WashU Design/Build/Fly
Role
Propulsion Engineer
Year
2021-2024
Team
WUDBF
Propulsion Engineer Overview
In my role as a propulsion engineer, I performed tests to identify the optimal motor, battery, and propeller configurations to maximize aircraft performance. Using MATLAB, RCbenchmark, and eCalc, I analyzed propulsion system data, helping our team to achieve competitive placements in the AIAA Design/Build/Fly competition: 19th out of 107 teams in 2023-2024, 29th out of 99 in 2022-2023, and 11th out of 97 in 2021-2022.
Motor and Propeller Selection
To identify optimal motor-propeller combinations, WUDBF used the eCalc propulsion design tool, setting key parameters like cruise velocity, endurance, thrust-to-weight ratio, and battery specifications. The search yielded four viable motor-propeller setups, which were then evaluated through performance plots. Among these, the SunnySky X4130-520 motor (red line) with a 13x6 propeller stood out, offering high thrust and speed across throttle levels.
Required vs. Available Thrust Analysis
The propulsion system’s dynamic performance was analyzed to confirm eCalc’s predictions and define the aircraft's speed range. Using APC Propellers' performance data—based on vortex theory and NASA’s airfoil analysis program—dynamic thrust values were calculated with RPM data from eCalc and interpolated in MATLAB. This analysis estimated the aircraft’s maximum velocity at 34.05 m/s, providing a more accurate cruise speed by factoring in actual drag effects beyond eCalc’s simplified assumptions.
Motor Test Videos
These videos show routine motor tests, where Adafruit strain gauge load cells, connected through a Tyto Robotics PCB to a laptop, capture experimental data for motor performance analysis.
CAD Drawings of the 2023-2024 Plane
The following SolidWorks drawings, created by the structures team, showcase the 2023-2024 aircraft. These detailed visuals include multiple configurations, an exploded view, component-specific illustrations, and a comprehensive Bill of Materials (BOM).
Isometric View
