on test tank.
Functional Limits
Feature
1- Bolt hole geometry on the inlet pump
3 holes.
2- Bolt connections to the steel frame.
3- Geometry and profile of the tank
shape for accurate results from
testing.
Analysis
These bolt patterns for the bottom of the tank
are asymmetrical. This is to avoid orientation
irregularities at the assembly stage. The tank till
fit only one way around to the tank. The position
tolerance is extremely tight relatively as this
must fit the position on the tank.
This detail from the engineering drawing is the
tolerance on one of the three bolt patterns and
water flow entry holes. This dictates the bore
hole tolerances which ensure the hole is under
not oversized. Any oversizing will allow water to
leak from the join and cause turbulent flow in
the stream of water entering the tank. These
tolerances are significantly loose. This
complies with the possibilities of the GFRP
material and natural textured surface and
volatility to temperature and humidity.
This is the exit manifold positioning in the test
tank component. The bolt hole pattern of 6x M6
bolts is tightly position tolerance to ensure the
correct alignment through the system. Like the
entry manifold. There is a tight tolerance on the
bore hole to ensure the water does not leak to
the exterior of the tank.
Furthermore, with this design, there is an MMC tolerance on the bolt hole positioning with the tank to the
manifolds at either end. This dictates that for example in detail B, the M in the geometric tolerance ensures
that these are guaranteed to assembly despite a slight position deviation. Their true position zone
88
increases and there is given bonus tolerance to ensure the bolts will still align. This is to reduce the
probability the manufactured part will be redundant and improves manufacturing time and cost
Figure 60 Chain mount to retain the USV for testing, product specification.
89
Table 45 Table explaining tolerances on chain mount.
Functional Limits
Feature
1- Thickness of the ring for connection
to USV
2- Flatness of the sides interfacing with
the steel tubes.
3- Bolt holes interfacing with the bolt
holes on the steel frame.
Analysis
This 50mm diameter hole is given a position
tolerance of 0.22 with an MMC mark. The
tolerance zone is given a bonus tolerance from
the hole size as it deviates with the
manufacture, allowing a higher probability the
part will fit after manufacture.
Thie flatness tolerance applies to both faces of
the connecting part of the retainer block. These
faces will be interfacing with the splash cover
frame, and any gaps could cause uneven stress
distribution. These parts will require CNC
machining with tighter passes over these faces
to ensure flush fitting with the steel frame.
The tight tolerance of dimension on this detail
is to ensure accurate location of the hole. Given
this part will have industrial connecting e.g.
carabiner with large force connected, any
deviation in the size position could result in
slightly weakened walls with thinner walls. This
could prove as a failure point. This cutout circle
must be exactly centred to the tolerance of 0.5
to ensure the wall thickness around is
sufficient.
90
This part was tolerance using the MBD feature on SolidWorks. Due to its symmetrical shape and 2D views
Figure 61 MBD for pipe that connects from storage tank to inlet pump.
being limited on geometric information. This MBD uses compound datum features inside the tube (A-B)
and C being a product of its functional limits where it connects to the storage tank. The position of the
furthest face from this connects to the pump inlet and therefore must be tightly controlled to ensure
alignment.
12 Design for excellence
This section covers explanation of design ideas regarding the ease of sustaining the facility through its
lifetime from manufacture to disassembly.
12.1DFM/DFA
Being a facility co-ordinating the function and working of majority pre-made, off the shelf parts, the parts
that must have DFA considered are those joining and interfacing the parts such as motor, pump, and tanks.
Below is documentation of DFA considerations for these components specifically.
Table 46 DFA decision breakdown and justification.
Topic Explanation
Tolerances Due to high vibrations and forces exerted on this facility, high
tolerance and extra manufacturing processes would be extra cost
and time that still risk water leaks or failure. The use of a gasket on
flat joins with water flow allows for a looser tolerance on handmade, moulded parts using GRP and can absorb the impact from
oscillation from the motor and pump components. This decision to
include gaskets may decrease serviceability however largely benefit
initial manufacture and safety in the machine.
91
Bolt on fittings Snap hooks for this assembly would be hard to manufacture and
not suitable for the pressures and loads exerted. Bolts are used
plentifully on this design despite the extra cost and assembly time.
This is a sacrifice to ensure that the assembly is reliable and safe
with the vibrations and forces exerted on joins.
Ease of Alignment with parts The manifolds are made with asymmetric bolt patterns on either
side that only align in the correct orientation between the pump and
the tank. Also, the use of one to three and visa-versa – as well as the
two manifolds being different in shape despite the same function,
ensuring that they are not placed the wrong way round – saving time
and risk in the manufacture process.
Tool Access Manufacture In this part of the manifold, the water end and exit diameters must
be tightly controlled, however the curvature of the pipe from these
two points are loosely controlled. Henceforth, for the ease of
access by fastening tools (hand or power tools), the path ensures a
slow gradient close to the bolt to allow room for a tool with typical
length of 250-300mm. See appendix Wii.
This tank design made from GFRP will require a mould for the shell to be layered and hardened with the
GFRP material and hardener. This mould will need to have some design changes to make it more suitable
for a mould. One of these is a slight draft angle so it can be formed and removed from the mould easier.
This will ensue that the mould will slide off the mould easier and there will be less chance of cracking or
torsion in the mould.
Table 47 Draft angle on tank to reduce mould
risk and complexity.
92
Table 48 Mould for GFRP layup to create test tank.
This mould is made from aluminium and will require to be brushed to finish and polished. There will be no
force on this besides the UDL of the GFRP sheets on top – this will require no structural support.
The GFRP sheets will be layered on top of this world with sufficient hardener. The sheets would be chopped
strand mat CSM layered with woven roving for better multidirectional strength and properties with contact
with the water. Using isophthalic polyester resin affords better corrosion resistance with constant
connection with water and a gel coat for outer layer protection and aesthetics.
Figure 62 Chopped strand mat GFRP type,
multidirectional fibres bonded in a single layer.
(Fiberglass.com, 2022)
93
12.2Design for Serviceability.
Several factors have been identified to improve the serviceability. These have been included in the design
specification to be considered when evaluating concept ideas.
Table 49 Design for serviceability decisions and justification table.
Topic Reasoning
Off-Shelf components Systems include pre-made subsystems such as the water propulsion
being a combination of pre-made induction motor, VFD and water pump.
This is for easy documentation and instruction from a third party and can
be completed or trained for by large data sets from the manufacturer. This
is because cost, money and time can be saved when components are
needed to be serviced through either the third party or warranty.
Modular Design The modular design with bolt interfaces makes every join of subsystems
removable and configurable easily and with little disruption to other
components. For example, if a component where to fail, it could be
removed with little to no damage to other parts and replaced quickly and
cheaply, hence keeping the overall cost to a minimum.
