Team Leader
Walter Strassburg
Joe O’Bryant
Iheanyi Umez-Eronini
Chief Engineer
Group 05010
Team Mentor
Gabe Marciano
Dr. Jeff Kozak
Greg Weimer
Taylor Valentine
HMMWV UAV Deployment & Ground
Sustainment System
Needs Assessment
 Currently, the technology to make an
autonomous military weapon such as
the DP-5X exists with minor setbacks:
 Transportation
 Guidance
 Communications
 Project 05010 will fulfill transportation
criteria for the DP-5X.
Initial Scope
 12/06/04 Project Requirements
 Trailer and launch system must:
 Transport:
 Delicate machinery (300lbs)
 Maintain safety of crew (2 person)
 Enable:
 Unmanned landing on trailer
 Waterproof storage of all components
 Be shock mounted with tie down system
 Be operable by low echelon military personnel
 Have a low cost
Current Requirements
 Project Requirements

Trailer and launch system must:
 Transport:
 UAV (300lbs)
 Fuel sufficient for 72 hours of sustained flight (1200lbs)
 Extra rotor blades for UAV
 Payload (250lbs and ~$1Million)
 Crane to support lifting of helicopter and adjustment of engine CG
 Ramps to load and unload aircraft
 Additional fluids and UAV support equipment
 Maintain safety of crew (2 person)
 Enable waterproof storage of all components
 Provide electrical service for UAV and electrical components
 Have a low cost
 Be operable by low echelon military personnel
System Design
Components









Waterproofing
Ramps
Boxes
Fuel Containers
Trailer Type
Lift Mechanism
Crane
Holding Mechanism
Attachment Points




Blade Packaging
Payload Packaging
Power Supply Adapter
Power Converter
Module
 Battery Charging
Module
Preliminary Designs
Required Load Organization
FCS Tools
And Misc. fluid/gear
Canopy
Crane
Payload(s)
8 Blades
Electrical Interface
24 Cubic Feet of Fuel
Distributed Over 4 Corners
DP-5X
Feasibility Assessment
 15 Subsystems
 >54 Concepts
Feasibility Assessment
 Weatherproofing
TONNEAU
COVER
SNOWMOBILE
TYPE
CANVAS WITH FRAME
Pugh Charts
Canvas
Baseline Concept:
concept 1
ATTRIBUTE
Metal
Plating
concept 2
Custom
Tonneau
concept 1
concept 3
Snowmobile
concept 2
Custom
concept 3
RELATIVE
Metal
WEIGHT
Plating
price
0.00%
3
3
3
4
leadtime
28.57%
3
4
4
4
ease of use
4.76%
3
3
3
3
breakdown/setup time
14.29%
3
4
4
3
ATTRIBUTE
trailer type
Tonneau
Cover
Snowmobile
concept 4
trailer type
Canvas
price
-
Cover
-
leadtime
-
x
x
ease of use
x
x
x
breakdown/setup time
x
+
+
durability
durability
9.52%
3
2
2
2
-
+
+
reliability
9.52%
3
3
2
4
+
-
-
-
safety
19.05%
3
3
3
4
weight
14.29%
3
4
4
5
Raw Score =
3.00
3.48
3.38
3.76
Normalized Score =
0.80
0.92
0.90
1.00
reliability
safety
weight
-
1
1
2
3
2
4
3
5
4
5
TOTAL =
-4
-2
-2
Column Total
0
1
1
2
2
3
3
Relative Weight
1
Additional 1 (Future Use)
Additional 2 (Future Use)
Additional 3 (Future Use)
Additional 4 (Future Use)
Additional 5 (Future Use)
Row + Column Total
U
S
U
S
U
X
S
Column Total
U
S
U
X
U
X
Row Total
U
S
X
X
U
Additional 5 (Future Use)
U
U
X
S
Additional 4 (Future Use)
U
S
X
Additional 3 (Future Use)
weight
U
S
Additional 2 (Future Use)
safety
U
Additional 1 (Future Use)
reliability
breakdown/setup time
ease of use
durability
cost
leadtime
ease of use
breakdown/setup time
durability
reliability
safety
weight
leadtime
Pairwise Comparison:
Place an "S" if the row
is more important.
Place a "U" if the
column is more
important
cost
Comparison of
Attributes
0
5
0
2
0
0
1
0
0
0
0
0
0
0
1
1
1
2
2
3
3
0
0
0
0
0
0
6
1
3
2
2
4
3
0
0
0
0
0
0.0%
28.6%
4.8%
14.3%
9.5%
9.5%
19.0%
14.3%
0.0%
0.0%
0.0%
0.0%
0.0%
21 100%
Feasibility Assessment


