Performance Improvements of an Unmanned Aerial System (UAS) with the use of an Aerodynamically Optimized Aeroshell

The Kennesaw All-Weather Autonomous Drone (KWAD III) is developed to meet the requirements of a customer who desired a low cost, all-weather, 3D printed, long range and endurance, high payload UAS. The primary requirements are a range of greater than 15 km and payload of at least 2 kg. The development strategy chosen, to select COTS components and 3D print significant improvements, is constrained by POP of 120 days and budget of $150,000. To reduce the high aerodynamic drag that a COTS plates-and-booms frame would generate, 3D printed aeroshells are utilized to cover the avionics stack and boom-to-frame interfaces. The aeroshell also provides protection against rainy weather. The aeroshell reduces aerodynamic drag. It reduced the parasite power required by 58%, which dramatically increased the estimated flight range from 14.4 km to 24 km, a 67% increase at a flight speed of 20 m/s. A payload lift of 10.72 kg is demonstrated. KWAD III is capable of lifting higher payload weights but was limited by the FAA max takeoff flight weight limit of 55 lb for small UASs. At this weight, KWAD III has a thrust to weight ratio (T/W) = 2.36. Powerful radios having transmit/receive range of more than 40 km allow KWAD III to be operated manually in line of sight and autonomously beyond visual range in GPS waypoint navigation. . Innovative technologies and design strategies are identified that would allow additional dramatic range and payload improvements.