Open configuration This system has taken up larger floor area than necessary with pipes
being open and not optimised in length. This is because to be able to
remove apart from the middle of the system, a worker can get to the part
without removing any other part and quickly swap it in and out. This is on
purpose to reduce time taken for manufacturing. Also joins and electrical
components and service corridors are all open - within reasonable
waterproofing specifications – to allow quick access and little disruption.
Design for Simplicity With initial and service cost as well as time taken to build a priority for this
facility, simplicity and efficiency in energy, time and personnel resources
are critical. The design philosophy of this is to simplify and reduce the
number of components for optimal performance. Also to recuse
13 Cost Analysis
13.1Materials Cost
Table 50 Material cost analysis.
Part
Mass
Inlet Pipes
Inlet Manifold
199809
220031.9
9
1718016.
5
Test Tank
94
Mass KG
Tonnes
199.809
220.03199
1718.0165
0.199809
0.2200319
9
1.7180165
Cost Per KG
Cost for
Materials
1.1
219.7899
1.1
242.035189
3
5154.0495
Steel Frame
Outlet Manifold
Return Pipe
Manifold Supports
Splash Cover Frame
Splash Cover
Total Raw material
Cost
551616.3
2
195000
942000
16074
200000
100000
551.61632
195
942
16.074
200
100
0.5516163
2
0.195
0.942
0.016074
0.2
0.1
1.1
606.777952
1.1
1.1
1
1.1
3
214.5
1036.2
16.074
220
300
8009.426541
13.2Off-shelf Components
Table 51 Off shelf component cost analysis and breakdown.
Hydrodynamic Parts
Quantity
Cost
Assembly
Cost
Maintanance
Regularity
Total Setup
Pump
2
50000
2500
1
105000
6 Pole AC Motor
2
12000
2500
0.3
29000
VFD
2
10000
300
0
20600
13.3Cost Evaluation
Total Cost of Assembly
210009.00
Total Cost of Transport
1098.00
Total Running Cost
125774.00
Total Labour Cost
57290
Total Purchase Cost
268398.00
The labour costs are estimate of median labour costs for the relevant jobs. The certification is the safety
auditing and checks to align with the guidelines of relevant standards agencies and is included in the total
cost. The total transport costs were also calculated and estimated from typical rates in the area of design.
95
This final cost of £268,000 Includes the labour, parts, pre-made components and raw materials. However,
does not include the land of which the facility will be positioned. This facility works in conjunction with an
organisation’s previous facility and due to its relatively small area of 20x20m. This cost can be included to a
previously purchased land.
14 Sustainable Design Analysis
A lifecycle analysis was completed using Granta Edupak on this facility. A comprehensive breakdown of
components, transport and lifetime operation as well as end of life total carbon footprint and impact was
completed.
The total energy used over the 10-year lifetime was 21.1GJ – 98.7% of this due to the large duration and
high frequency of dual electric motors running for the two pumps. The total CO2 impact being 635 tonnes
of CO2 over the 10 years.
For materials impact and discarding at the end of life. The largest contributor was the GFRP tank containing
70% of material energy. The use of recycled steel on the steel frame could reduce the overall impact of the
facility. This may induce a higher cost however with the current facility being 40k lower than the PDS
budget, there is room for improving the CO2 footprint of manufacturing and materials. Material end of life
analysis consists of downcycling options that could have an impact of approximately 53 MJ of energy from
components such as the steel frame and pipework.
Table 52 Lifecycle assessment.
Problem
Solution
Estimate Improvement
Energy Source
An installation of solar panels locally could decrease
the amount of
energy taken from non-renewable sources over the
lifetime.
Incorporating recycled elements in the metalwork
such as previously
used and downcycled steel and aluminium
Using a lower impact material for the test tank - may
involve redesign
for different manufacturing process
More design work completed to decrease the time
taken and material
wasted in the disassembly process - reusable and
non-finite joints etc.
Depends on percentage shift - Up
to 97%.
Material Selection
Tank Design
Design for
disassembly
96
Could reduce by 60%
Could reduce manufacturing
footprint by up to 40%
Could save 2000 Kg CO2
Final Design
Below is an example of a test using this facility.
Operation
1 – Tank Fill
Outcome
Tank will fill with water
held in the storage
tank.
2 – Insert USV
The USV to test is
lowered into the full
tank until buoyant.
The USV is then
chained to the mounts
and a visual inspection
of the connections and
USV is completed
The operator increases
the slider on the GUI to
begin the motors.
3 – Safety
Checks
4 – Begin low
speed
5 – Full speed
test
6 – Collect
Data
7 – Stop and
Drain
97
The operator ensures
that the test is safe
before sliding the
sliders to maximum
speed.
The data from the
gauges are used to
ensure safety and
logged to the storage
system.
The tank is safely
stopped flowing and
then drained and reset.
Control
The web-based GUI will dictate a state change and request
the inlet pump to begin spinning. The VFD will be controlled
and frequency increased to control the AC motor to begin
water pumping into the tank.
The gantry lifts the USV from the loading area and moves it
into the test tank. The GUI is used to control the linear motion
of the gantry and lower.
There are chains that attach from the USV to the retention
mounts. These are checked along with the splash cover
integrity to ensure the test can run safely.
Due to the vibration and resonance study, the operator
begins the motor that begin one at a time. The water begins
flowing around the USV at slow speed. The propulsion
system on the USV is started to simulate high speed.
The VFD produces high frequency output to the AC motors
which spin fast and thus, the pumps accelerate the water up
to 9m/s for the high-speed test. The outlet motor is equally
sucking the water out the back of the tank and into the
storage tank for recirculation.
The operator and USV owner monitor the data to ensure no
catastrophic failure in the control system and onboard the
USV. This data is logged for post-simulation analysis.
The flow rate reduces to 0. The USV is removed using the
motorised gantry after being unattached and the tank drained
by running the outlet pump to the storage tank.
98
15 Next Stages of Design
Figure 63 Graphic showing remaining systems to design and improve compared to initial design.
15.1.1.1 Black Box 1
The recycle energy part of my initial design was included to reduce the overall energy cost of the system
during its normal operation. The idea that some of the kinetic energy from the water could be transferred to
electricity and stored for later use. This transfer would take place when the water left the test tank and
needed to slow down to be in the storage tank. There is energy lost in the system here as noise/chaotic
motion in the tank that is a possible point for development. This would have a large effect on the overall
carbon footprint in the design as the lifecycle assessment proved this is the largest of the four life stages.
15.1.1.2 Black Box 2
Linking into black box 1, the water return system is underdeveloped and not optimised. The efficiency of
the water return system is significantly less than that of the facility standard. The first recommendation is
the optimisation of pipe diameter as this could lead to cost reduction if pipe is too large for necessary use.
