Multi-Axial Payload Tray
Honeywell Aerospace (Southborough MA)
Problem:
For an upcoming experimental project, a new battery payload system needed to be designed to hold larger batteries underneath a drone on guide rails.
This device needed to move in both the x and z directions to not only hold the batteries but also offer potential for center of gravity balancing.
Objective:
Design a multi-axial payload tray assembly to allow for the apparatus to move in both the x and z directions.
Tray must be sturdy enough to hold the weight of the batteries without flexing and breaking under stress while also saving on weight.
The four rail mounting brackets must have capabilities of allowing the tray to move in both the x and the y directions while also having a securing mechanism in order to keep the tray in place and not shift during flight.
Skills Demonstrated:
3D Modeling with assembly’s in SolidWorks.
Complex problem-solving skills.
Ability to work with vendors to procure quotes and lead time to generate parts.
Process: ​
The brackets incorporated a clip like mechanism in which the interior collar of the bracket was tapered to allow for the brackets to be fixed in the y-direction in respect to the payload rods under the drone.
The top of the brackets also had press fits on one side that could then be tightened down with screws to completely hold the brackets in place on the rails, or loosed to move the brackets along the rails in the y-direction.
Press fit holes were created on the bottom of the bracket to allow for a connection with the battery tray.
The tray was then designed with slotted holes to facilitate a connection between the tray and the bracket.
These slotted holes allow for the tray to move in the x-direction (perpendicular to the payload rails) when the battery brackets are fixed.
The tray and the brackets had substantial cutouts to save wight while not compromising strength.
Outcomes:
Both the tray and the brackets were ordered from off-site facilities as well as the mounting hardware for this design.
Once assembled, a functionality test was performed in which the design passed the initial objective and performed admirably in the flight demo assisting in balancing the center of gravity of the drone.
Gained experience with making items weight efficient while not compromising their structural integrity.
Became familiar with how to design items to be 3D printed and how to incorporate press fits and tapered fits into designs.