Gyrochute

The Gyrochute is an Aerial Delivery platform which uses the principle  of Autorotation  and Rotor dynamics to descend the Payload to the designated location. The Gyrochute has been designed for structural integrity, payload safety and aerodynamics combining the concept of Structural rotor dynamics and Aerodynamics to fulfil its intended purpose.

 
"The description of the projects excludes the real project pictures  and design description as it is a patented project and cannot be published."

MISSION

• Development of an Aerial delivery platform capable of delivering modular payload packages to remote and disaster locations. The platform is passive and does not require external power sources to function.

• Used Cases 

  • 1. Emergency Services 

    2. Defence 

    3. IOT (internet of things) 

    4. Space Re-entry vehicle

• Focus on sustainable design and biodegradability to eliminate the need for recovery

PROJECT STAKE HOLDERS

• NSW Smart Sensing Network 

• NSW Telco Authority

• University of New Castle

• Macquaire University

Role and Team Structure 

I served as Mechanical Engineer   for the Dandelions-1 satellite payload  . My main responsibilities included:

1. Preparing CAD models for the Mechanical and thermal management systems using AUTODESK INVENTOR. 

2.  Validation of the Mechanical/structural components to qualify for space environment. 

3. Running  Dynamic structural (MODAL,RANDOM VIBRATION, HARMONIC, SHOCK RESPONSE) simulation on the payload and ensuring the natural frequencies are within the allowable limits as per the launch provider's criteria. 

4. Visiting Flight qualification test centres to perform shake table test( Vibrational) and Thermal vacuum  ( functionality test ) 

5. Procurement  of Materials needed to mount the sub-systems of the payload 

6. Integration of the payload and ensuring that the mechanical components are well within the tolerance limits (0.005mm). 

7. Design and implementation strain gauge- composite installation to prepare the material samples for data acquisition. 

8. Implementing design matrix ,issue analysis , KPI framework in the workflow for efficient and precise design choices.

Mechanical Design Team members : 

1. Lea Molnar - Lead Aerospace engineer 

  a. Stakeholder management and communication 

        b. Aerodynamic Optimization 

c. CAD design and assembly 

d. Project Management

e. Flight qualification test planning 

2. Vidisha - Aerospace Engineer 

 a. Procurement 

 b. Airframe assembly and integration 

 c. Model Clearance checks 

 d. CFD simulation 

e. Pre-processing ANSYS Models. 

Outcome and Accomplishments 

Throughout the course of this project, I have gained valuable skills and knowledge that have helped me develop as a professional. The following are some of the outcomes and achievements that I have attained:

• I have Successfully Completed the tasks handed over by the leads and completed them in time with addition of innovative touch to the research methodology. 

• I have demonstrated expertise in  Composite Modelling and  Structural dynamics along with rotor dynamics   to ensure the rotorcraft could withstand the extreme failure conditions. 

• I have developed strong problem-solving skills in the aerospace domain in regards to aerodynamics , airframe sizing and Aerostructures. 

• Improved Communication and Collaboration Skills

Some of the noticeable achievements that I have made during the process of design are : 

1. Produced High-Quality Deliverables

   1. • 1. • Produced high quality deliverables that met the project requirements by using Issue analysis Framework to avoid discrepancies and mitigate them in the next integration.

• Ensured that the Gyrochute model had very less discrepancies in the manufactured product compared to the original design (CAD).  

• Ensured that the simulation results were somewhat similar to the actual flight test.

This has helped me develop the attention to detail required to produce work that meets the highest standards.

2. Gained Valuable Experience

• Through this project, I gained valuable experience that has helped me grow as a professional , due to its requirement for dynamic design approach. . I developed my project execution , problem-solving, communication, and collaboration skills. This experience will be invaluable as I move forward in my career.

Project Details 

Design approach 

Gyrochute was designed taking in to account the principle of Autorotation and Stabilising this phenomenon. The process of designing the Gyrochute was mainly focussed virtual simulation (ANSYS) of the phenomenon in different geometries and validating the geometry for aerodynamics and structural dynamics.
The Gyrochute is  made up of the components such as : 

1. Propeller Blades

2. Payload hub &

3. Landing impact structure

The design of the Gyrochute followed the following approach as listed below: 

1. Problem Statement  

The Gyrochute design was considered focusing on the connectivity challenge to cater the needs of  the customers to drop communication package in to the  designated location. The system had to be unpowered and mode relaible , so autorotation and stabilising the system was the prime focus of the project. 

2. Design 

   • Aero Design : The aero design of the Gyrochute was carried out using similar approach to the process used for aircraft. Initially, the wing profile research was carried to find the most suitable wing profile. Followed by the CFD simulation on the profile to obtain all the dimensionless numbers such as lift, drag. The data was then used to carry out the ANSYS Fluent simulation on the estimated wing span. After the process of determining the wing profile, the airframe sizing was carried out to ensure the correct size of the Gyrochute for the different payload sizes. 

   • Airframe design:  The airframe of the Gyrochute was manufactured using composite materials. The wing profile was studied to ensure that the wing profile is manufacturable and some simulations were run on the Gyrochute airframe to study its aero elastic behaviour. The modelling of the Gyrochute was carried out on the sized model to better compensate the weight carrying capacity of the Gyrochute. The airframe design was an intensive process which involved the following: 

a. Preparing CAD model which would be used for manufacturing and for analysis 

b. Preparing Space claim model to simplify the model for reducing computational time. 

c. ANSYS ACP-Pre/Post  model was prepared to model the Gyrochute body 

d. Pre-stressed zone model was created to replicate the pre-existing stresses on the Gyrochute body. 

e. Modal analysis of the Gyrochute was carried out to create Campbell diagram which represents the change of natural frequency of the system  with the increasing RPM. 

f. Combining the study with the CFD data to get the accurate pressure mapping , this would enable the multiphysics study of the model . 

Gyrochute Flight test 

The Flight test for the Gyrochute was carried out on a local farm in Melbourne, Victoria.  The Testing of the products was carried out using high power drones. 

Aim

The aim of the flight test was to verify the following : 

1. Payload survivability and functional testing of communication package. 

2. Verifying the simulation results such as Terminal velocity , drifting, fluttering  to further optimize the Gyrochute for  weight handling capabilities. 

3. Observing the behaviour of the Gyrochute in the Gust winds. 

Procedure

The procedure for testing the Gyrochute was carried out using the following process: 

1 . The Drones raised the Gyrochute tethered via rope over the release point ( at 30, 50,60,100 metres). 

2. The Gyrochute was released from the drone using release mechanisms  and let to free fall. 

3. After the drop , the Gyrochute flight behaviour was studied to study its flight behaviour. 

Outcome

• The Gyrochute Behaved somewhat in similar way to the expected. 

• The Gyrochute delivered the payload safely on ground and the communication test was successful .