The second recommendation is the optimisation of the pipe support. Being such a long pipe, it is prone to
Figure 64 Lifecycle assessment report from Granta Edupak.
99
damage and effect from the vibration on the system. However excessive support can increase cost
dramatically.
15.1.1.3 Black Box 3
The final system that needs developing is the data collection system. This so far consists of suggestion of
connection types and interface types as well as the network architecture for the GUI. However, to test
accurately the performance of a USV, there must be comparable metrics and calibration implemented. To
gain correlation with a good and bad performing USV, similar data must be collected and linked to working
mechanical properties in a numerical and reliable manner. This could be outsourced or with primary
research sources and de-classified data, could be completed.
16 Evaluation
As an evaluation of the management for this project, the initial Gantt chart was adapted in practice to
involve more overlapping tasks such as the design itself and the evaluation of the design. This was due to
the design method chosen and the nature of the project – being many integrated systems that rely on one
another. This constant evaluation as validation that the systems would work together and meet PDS and
regulations. With this project also, some tasks had extended personal deadlines while other had shorter
deadlines. This was down to two reasons. The first being realisation of real deadlines and being forced to
black box and leave some systems underdeveloped that where not critical to the performance of this
project. These include the software and data collection system. This can be handed to a team of software
engineers who can effectively develop this system. This time I saved here was better spent on simulation of
fluid flow and hardware design and material selection. The second being that other parts required more
time. Such as the CFD on the manifold work and the optimisation of cost for the system itself. To reduce
the cost required immense evaluation and critical decision-making to optimise the system for cost.
For an evaluation of the technical execution, the design work was completed efficiently with adherence to
the system engineering design method. This highlighted the evaluation and breakdown of systems into
subsystems and treating these like the full design – with time to ensure they would be compatible together.
This worked well as being a single person project, there was time to spend on each system and this time
could be flexible with specific duration. However, critical evaluation concludes that more time could be
100
spent optimising and reducing costs even further. This testing as well as more study on the data
acquisition system from the sea drones could have been included to produce a more rounded design. In
addition – more market research on the drones themselves could have yielded more narrow scope and an
easier design process. Discussion and response from primary resources could have been valuable for this.
17 Recommendations
This project involved a large amount of work across several engineering disciplines. Managing research
from little numerical research data on the subject in question and the integration of these systems would
have benefitted from a wider range of abilities in the project. This project however has been successful and
shown that the concept can work at a significantly lower cost and impact to a customer than the previous
facilities of the kind with sufficient simulation and engineering critical decisions to support this point. The
design, while not being complete, has allocated black boxes to be expanded and developed further with
specific requirements for this. Given this, the structure, material selection and component selection are
completed successfully and proved functionality in simulation and prototyping.
18 References
Association for Uncrewed Vehicle Systems, 2022. s.l.:s.n.
Boating World, 2025. What percentage of a cruise ship is submerged underwater?. [Online]
Available at: https://www.boatingworld.com/question-answer/what-percentage-of-a-cruise-ship-issubmerged-underwater/
BPlan, 2025. What are pain points of running professional underwater drone service.. [Online]
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[Accessed 2025].
BPS.Space, 2024. How NASA tests spacecraft re-entry.. [Online]
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[Accessed December 2024].
Clark, B., 2024. Sea Drones in the Russia-Ukraine War Inspire New Tactics. [Online]
Available at: https://spectrum.ieee.org/sea-drone
[Accessed 2024].
Fiberglass.com, 2022. Fiberglass. [Online]
Available at: https://www.fibreglast.com/collections/fiberglass-mat
[Accessed 2025].
GAO Tek, 2024. Operation, Maintenance, and Calibration of Underwater Drones. [Online]
Available at: https://gaotek.com/operation-maintenance-calibration-of-underwater-drones/
[Accessed 2025].
Haolin Liu, S. Z. M. I. S. J., n.d. Adaptive Fault-tolerant Control of Underwater, s.l.: s.n.
101
Jamal Ansary, N. F., 2022. Swarms of Aquatic Unmanned Surface Vehicles (USV), a Review From
Simulation to Field Implementation, s.l.: s.n.
Macdonald, A., 2024. The New Frontier for Drone Warfare Is Deep Underwater. [Online]
Available at: https://www.wsj.com/tech/underwater-sea-drones-ghost-shark-manta-ray-7e22e140
[Accessed 2025].
MathWorks, 2015. Using MATLAB with Python. [Online]
[Accessed 2025].
Ocean Infinity, 2024. Home page.. [Online]
Available at: https://oceaninfinity.com/
Porter, T., 2024. NATO countries are racing Russia to develop drones capable of operating in the Arctic.
[Online]
Available at: https://www.businessinsider.com/nato-allies-race-russia-develop-arctic-drones-weathercold-china-2025-5
[Accessed 2025].
Porter, T., 2025. NATO countries are racing Russia to develop drones capable of operating in the Arctic.
[Online]
Available at: https://www.businessinsider.com/nato-allies-race-russia-develop-arctic-drones-weathercold-china-2025-5
[Accessed 2025].
Science Direct, 2015. System Engineering Approach. [Online]
Available at: https://www.sciencedirect.com/topics/computer-science/system-engineering-approach
[Accessed 2024].
Sutton, H. I., 2024. Uncrewed Platforms Have Been Critical to Ukraine’s Success in the Black Sea. [Online]
Available at: https://www.rusi.org/explore-our-research/publications/commentary/uncrewed-platformshave-been-critical-ukraines-success-black-sea
[Accessed 2025].
Tapflo, 2023. BA400G D500 High-Flow Pump. [Online]
Available at: https://www.tapflopumps.co.uk/catalogue/centrifugal-pump/ba400g-d500-high-flow-pump/
[Accessed 2025].
Tapken, P., 2018. Hydro International. [Online].
The Business Research Company, 2024. Unmanned surface Vehicla global market report. s.l.:s.n.
UnitedNations SDG , n.d. United Nations Sustainable Development Goals. [Online]
Available at: https://sdgs.un.org/goals
[Accessed 2024].
University of Southampton, 2024. Boldrewood towing tank. [Online]
Available at: https://www.southampton.ac.uk/research/facilities/towing-tank
102
University of Strathclyde, 2024. Naval Architecture, Ocean & Marine Engineering. [Online]
Available at:
https://www.strath.ac.uk/engineering/navalarchitectureoceanmarineengineering/workingwithbusinessorg
anisations/ourfacilities/kelvinhydrodynamicslaboratory/
Zhixiang Liu, Y. Z., 2016. Unmanned surface vehicles: An overview of developments and, s.l.: s.n.