Ramps







Individual
Folding Tailgate
U-Haul Style
Telescoping
Storage Boxes





Custom Order
Pre-Built
New Design



Flatdeck
Extended Flatdeck
Partially Enclosed





Custom Bladder
Pre-Built Bladder
“Jerry Cans”
New Design

Trailer Deck
Fuel Container
Lift Mechanisms




4-Bar
Scissor
Crane
Fold-Down Sides




Tri-fold Deck
Bi-fold Roof
Flat Deck
Ground



Manual
Manual, Folding
Powered, Folding



Latches
Ratchet Tie-Down
Self Clinching
Tie-Down
Rotor Catch Ring
Launch Platform
Crane



Holding Mechanisms


Attachment Points



Protruding Clip
Recessed D-Ring
Clinching Cam



Cabinets w/foam
Floating Net
Self-Level
Suspension
Payload Packaging
Blade Packaging



Shelves
Foam Block
Shredded Foam





VTC 1015
VTC 1500
Traco
Schaefer
Self Designed



Power Stream
Major Power
GSL
DC-DC Converter
12 Volt DC Charger
Electrical Subsystem
Overview
 Given a HMMWV’s 24V60A electrical system,
provide the ability to:
 Charge the UAV batteries.
 Power the computer
station.
 Power any additional
devices needed to
implement system design.
 Initial Ideas:
 Power Inverter
 Gasoline powered
Generator
 Combination of DC
input devices and
Power Inverter
Electrical Subsystem
Design
(A) NATO
Slave Plug
(L) Crane
B
I
(M) UAV Battery
J
(C)
Side of Trailer with
Input and Output
connectors
H
D
I
(N) Computer
Station
K
(E)
DC to DC
Converter
F
(G) 12V
Battery
Charger
 Provides
necessary power
connections.
 Parts are modular
and can be
replaced
individually.
 Safety and ease of
use is maintained
via plug/play
capability.
Feasibility Assessment
24V to 12V DC-DC Converter
Concept 1
Concept 2
Concept 3
Concept 4
Concept 5
Weight
MP VTC1015 ||
Traco 53622
SP C3822
Self Designed
MP VTC1500
Lead Time
40%
4
3
3
1
2
Cost
20%
1
2
2
5
3
Availability from Multiple Distributors
10%
4
2
2
1
2
Ruggedness
20%
3
3
4
1
3
Ease of Integration into Design
10%
3
3
3
5
3
Raw Score
3.1
2.7
2.9
2.2
2.5
Normalized Score
1.00
0.87
0.94
0.71
0.81
Attribute
12V DC Battery Charger
Concept 1
Concept 2
Concept 3
Weight
PST-DU700
MP BCD600
GSL Maximizer
Lead Time
40%
4
3
2
Cost
20%
4
3
2
Availability from Multiple Distributors
10%
2
4
2
Ruggedness
20%
3
3
2
Ease of Integration into Design
10%
4
4
4
Raw Score
3.6
3.2
2.2
Normalized Score
1.00
0.89
0.61
Attribute
Electrical Design
Issues
Section
B->C->D->E
E->K->C->I
G->H->C->J
E->F->G


Length Max Voltage Drop Current Resistance/1000 feet
(ft)
(V)
(A)
(Ω/1000ft)
28
9
9
3
4
1.6
1.6
1.6
200
120
60
60
Problem: Resistance of wires is
an issue when transmitting power
over long distances.
Solution: Calculate maximum
resistance tolerated and choose
wires based on that value.
0.714285714
1.481481481
2.962962963
8.888888889
AWG
Actually
will Use
8
11
14
19
4
10
14
14
Vibration Analysis of
Critical Components




