Lightweight UAV Launcher

Lightweight UAV Launcher
Senior  Project  for  Aerojet Rocketdyne
Final Report
Team Rocket Power
Table of Contents
Executive  Summary 3
Introduction .4
Background 4
Objectives 7
Requirements 7
Additional  Design  Considerations .10
Design  Development 11
Ideation .11
Comparative  Analysis 11
Launching  Mechanism 11
Energy  Storing  Mechanism .13
Frame 14
Track 15
Overall  Conceptual  Design 16
Conceptual  Design 17
Final  Design 18
Details .20
Analysis .24
Launch  Mechanism .25
Winch  Mechanism 27
Carriage .29
Structure .30
Assembly .33
Manufacturing .33
Track 34
Bungee  Interface .34
Carriage  Assembly .34
Bumper  Assembly .35
Winch  Assembly 35
Assembly  Hardware 35
Considerations 36
Design  Verification  (Testing) .38
Component  Testing .38
Performance  Testing 42
Project  Management  Plan 46
Recommendations .47
Lessons  Learned 47
Design  Modifications 48
Further  Investigations  Needed .50
Conclusion .512
References .52
Appendix  A.  Hand  Calculations .53
Appendix  B.    Quality  Function  Deployment .62
Appendix  C.  Decision  Matrix .63
Appendix  E:  FEA 65
E.1:  Winch  plate .66
E.2:  Carriage  pullback 67
E.3:  Carriage  impact 68
E.4:  Lower  bungee  connection 69
E.5:  Roller  shaft 70
E.6:  Bumper  weldment .71
E.7:  Rake  Connection 72
E.8:  Track 73
E.9:  Bent  track 74
Appendix  G:  Testing  Procedures .83
Appendix  H:  Spec  sheets  for  sourced  components .92
Appendix  I:  Bill  of  Materials 98
Appendix  J:  Detailed  Drawings
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