19 Appendix
Appendix A – Project Proposal
DESIGN ENGINEERING PROJECT 3 (60 credits): Project Proposal
Student Name: Harry Meston
Project Title: Maritime Drone Test Rig
Project overview. What is the problem designed to overcome, why is it important, what is your initial vision; include annotated
sketches:
Maritime drone test rigs are increasingly important as drones become critical to enhancing safety, efficiency, and sustainability in
marine operations. These rigs provide essential infrastructure for validating drone performance, ensuring reliable operation in realworld conditions. By facilitating rigorous pre-deployment testing, test rigs minimize the risk of operational failures, enhance safety,
and reduce costs associated with field deployment. They accelerate the development of innovative technologies, such as AI-based
navigation and advanced sensing, while also fostering industry growth by meeting the growing demand for high-performance drones.
The Maritime Drone Test Rig will play a key role in accelerating innovation by providing a controlled environment for testing
prototypes and refining technologies. It will enhance safety by allowing for the validation of emergency response protocols and failsafe mechanisms under controlled conditions. Moreover, the rig will support the growth of the maritime drone sector, attracting
researchers and businesses to collaborate on advancing this critical technology. By ensuring drones can operate reliably, the rig will
also contribute to environmental monitoring efforts and ensure compliance with operational regulations.
My initial view.
This test rig will incorporate advanced features such as adjustable wave tanks, current generators, and salinity control to simulate
diverse marine environments. As shown below, my initial view is of a body of water with flow control, a re-circulating water body to
simulate the environment of the drone in operation. These sketches are not showing the systems that could run on the performance
capabilities of the rig. Measurements will need to be taken such as vibration, stress in the body, temperature sensors, and speed and
battery live data.
103
Why will this be useful?
Maritime drones are becoming increasingly effective and produced especially due to demand acceleration by the Ukraine war. For
example, the U.S. coastguard say are increasing spending on these technologies including large financial contract for best drone
monitoring solution (Unmanned System Technologies: drone Maritime Target Applications). This sector is mainly held by defence and
security operations, with the total market being worth an estimated 4 billion by 2030 (Next Move Strategy Consulting. (2023). Size
of the global unmanned ground vehicle (UGV) market in 2022, with a forecast through 2030 (in billion U.S. dollars).
These drones are proving extremely efficient and effective through practice by Ukraine military. However, these drones are being
hacked together in the quickest possible ways as the demand is so high and the use of them is new. Corners in production are being
Figure 65 Graph showing projection of market
value of USV's
cut and the rate that a drone doesn’t act the way it is supposed to is high. This is partially due to no time or effective way to test
these drones before they are needed in battle. What I intend to overcome is this “workaround” for not having sufficient test apparatus
meaning drones are less effective than they could be at lower costs and produced more quickly. My initial vision is a test chamber
which can simulate high speed water, winds, temperature changes etc to match that of what these drones will be operated in as well
as measuring factors such as efficiency, lifespan, service, runtimes and other factors that cannot be definitively concluded with the
use of computer simulation to help optimise their use.
104
Aim, Objectives and milestones of Project:
The aim I intend to achieve is to through gather relevant market research and gaining understanding of relevant processes in
manufacture and function, increase the effectiveness and efficiency of USV’s through speeding up the manufacturer and prototype
stages for testing and designing and completed with final design and proof of concept for key features and services.
Due to this design having many complex sub-systems such as water pump, jets, monitoring devices etc, each system will have a short
amount of time before moving onto the next stage with time allowed for iterations in the design and loopbacks. I intend to design
each system using standard components, pumps etc where possible as these can produce large datasheets with values and test
results. If possible, I can create a small-scale prototype o show concept conveying the working mechanism of the water flow,
monitoring etc.
These subsections are as followed:
▪
Market research and feasibility Ethics study and risk assessment. Gather information whether this will be used, how and
▪
where it will be used, and weather idea is possible.
Summary of needs analysis and create PDS
▪
Begin concept design and evaluation against pods and arrive at selected schemes for each mechanism.
▪
Embodiment of schemes and more detail in concepts via analysis, drawing CAD etc.
▪
Final drawings and proof of concept.
In terms of project milestones, my project will be presented at the industrial review night before any stages of physical development.
By this stage I will have focused heavily on creating a product design specification as well as detailed component drawings. This stage
as well as the VIVAs will be a point of specification review and iterative changes in the feedback loop before beginning any final
design.
Gantt Chart for Maritime Drone Test Rig Design Process
Task/Phase
1. Project Initiation
2. Proposal Development
3. Research Phase
4. Design Phase
5. Prototyping
6. Festival of Design Engineering (FODE)
Start Date
Sept 23, 2024
Sept 30, 2024
Sept 30, 2024
Dec 26, 2024
May 28, 2025
June 16, 2025
End Date
Sept 30, 2024
Oct 11, 2024
Dec 25, 2024
May 27, 2025
June 15, 2025
June 30, 2025
Please describe using bullet points your preliminary view on the technical challenges:
105
•
Creating high speed water flow that is realistic to that of a craft flowing through water.
•
Create air that can mimic that of high speed, low speed, and 360 degrees of possible directions.
•
Have suitable run times. Can run for hours at a time and not for a few minutes.
•
Measure the feedback from the prototypes without fastening it.
•
Simulate realistic environment for the drone to be run for long time.
•
Measure suitable and accurate data from the test subject.
Initial view of security risks and how they can be mitigated:
Risk: virus/hacking of relevant computers used. Mitigation: ensuring that all drives are named, filed and encrypted/decrypted before
and after use.
Risk: ideas that are confidential becoming known. Mitigation: ensure no sharing data or ideas before any milestone in the project to
ensure all ideas are my own and kept that way.
Risk: Research and data from external companies given require limitations in this project development. Mitigation: All sensitive data will
be only visible to me (the developer) and to the assignment marker. Any published copies will have censored information on report,
studies and summary of overall project.
Please describe how this project maps to the Sustainable Development Goals: https://www.un.org/sustainabledevelopment/
•
Reduce unnecessary steps to production, energy requirements and make a more efficient, in terms of material, energy, cost,
production process.
•
Reduce chance that drone will fail and be a waste.
•
Peace, justice, and strong institutions.
Preliminary view on Intellectual Property Rights:
No current patents exit for any kind of maritime drone test rig. They do exist for air-drone types.
For an initial view on the subject, no partnerships for IPR’s are initiated, therefore any developed work will be owned by myself – in
a non-secure by legal administrative way. In terms of physical design, mechanical systems and unique integrations of control systems
and electronics will – upon a developed concept – need looking into for the correct IPR’s and ownership. This applied for any firmware
that is created and when other developers’ libraries are included such as pre-existing sensor libraries in Arduino IDE.
Another subject relating to this is the drive for these drones for military purposes. Being a competitor for funding by the government
for example for military use, this will initially require the secrecy that most military developments require. However, this project Is
not for that purpose specifically and can be developed without such requirements.