Helicopter and payload must be protected from vibration during high speed
transportation over rough terrain
Terrain
 65 mph requirement
 Defined by the sponsor
 “Rough terrain” approximation
 Sinusoidal Ground Profile
 10” amplitude
 48” wavelength
 A fairly conservative estimate
Payload Protection
 Delicate payload must be protected from accelerations in excess of 2.5 g’s
during transportation
Helicopter Protection
 Acceleration of helicopter must not exceed 3 g’s
 No additional vibration isolation needed
 Stock trailer suspension meets this requirement
Vibration Analysis of
Critical Components
 Mathematical Model
 Calculated/estimated values for trailer tires, springs, dampers
 System of second order differential equations describing 3 degree
of freedom system under forced oscillation
 Input into Simulink
**
*
*
m1 x1  c1 x1  k1 x1  c1 x 2  k1 x2  m1 g  0
m2 x 2  c1  c2  x 2  k1  k 2 x2  c1 x1  k1 x1  c2 x 3  k 2 x3  m2 g  0
**
*
*
*
m3 x 3  c 2  c3  x 3  k 2  k 3 x3  c 2 x 2  k 2 x 2  c3 x 4  k 3 x 4  m3 g  0
**
*
*
*
Vibration Analysis of
Critical Components
Matlab Simulation
Vibration Analysis of
Critical Components
Vibration Analysis of
Critical Components
 Packaging foam selected for padding material
 ILD (Indentation Load Deflection) calculated from
desired spring constant
 Two layers of 3” thick foam to provide adequate travel
 Sides of payload container will be lined as well
 A cost effective solution
 Available from www.foambymail.com
Fuel Tank Selection
 Tanks need to conform to trailer loading
plan
 Located under toolboxes
 Space interrupted by the wheel wells
 Tanks must be suitable for military
transport
 Ballistic tolerant
 Prevent sloshing
 Fuel Safe Fuel Bladders
 Available in custom shapes and sizes
 Semi-rigid – able to deform slightly
to absorb shock
 Can be manufactured to military
specs
 Contain foam baffles to prevent fuel
from sloshing
Integration:
Requirements

Trailer Design- Built off of a standard military HMMWV trailer matching the off-road capabilities of
the HMMWV itself.

Trailer must carry 1200lbs of JP8 fuel, storage for eight main rotor blades each six feet in length,
delicate storage for $1MM payload, UAV with folded tail, 500 lb. crane, electrical ground sustainment
equipment, and FCS tools as well as miscellaneous fluids and solider gear. Must be waterproof.

Major issue is carrying all required loads while remaining within the trailer’s rated load capacity of
3000 lbs.
Standard military LTT-FE HMMWV offroad trailer from Silver Eagle Inc.
Integration: Fuel
Storage

Fuel containers are simple sheeted steel framework with custom manufactured bladders within,
specifically designed to provide required volume while keeping CG low and weight distributed.

Standard trailer deck does not extend to the outer corners of its frame. This area is required for all loads
to be contained on the unit.

Issues: Many parts require extensive welding and accurate cutting. Steel is durable and military tough,
however it is also very heavy reducing the amount of cargo the trailer will be able to carry.
Integration:
Payload,
Blades, Tools…

Storage boxes designed according to volume required per contained load, as well as symmetric,
structural design for future launch/landing platform to be added at a latter date.

Payload boxes in the front of the unit were not able to be made square due to the turning radius of the
crane’s power pack. Payload boxes are top loading for vertical lifting access.

Blade storage box consists of a side loading 84” long compartment with a single shelf integrating a
divider/cushion system.

The two door compartment tool box on the opposite side will provide storage for and operation of the
system’s electrical requirements, FCS tools, miscellaneous fluids, and solider supplies.
Integration: Crane

The Crane serves as a winch to raise and lower the UAV up/down a ramp, lift the payload into place for
assembly, and adjust engine location for CG optimization. It is also able to lift the entire UAV to a
future platform height.

