Abstract
This paper presents different methods for the design of a hand-launchable, fixed wing, fuel cell-powered unmanned aerial vehicle (UAV) to maximize flight endurance during steady level flight missions. The proposed design methods include the development of physical models for different propulsion system components. The performance characteristics of the aircraft are modeled through empirical contributing analyses in which each analysis corresponds to an aircraft subsystem. The contributing analyses are collected to form a design structure matrix which is included into a multi-disciplinary analysis to solve for the design variables over a defined design space. The optimal solution is found using a comprehensive optimization tool developed for long endurance flight missions. Optimization results showed a significant improvement in UAV flight endurance that reached up to 475 min with take-off ratio equals to 59 min/kg. Wind tunnel and bench-top tests and HiL simulation tests are performed to validate the results obtained from the optimization tools. Validated optimization results showed an increase of the overall UAV flight endurance by 19.4% compared to classical approaches in design methods.