The project will adhere to national and international intellectual property laws and regulations, including maritime-specific standards,
to ensure the apparatus meets global compliance requirements.
AHEP-3 Learning Outcomes
The project must be able to demonstrate the following:
in project?
Engineering Analysis
Ability to apply quantitative methods in order to understand the performance of systems and components.
Ability to use the results of engineering analysis to solve engineering problems and to recommend appropriate
action.
Yes
Yes
Design
Be aware of business, customer and user needs, including considerations such as the wider engineering context,
public perception and aesthetics.
106
Will be a
challenge.
Define the problem, identifying any constraints including environmental and sustainability limitations; ethical,
health, safety, security and risk issues; intellectual property; codes of practice and standards.
Work with information that may be incomplete or uncertain and be aware that this may affect the design.
Apply problem-solving skills, technical knowledge and understanding to create or adapt design solutions that are
fit for purpose including operation, maintenance, reliability etc.
Manage the design process, including cost drivers, and evaluate outcomes.
Communicate their work to technical and non-technical audiences.
Yes
Yes
Yes
Yes
Yes
Economic, legal, social, ethical and environmental context
Understanding of the need for a high level of professional and ethical conduct in engineering and a knowledge
of professional codes of conduct.
Knowledge of management techniques that may be used to achieve engineering objectives.
Understanding of the requirement for engineering activities to promote sustainable development.
Awareness of relevant legal requirements governing engineering activities, including personnel, health & safety,
contracts, intellectual property rights, product safety and liability issues.
Yes
Yes
Yes
Yes
Engineering practice
Knowledge of contexts in which engineering knowledge can be applied (eg operations and management,
application and development of technology, etc)
Ability to use appropriate codes of practice and industry standards
Yes
Yes
General Skills
Apply their skills in problem solving, communication, information retrieval, working with others and the effective
use of general IT facilities.
Plan self-learning and improve performance, as the foundation for lifelong learning/CPD.
Plan and carry out a personal programme of work.
Yes
Project Team Comments:
Print Name:
Appendix B - Initial Gantt chart at the project planning stage.
107
Yes
Yes
Exercise initiative and personal responsibility, which may be as a team member.
Project Unit Leader Signature:
Yes
Date:
Stage 1 - Requirements
Analysis
01/09/202
4
01/10/202
4
01/11/202
4
01/12/202
4
01/01/202
5
01/02/202
5
01/02/202
5
07/02/202
5
13/02/202
5
19/02/202
5
25/02/202
5
03/03/202
5
15/03/202
5
15/04/202
5
15/05/202
5
15/06/202
5
15/07/202
5
Project Proposal
Ethics Evaluation
Risk Assessment
Market Research
Feasibility Study
PDS Creation
Stage 2 - Concept
Development and
system Design
Function Means Analysis
Preliminary Concept
Detailed Design
Evaluation of
Architecture
Detailed Mechanical and
Electrical Design
Detailed Functions
Analysis
Software and Data
Acquisition Plan
Final Detailed Concept
Stage 3 - Embodiment of
Concept
Proof of Concept Design
Ideas for FODE
Detailed Design Ideas
Fabrication
Sensor integration
fabrication
Firmware Creation
Environmental Testing
Optimisation
Data Analysis
Evaluation
FODE
Appendix – C Ethics Checklist
108
09/03/202
5
########
#
Research Ethics Checklist
About Your Checklist
Ethics ID
61033
Date Created
23/11/2024 15:34:58
Status
Approved
Date Approved
27/01/2025 10:31:42
Risk
Low
Researcher Details
Name
Harry Meston Meston
Faculty
Faculty of Science & Technology
Status
Undergraduate (BA, BSc)
Course
BSc (Hons) Design Engineering
Project Details
Title
S.T.R.E.A.M (Surface Testing For Research and Evaluation of Autonomous
Machines).
Start Date of Project
22/09/2024
End Date of Project
31/07/2025
Proposed Start Date of Data
Collection
01/12/2024
Supervisor
Nigel Garland
Approver
Nigel Garland
109
Summary - no more than 600 words (including detail on background methodology, sample, outcomes, etc.)
My initial idea is for a test machine that can evaluate performance of sea drones. These devices are a quickly growing
industry. This machine could be used to speed up manufacture and design process, improve systems and dynamic
properties as well as reduce cost and wastage.
My initial project proposal is as follows. A chamber where high speed water, winds and other atmospheric conditions can
be simulated. This will need to be done quickly and repeatably with little cost of building the apparatus, maintaining the
apparatus and be able to run for long periods of time and with quick turnaround.
Large scale examples already exist, large building size construction with massive pools of water with wave simulation and
atmospheric simulation, however these are few and far between which causes long waits, large money to maintain and
build as well as far to travel for a company to use. I intend to make it easier to test shapes, systems and prototypes for
companies developing such devices.
Filter Question: Does your study involve the use or re-use of data which will be obtained from a
source other than directly from a Research Participant?
Additional Details
To gather data and research for this project, I plan to combine studying
existing information with reaching out to industry professionals. I’ll start by
reviewing literature on boat testing, marine devices, and system evaluation.
This will include articles, research papers, and case studies to get a clear
understanding of the processes, methods, and challenges involved. This
research will help me build a strong base of knowledge and figure out what
areas need more attention.
Please describe the data, its source
and how you are permitted to use it
Alongside the literature review, I’ll connect with local companies that have
large boat test facilities, like the one in Portsmouth. These places will give me
a chance to see how testing is done in real-world settings and learn more
about the challenges they face. I’ll gather data on how the devices perform
during these tests and understand what factors influence their success.
I also plan to reach out to companies that design and work with marine
systems. Their input will be key when it comes to evaluating the device during
testing. They can provide hands-on insights into performance, offer feedback,
and suggest improvements. Combining what I learn from research and
industry will give me a solid, practical understanding for my project.
Research Data
Will identifiable personal information be collected, i.e. at an individualised level in a form that
identifies or could enable identification of the participant?
No
Will research outputs include any identifiable personal information i.e. data at an individualised level
in a form which identifies or could enable identification of the individual?
No
110
Storage, Access and Disposal of Research Data
Where will your research data be stored and who will have access during and after the study has finished.
I will be the sole non-university staff member reviewing the data collected for this project. My supervisor, who is a
university staff member, may also access the data to guide and oversee my work. Additionally, markers will review the
data if it is included in my final report, as part of the assessment process. Once the project is completed and assessed,
access to the data will return exclusively to me. This ensures that the information is handled securely and remains within
the boundaries of academic use, maintaining confidentiality and protecting the integrity of the research process.
Once your project completes, will your dataset be added to an appropriate research data repository
such as BORDaR, BU's Data Repository?
Yes
Final Review
Are there any other ethical considerations relating to your project which have not been covered
above?