The Crane mounts on a 12” x 12” flat mounting plate at the front of the trailer.

The mounting plane was raised and strengthened to provide the necessary area for mounting the crane
and reduce torsional stresses induced on the trailer tongue frame by distributing the load.
Integration:
Weatherproofing

A simple tube supported canvas cover bungee corded to the trailer frame will keep the UAV
dry and serve as protection from the elements.

The canvas and tube frame is completely removable allowing two men to quickly unload
and prepare the UAV for launch.
Required Load Organization
FCS Tools
And Misc. fluid/gear
Canopy
Crane
Payload(s)
8 Blades
Electrical Interface
24 Cubic Feet of Fuel
Distributed Over 4 Corners
DP-5X
Stress Analysis of Major
Structural Areas








Cube dimensions = 22’’ x 33’’ x 15’’
Cube Volume = 10,890 in3
Density of JP8 fuel of 6.7 labs/gal
1 gallon = 231 in3
Overall concentrated Force = 315.8lbs
Max. Stress = 15,245 lb/in2
Max. deflection = 4.55 x 10-3 in.
Max. allowable stress = 100,000 lb/in2
Stress Analysis of Major
Structural Areas




The weight of the fuel, as well as an additional
1,000lbs. (1600lbs.)
Trailer must be operational in rough terrain with
bumps causing a force of up to three times that of
gravity, therefore this entire load is multiplied by
3g.
Load is distributed.
Max deflection = .0106 inches
Budget














Trailer
Crane
Tool boxes
Ramps
Fuel bladders
Tie downs
Steel tubing
Electrical wiring
Electrical connectors
Foam padding
Travel
Office supplies
Miscellaneous
Total
Final Purchase Prices
Item
Quantity
Vender
60 in.
Metal Supermarkets
$44.00
7'' x 24''
Metal Supermarkets
$45.00
Structural steel square tubing
100 ft.
Metal Supermarkets
$225.00
Structural steel square tubing
105''
Metal Supermarkets
$85.00
Structural steel square tubing
52 in.
Metal Supermarkets
$60.00
53 sq. ft.
Metal Supermarkets
$240.00
$368.00
Structural steel square tubing
Structural steel plate
Structural steel sheet
Structural aluminum round tubing
Price ($)
46 feet
Metal Supermarkets
75 sq. in.
Metal Supermarkets
$28.00
Structural aluminum round tubing
40 in.
Metal Supermarkets
$304.00
Structural steel angle
10 ft.
Structural aluminum plate
Electric/Hydraulic Mast Crane
Metal Supermarkets
Venturo Manufacturing Inc.
Base Trailer
Silver Eagle Manufacturing Co.
Custom steel boxes for payloads, blades and
miscellaneous storage.
4
Miscellaneous hardware
Recessed tie down anchors
Ramps
Nato Slave Plug
$24.00
$5,275.00
$11,332.00
Maintainer Corp.
$4,800.00
1
Fastenal
$5,000.00
6
Erickson Manufacturing
3
AZTrucks, Inc.
$52.74
$300.00
1
Pending
#4 AWG Wire
60 ft.
B & C Specialty Products Inc
$168.00
#10 AWG Wire
25 ft.
B & C Specialty Products Inc
$12.00
#14 AWG Wire
40 ft.
B & C Specialty Products Inc
24VDC-12VDC Converter
1
Schaefer Power
12VDC Battery Charger
1
PowerStream
$115.00
Wire Connectors
8
Anderson Power Products
$174.16
16-14 AWG Spade Terminals (100 pack)
4
Grainger
$12.47
Insulated Battery Clamps (10 pack)
6
Ace Hardware
$35.01
Total Cost
$40.00
$10.80
$3,675.00
$32,425.18
Future Work Schedule
 Finalize design optimization
 Review final design with sponsor
 May require an additional visit





Acquire materials for construction
Begin product construction
Finish construction
Testing and evaluation
Write CDR
Questions?
Another UAV
 The AAI Shadow TUAV
Launch and Recovery
Portable Ground Control
Stations