This is the presentation we gave at the SWE National Team Tech Competition for the hinge moment measurement system. I was a co-directed of the team, I primarily oversaw the design and construction process.

2. ‘Conceptual Aircraft Hinge Moment Measurement System’(CAHMMS) California Polytechnic State University - San Luis Obispo with Lockheed Martin Aeronautics Company October 30, 2009 Cal Poly SWE – Team Tech 2

3. October 30, 2009 Cal Poly SWE – Team Tech 3 Team Tech Overview Project Background Team Dynamics Engineering Process Phase 1: Brainstorming Phase 2: Design Phase 3: Manufacturing Phase 4: Validation Industrial Interface

4. Project Background

5. Purpose Currently measures forces acting on entire aircraft Lockheed (LMC) wanted to measure forces acting on individual control surfaces Use data to determine appropriate actuator/servo size for flight Current actuation systems are too heavy October 30, 2009 Cal Poly SWE – Team Tech 5

7. Desirable, but not required

8. ± 30º deflection

9. ± 1º position accuracyDevice Compatible with low turbulence wind tunnel environment (Cross Section: 2’x3’) System must not affect flight characteristics of aircraft model Must work with typical control surface Must be accurate to within 5% 5in span 2in chord Wind Tunnel at Lockheed Martin facilities in Palmdale, CA 0.2in thick 10/30/2009 Cal Poly SWE – Team Tech 6

10. Universal design Compatible with SLA models Design validation for accuracy Analyzing Computational Fluid Dynamics (CFD) Comparing against published data Guidance from engineering advisors Team Specifications October 30, 2009 Cal Poly SWE – Team Tech 7

11. Team Dynamics

12. October 30, 2009 Cal Poly SWE – Team Tech 9 Team Establishment Students were selected based upon: Variety of engineering disciplines A range of technical experiences Dedication to project Communication abilities Interests in learning and applying knowledge

13. Demographics October 30, 2009 Cal Poly SWE – Team Tech 10

14. Team Development Initial project objective description Weekly meetings Cal Poly wind tunnel tour SolidWorks Tutorials Independent research Team website October 30, 2009 Cal Poly SWE – Team Tech 11

15. October 30, 2009 Cal Poly SWE – Team Tech 12 Team Building Ice breakers Board games Ice cream socials Team dinners End-of-the-Year Banquet

16. Engineering Process Brainstorming, Design, Manufacturing, and Validation

17. Design Process October 30, 2009 Cal Poly SWE – Team Tech 14

18. Schedule - Final Schedule - Initial Preliminary Design Review Detailed Design Review Final Design Review Preliminary Design Review Detailed Design Review Final Design Review Progress Report Progress Report Project Proposal Final Report Project Proposal Final Report

19. Phase 1: Brainstorming

20. October 30, 2009 Cal Poly SWE – Team Tech 17 Phase 1 Obstacles

22. Phase 2: Design

23. October 30, 2009 Cal Poly SWE – Team Tech 20 Phase 2 Obstacles

24. Team Organization LMCAdvisors SWEAdvisor Directors Subgroups Pod Developed device housing Attachment Developed attaching device to wing model Testing Developed testing and validation procedures Electronics Developed software and chose internal measuring mechanisms October 30, 2009 Cal Poly SWE – Team Tech 21

25. Work Breakdown Structures Students able to communicate and set realistic project goals October 30, 2009 Cal Poly SWE – Team Tech 22

27. SolidWorks labs

28. Compatible with rapid prototyping systems

29. Compatible with Computational Fluid Dynamics (CFD) testing programs

30. Easy visual aid, virtual prototypeOctober 30, 2009 Cal Poly SWE – Team Tech 23

31. First Generation Top Half of Pod Bottom Half of Pod October 30, 2009 Cal Poly SWE – Team Tech 24

32. First Generation Issues October 30, 2009 Cal Poly SWE – Team Tech 25 Oversized pod Increased noise levels No internal heat dissipation Non-versatile attachment system Weak mounting structure

33. Second Generation October 30, 2009 Cal Poly SWE – Team Tech 26

34. Tri-Pod Mount Design October 30, 2009 Cal Poly SWE – Team Tech 27

35. October 30, 2009 Cal Poly SWE – Team Tech 28 Generation Comparison

36. Hinge Design – Press-Fit Pin March 10, 2009 Cal Poly SWE – Team Tech 29

37. Sweep Surface Contours of Velocity Magnitudes CFD Analysis Sweep Surface Contours of Pressure Coefficient All CFD testing done by team No prior experience Programs learned from ground zero Proof that pod did not inhibit flight characteristics Wind tunnel simulation Sweep Surface Contours of Pressure Coefficient Sweep Surface Contours of Velocity Magnitude October 30, 2009 Cal Poly SWE – Team Tech 30

38. Phase 3: Manufacturing

39. October 30, 2009 Cal Poly SWE – Team Tech 32 Phase 3 Obstacle

41. Rapid Prototypes (RP) were provided by LMCOctober 30, 2009 Cal Poly SWE – Team Tech 33

44. Phase 4: Validation

45. October 30, 2009 Cal Poly SWE – Team Tech 37 On-Site Testing 2 days on-site validation at Lockheed Martin facilities in Palmdale, CA Access to wind tunnel and measurement validation Compatible with wind tunnel environment Within 3% of NACA publications

46. ProjectSummary October 30, 2009 Cal Poly SWE – Team Tech 38

47. Time Labor Weekly meetings (~2 hrs/wk) Subgroup meetings (~3 hrs/wk) Individual research & design Team tutorial sessions Design Reviews October 30, 2009 Cal Poly SWE – Team Tech 39

48. Budget Allocation Summary Prototyping Pod group $ 1,200 Attachment group $ 320 Electronics group $ 130 Testing group $ --- Travel Design Review (LMC) $ 500 Annual Conference $ 1,400 Marketing/Publishing $ 700 Team Development$ 250 Project Total$ 4,500 October 30, 2009 Cal Poly SWE – Team Tech 40

49. Industrial Interface

50. Provided all project funding Initial site visit Weekly phone conferences Quarterly design reviews Donation of parts October 30, 2009 Cal Poly SWE – Team Tech 42 Working with Lockheed

51. "The team tackled CAD, motion control, mechanism design, precision instrumentation, CFD, and a final wind tunnel validation test at our facility that was extremely successful. I was deeply impressed by the enthusiastic professionalism and hard work of the students. The team can be extremely proud of the success they have achieved over the challenging and interlocking facets of this project." Mark Buchholz Lockheed Martin Aeronautics Company Aerodynamics Engineer October 30, 2009 Cal Poly SWE – Team Tech 43 Advisor Quote