Yes
If Yes, please explain.
One potential market for this device will be military applications. However, this project can be also marketed to research,
co-operate and other non-millitary uses. None of the data collected will be sensitive as it will be gathered from
companies via a questionnaire . I will not be gathering any raw data from any of these institutions.
Risk Assessment
Have you undertaken an appropriate Risk Assessment?
Attached documents
Participant agreement form mk1.pdf - attached on 23/01/2025 22:47:29
questionnaire mk1.pdf - attached on 23/01/2025 22:48:28
Participant information form mk1.pdf - attached on 23/01/2025 22:48:42
111
Yes
Appendix – D Full product design specification.
Product Design Specification
PDS Value
Requirements Value
Objective
Metric
Test area padding of
0.5-1m
Test area will be
between 4 and 5m long
Test area will be
between 2 and 3m wide
Test area will be
between 1.5 and 2m
wide
Value
Unit
0.5<x<1
m
4<x<5
m
2<x<3
m
1.5<x<2
m
50-500
N
1<x<50
kN
10 to 50
Celsius
5 to 16
Celsius
0.5 to 10
kW
Performance - 1
Geometric (G)
(G)1.01
1.1
(G)1.02
1.1
(G)1.03
1.1
Allow for sufficient
movement of drone
Fit average size of USV
(length)
Fit average size of USV
(width)
(G)1.04
1.1
Fit average size of USV
(Depth)
(e)1.1
1.4
Measure propulsion
(e)1.2
1.4
(e)1.3
1.4
(e)1.4
1.4
Measure forces on hull
Measure Temperature
inside USV
Measure Temperature
of water
(e)1.5
1.4
Measure Power Draw
(e)1.7
1.4
(e)1.8
1.4
(e)1.9
1.4
(e)1.10
1.4
(e)1.11
1.4
Measure Barometric
Pressure
Measure Humidity
inside hull
Measure state of
charge SOC
Measure state of
charge SOC
Measure Battery
Temperature
(e)1.12
1.4
Measure Vibration
(e)1.13
1.4
(e)1.14
1.4
(e)1.15
1.4
Measure Roll
Include accurate
sensor response and
real time updates
Run from mains
electricity
(D) 1.16
1.4
Simulate water moving
at 60% of average USV
top speed
(D) 1.17
1.4
(D) 1.18
1.4
(D) 1.19
1.4
Sufficient water us
supplied to pumps
Water must be held and
supplied as requested
by pumps
Test must last for
sufficient time
2.01
2.3, 2.2
Must be cost effective
2.02
2.3, 2.2
Must be cost effective
Electrical (e)
Include force sensor
behind USV propulsion
Include load cells on
key points on hull
Include thermistor
sensor inside USV
Include thermometer in
water pipes and in pool
Include power meter
inline with battery
system
Include Barometer
inside water pump
system
Include hygrometer
inside hull
Include voltage sensor
inline with power
Include current sensor
inline with power
Include thermistor
close to battery unit
Include accelerometer
on board USV
Include IMU sensor
onboard USV
High frequency of data
collected
Pascal
30 to 90
Percent
12 to 96
Volts
21 to 42
Amps
0 to 50
Celcius
10 to 50
g
250-2000
ω/s
20-100
kHz
25
m/s
30
m^3/s
1000
Tonnes
1
Hour
<800,000
£
1000
£
(e)1.16
Dynamic(D)
Water will flow at up to
25m/s
Flow rate can reach 50
meters cubed per
second
1000 tonnes of water
on hold for each test
Test must run for no
more than 1 hour
Scope - 2
112
No more than 800K
purchase cost
No more than 1k per
day in resource cost
2.03
2.4
Move USV in and out
rapidly
2.04
Must be reliable
2.05
Must be reliable
2.06
Must be reliable
2.07
Must be reliable
2.08
1.2
Must be reliable
2.09
3.7,1.7
Must be easily
maintainable
2.1
3.7,1.7
Must be cheaply
maintainable
3.01
3.2, 1.3
Only for UK sale and
use
3.02
1.3
Only for UK sale and
use
3.03
1.3
Only for UK sale and
use
3.04
1.3
Only for UK sale and
use
3.05
1.3
Only for UK sale and
use
3.06
1.3
Only for UK sale and
use
3.07
1.3
Only for UK sale and
use
3.08
1.3
Only for UK sale and
use
3.09
1.3
Only for UK sale and
use
3.1
1.3
Only for UK sale and
use
3.11
1.3
Only for UK sale and
use
Take between half an
hour and an hour to
change USV
Last for up to 720 hours
per year operational
time
Last up to 4 hours
testing total per day
On-site construction of
1 -2 months
Pre-fab construction 3
to 6 months
Prioritise off-the-shelf
components where
possible
Prioritise components
with manufacture
warranty and technical
callout for component
or system
Prioritise components
with manufacture
warranty and technical
callout for component
or system, allow 22,000
for maintenance per
quarter
30-60
Mins
720
hours
4
hours
1 to 2
Months
3 to 6
Months
N/a
N/a
N/a
N/a
22,000
£ per three months
ISO 12100:2010, BS EN
ISO 13849-1:2015, ISO
13850:2015
N/A
ISO 11161:2007
N/A
ISO 9763:2004
N/A
ISO 8068:2014
N/A
ISO 2631-1:1997
N/A
ISO 14222:2017
N/A
IEC 61508
N/A
ISO 26262:2018
N/A
ISO 9001:2015, ISO
17025:2017
N/A
ISO 14001:2015, ISO
14064-1:2018
N/A
ISO 19901-1:2015, BS
5950-1:2000
N/A
2.11
2.12
Market Coherance - 3
113
Ensure all safety
standards in the UK are
met
Ensure that all
integrated systems are
safe and meet the
relevant standards
Ensure all water jet
technology is coherent
with the UK standards
Ensure all water jet
technology is coherent
with the UK standards
Ensure all standards for
vibration and
mechanical oscillation
are complied with
All propulsion systems
integrated systems are
in accordance with UK
standards
All electrical systems
are commissioned and
signed off - complying
with UK standards
Autonomous system
control is up to UK
standards
Electrical systems are
checked and
commissioned and
operate under UK
standards and law
Environmental
standards are met
including gasses and
waste produced
Steel work is in
accordance with UK
standards for sea
mounted steel
framework
construction
3.12
1.3
Only for UK sale and
use
3.13
1.3
Only for UK sale and
use
4.4
Must be resource
efficient
Fastening systems of
USV are sufficient with
UK marine standards
Steel structures in
facility framework are
in accordance with UK
standards.
ISO 13686:2001
N/A
BS EN 1993-1-1
N/A
N/a
N/a
N/a
N/a
20 to 40
Percent
N/A
N/A
N/A
N/A
10 to 20
Percent
Sustainability - 4
4.01
4.02
4.4
4.03
4.3
Be able to run from
renewable energy
source
Be able to support
sustainable power on
site
4.04
4.4
4.05
4.4
4.06
4.4
4.07
4.4
Be able to utilise regen
power capabilities
Be able to reduce
energy use where
possible
Use water from test
tank area for facility
utilities
Harness naturally
occurring water to
reduce water grid
consumption
4.4
Include external
electricity cutoff
Allow for power from
210v UK mains or 450v
UK industrial mains
with green power
linkage
Be able to regen 20-40
percent of power per
run
Include Standby more
for apparatus
Use test area water for
plumbing, heating and
personal facilities
Draw water from rain,
nearby bodies of water
and discharge
responsibly
Safety - 5
5.01
5.02
5.04
1.3
5.05
1.3
5.06
1.3
5.07
1.3
N/a
Emergency water
discharge from
chamber in case of leak
Utilise water from tank
in non-electrical fire
Loose interconnecting
wires tied to frame
running parallel
Use treated steel or
plastic to ensure no
water contamination
5.08
1.3
Include ladder access
to all components
7.01
1.4, 1.6
Display Temperature
7.02
1.4, 1.6
Display valve states
7.03
1.4, 1.6
Display pump states
7.04
1.4, 1.6
Display tank level
7.05
1.4, 1.6
Display tank volume
7.06
1.4, 1.6
7.07
1.4, 1.6
7.08
1.4, 1.6
Display Temperatures
Displace Water
pressures
Display kill switch and
emergency cutoff
7.09
1.4, 1.6
Display Test time
7.1
1.4, 1.6
Display USV Speed
N/a
All electricity
components be
waterproof to IP67
Include control system
for refill and empty.
Have separate
discharge point.
Ensure no wires are
loose.
Follow standards for
cranes and offshore
steel frames,
Ensure open plan and
easy access for
maintenance.
N/a
N/a
UK waterproofing
standards
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
10 to 50
Celsius
N/A
Variable valve position
N/A
Boolean pump state
0 to 100
Percent
10 to 50
Celsius
0 to 10
Bar
N/A
Boolean
0-60
Minutes
0-50
Knots
Controls - 7
114
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
Display USV
temperature
Display USV battery
state
Display hull integrity on
USV
Display USV load
capacity
Display USV live video
stream
7.11
1.4, 1.6
7.12
1.4, 1.6
7.13
1.4, 1.6
7.14
1.4, 1.6
7.15
1.4, 1.6
7.16
1.4, 1.6
7.17
1.4, 1.6
Display Power curves
Display free body
diagram on USV live
time
7.18
1.4, 1.6
Therman camera
7.19
1.4, 1.6
High speed camera
7.2
1.4, 1.6
Stereo vision
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
To be decided in design
stage.
10 to 50
Celsius
0-100
Percent
N/A
Visual Diagram
0-100
Percent
N/A
MP4
N/A
Graphic
N/A
Graphic
10 to 50
Celsius
>1000
fps
N/A
N/A
Electrical Feasibility
Electrical requirements
Head
Typical Efficiency
2
0.5
0.8
Power Consumption
Power regen Percentage
0.1
0.5
M
0.65
1080136057
W
1080.136057
Mw
32404.0817
Average Power Cost per MW
50
Average Hours Used per day
2
0.4
Power regen Power
432.0544227
Power regen cost
21602.72113
20 Design Stages
Stream Test app.
Appendix E - Moody diagram for calculating pipe
losses.
115
Appendix F - Pump selected.
21602.72113
Appendix Fi - Storage tank selected.
Appendix G - Dummy interface.
Appendix H - Sensor interface setup for strain
measurements on hull.
Appendix I - STREAM Data collection App
Appendix J - VFD Architecture https://www.plctechnician.com/news-blog/variablefrequency-drives-basics-and-common-applicationsvfds
Appendix K - VFD Inputs and Outputs https://www.instructables.com/A-Simple-Driverfor-VFD-Displays/
116
Appendix L - AC Motor Diagram https://www.galco.com/comp/ac_motor.htm
Appendix M - Motorised Gantry Datasheet. https://www.hoistuk.com/wpcontent/uploads/VGIM-Steel-Motorised-GantryTechnical-Guide.pdf
Appendix N - Unoptimized inlet manifold side view for Appendix O - Test tank fluid flow around dummy
fluid flow velocity.
USV.
117
Appendix P - Optimised nozzle and pipe geometry CFD. Appendix Q - Stress FEA on the steel frame for the
Appendix R - Displacement at extreamities from the
steel frame .
Appendix T - Final Design render with control hut
showing.
118
tank.
Appendix S - Equations for nsubsonic nozzle fluid
flow.
Appendix U - Top view final assembly render.
Appendix V - View from final design of pumps and
motor joint.
Appendix W - Engineering drawing of Steel frame
tank assembly.
Appendix Wi – Mounting of manifold to tank.
Appendix Wii - Manifold Support on Manifold.
Appendix Wiii – Cross section of assembly
Appendix Wiiii – MBD of pipe from storage tank to
pump inlet.
Product name
Appendix X - Granta Edupak Shortened Lifecycle Audit Report.
Country of use
Product life (years)
STREAM
Facility
United
Kingdom
10
119
Eco Audit
Energy details
CO2 footprint details
Phase
Energy
(MJ)
Energy
(%)
CO2 footprint
(kg)
CO2 footprint
(%)
Material
2.57e+05
1.2
1.64e+04
2.6
Manufacture
0
0.0
0
0.0
Transport
7.62e+03
0.0
472
0.1
Use
2.08e+07
98.7
6.18e+05
97.3
Disposal
2.56e+03
0.0
179
0.0
Total (for first life)
2.11e+07
100
6.35e+05
100
End of life potential
-5.52e+04
-3.94e+03
Summary
Energy Analysis
Energy (MJ/year)
Equivalent annual environmental burden (averaged over 10 year product life):
120
2.11e+06
Report
Detailed breakdown of individual life phases
Summary
Material:
Component
Material
Recycled
content*
(%)
Part
mass
(kg)
Qty.
Inlet Pipes
High carbon steel
Virgin (0%)
2e+02
1
2e+02
6.4e+03
2.5
Inlet Manifold
High carbon steel
Virgin (0%)
2.2e+02
1
2.2e+02
7.1e+03
2.8
GFRP, epoxy matrix (isotropic)
Virgin (0%)
1.8e+03
1
1.8e+03
1.8e+05
69.7
Steel Frame
High carbon steel
Virgin (0%)
5.5e+02
1
5.5e+02
1.8e+04
6.9
Outlet Pipe
High carbon steel
Virgin (0%)
2e+02
1
2e+02
6.3e+03
2.5
Return Pipe
High carbon steel
Virgin (0%)
9.4e+02
1
9.4e+02
3e+04
11.9
Manifold Supports
Age-hardening wrought Alalloys
Virgin (0%)
16
1
16
3.1e+03
1.2
Splash Cover Frame
High carbon steel
Virgin (0%)
2e+02
1
2e+02
6.5e+03
2.5
Acrylonitrile butadiene styrene
(ABS)
Reused part
1e+02
1
1e+02
0
0.0
9
4.2e+03
2.6e+05
100
Test Tank
Splash Cover
Total
Total mass (kg)
Energy (MJ)
%
*Typical: Includes 'recycle fraction in current supply'
***User-defined material
Summary
Manufacture:
Component
Process
Amount processed
Energy (MJ)
Total
%
100
Summary
Transport:
Breakdown by transport stage
Distance (km)
Energy (MJ)
Truck 7.5-16t, EURO 6
50
7.3e+02
9.6
Truck 7.5-16t, EURO 6
50
7.3e+02
9.6
Truck 16-32t, EURO 6
20
2.3e+02
3.0
Storage Tank
Truck >32t, EURO 6
2e+02
1.3e+03
16.9
Pre-Made components
Truck 16-32t, EURO 3
1e+02
1.2e+03
15.2
Control Unit
Truck 3.5-7.5t, EURO 6
1e+02
3.5e+03
45.8
5.2e+02
7.6e+03
100
Stage name
Transport type
Steel Pipes
Steel FrameWork
Test Tank
Total
%
Breakdown by components
Mass
(kg)
Energy (MJ)
Inlet Pipes
2e+02
3.6e+02
4.7
Inlet Manifold
2.2e+02
4e+02
5.2
Test Tank
1.8e+03
3.2e+03
42.4
Steel Frame
5.5e+02
1e+03
13.1
Outlet Pipe
2e+02
3.5e+02
4.6
Return Pipe
9.4e+02
1.7e+03
22.4
Component
121
%
Manifold Supports
16
29
0.4
Splash Cover Frame
2e+02
3.6e+02
4.8
Splash Cover
1e+02
1.8e+02
2.4
Total
4.2e+03
7.6e+03
100
Use:
Summary
Static mode
Electric to mechanical (electric motors)
Energy input and output type
Country of use
United Kingdom
Power rating (kW)
2.4e+02
Usage (hours per day)
4
Usage (days per year)
1.8e+02
Product life (years)
10
Relative contribution of static and mobile modes
Mode
Energy (MJ)
%
Static
2.1e+07
100.0
Mobile
0
Total
2.1e+07
100
Disposal:
Component
Inlet Pipes
End of life option
Energy (MJ)
%
Recycle
1.4e+02
5.4
Inlet Manifold
Recycle
1.5e+02
6.0
Test Tank
Downcycle
8.9e+02
34.8
Steel Frame
Recycle
3.9e+02
15.1
Outlet Pipe
Recycle
1.4e+02
5.3
Return Pipe
Recycle
6.6e+02
25.8
Manifold Supports
Landfill
3.2
0.1
Splash Cover Frame
Recycle
1.4e+02
5.5
Splash Cover
Downcycle
Total
122
50
2.0
2.6e+03
100
Appendix Y - Security assessment and Evaluation Security Management Plan: Project S.T.R.E.A.M
Stage
Cyber Security Threat
Identification
This threat relates to unauthorised
or remote access to the facilities
control or data collection system.
This could potentially lead to
remove startup or test manipulation
with results being incorrect,
damaged or lost
One way to avoid this is use
physical access control such as two
factor authentication with physical
verification such as RFID card.
Another mitigation strategy is the
use of firewalls and isolated
networks alongside regular
firmware updates.
Mitigation
Review
Monthly, review of access logs,
audit trails and contractor ID check
and log. Annual penetration test by
team and monthly staff training or
refresher.
Emergency
Response
Identify staff and revoke
credentials. Incorporate manual
control switch on and off site - do
this automatically if incorrect
procedure is completed.
Documentation
Maintain control logs and breach
investigation reports. Make visible
network architecture diagrams and
change logs. Document all actions
with photos where necessary.
Unauthorised Personnel in Test
Area
Risk of unauthorised or untrained
individuals entering closed areas
during testing. This could lead to
injury, death or corrupt results.
Loss or Theft of Test Results
and Logs.
Risk of data loss or
unauthorised data transfer.
Test data may complain
information or design IP that’s
confidential.
Implement badge-based access
control. Due to this site being
local to a company’s other site,
possibly on the same ground,
include separate badges for this
area. Display clear warning signs
and physical barriers - electronic
control and verify. Complete site
safety inductions for workers and
visitors.
Log manually and electronically
all visitors. Random staff checks
to ensure compliance. Review
CCTV periodically and randomly
and inform staff of this and make
sure it meets GDPR guidelines.
Use encrypted storage on
portable and local cloud
storage rack. Restrict external
devices such as phones and
USB. Require logins for data
handling, auto lock screens
and non-photographable
screens.
Escort off site with total site
security. Incrementally check all
machines plus visual inspection
to ensure no catastrophic
compromise. Re-calibrate
machine. Notify security lead.
Log incident analogy and
electronically. Bring update to
register and reflect incident in
training. Record security
effectiveness and monthly
review.
Conduct monthly integrity
checks and permission audits.
Regular review of encryption
and storage policies. IT admin
to verify backup and test
quarterly. This could be from
on-site or contractor.
Immediately isolate machines
or accounts. Notify leaders
and follow protocol. Restore
last backups if data loss
occurs.
Record data breach in data log
- analogue and digital copy.
Maintain updated inventory
and access rights. Increase
training.
Intellectual Property Rights Analysis Post-Project
IPR Aspect
Identification
Ownership
Protection
Third Party
Usage
Confidentiality
123
Application to STREAM
This project includes forms of original IP. This includes mechanical system of the USV test tank and its
assembly and mounting systems. Also control systems used to monitor and automate testing as well as
GUI design are products of this project. These are all unique and original to this project and can be
vulnerable to exploitation.
The IP of this project solely relies with me (Harry Meston) being a university project and including no
external industrial partners.
Copyright automatically protects original written content, software and graphical elements of the design.
Potentially a patent for new design systems such as the push-pull pump configuration using
hydrodynamics as these may be susceptible to risk. However, these systems are not unique enough to
justify the cost for a low chance of patent completion.
Parts here that come from third party developers and designers include software libraries such as MATLAB
development library for the data collection app. SolidWorks and python are included and must be cleared
for any IP infringement could this product become commercial.
In usage, this facility will produce sensitive results either sensitive to the commercial owner or defence
contractors and industry – these must be protected both in hardware and data protection. Their own
designs being tested could be confidential or un-released designs and could require further security
management.
124