This week during lab, a few more tests were completed with the kite using the plastic bag. We tested the newly printed end caps for the kite which helped keep the vertical carbon fiber rods from puncturing the plastic. This improved the durability of the kite and gave us a place to attach the material on the top of the thin carbon fiber rods. Because of the low profile of the end caps and the light weight of the end caps the actual performance of the kite seemed to not be affected. We determined that this was a suitable prototype to outfit with the nylon.
Before starting the outfitting process we took a few measurements. The first measurement we took was the weight of the kite. For our first prototype the kite was 25.1 grams. The other measurements we took were the locations of the bridal points. The tethers closer to the front of the kite on the diagonal outer pieces of the kite, see Figure 2 from last week, were 12 cm from the front point of the kite. The tethers farthest from the front of the kite on the diagonal pieces of the kite were located 10 cm from the back corner of the kite. Lastly, the last set of tethers, on the center piece of the kite, where located all the way at the back of the kite. We felt that it was important to measure these things be redoing the kite in nylon.
We were then ready to take apart the kite and outfit it with nylon. The first step was to take off the plastic in the best condition possible to be able to use it as a template for the nylon. The plastic, removed from the kite is picture in Figure 1 below. As you can see we were able to remove the plastic in pretty good shape with minimal tares. We used this template to draw the outline of the needed fabric on the nylon. After drawing the exact template we then added an inch to each side so that we would be able to fold the kite over along the edges to create a strong connection point to the frame of the kite by creating a pocket for the rods to go through. We then used a soldering iron to cut out the needed pattern from the yard of nylon that we purchased. The cut out material is picture in Figure 2.
Figure 1 - Plastic Used to Make First Prototype
Figure 2 - Nylon Cutout for Prototype
After cutting out the nylon it was time to attach it to the kite. Using gorilla tape to do this it took about 15 minutes to do this. The fabric was able to be wrapped around and taped to the 3 horizontal carbon fiber rods and taped to the top of the end caps on the vertical rods. The kite was then outfitted the way the kite was outfitted in the first flight with the plastic that was successful. Using the nylon though our test flight was not successful and Daniel wishes it was just that his flying skills were a little bit off. When using the plastic the area from the end caps to the front point of the kite were taunt the entire time. When we added the nylon though this area became very lose because the nylon put more strain on the frame then the nylon. The nylon was pulling the vertical rods forward a lot, to the point that the kite was not able to fly.
After being stumped for a little while we were able to come up with a solution though. We came up with a plan to add two diagonal supports that will run from the front point of the kite up to the top of the vertical carbon fiber rods. This will keep the vertical rods from having the ability to be pulled forward. This will also increase the overall rigidity of the kite along with the weight. The first sketches of this design are pictured below in Figure 3 and Figure 4. Figure 3 pictures the top view of second prototype while Figure 4 depicts the back view. As you can see from Figure 3 the back view of the kite does not differ from the first prototype.
Figure 3 - Basic Top View Sketch for Second Design
Figure 4 - Basic Back View Sketch for Second Design
While this week we were not able to complete our primary task of the week, which was to outfit the kite in nylon, we made important steps in the right direction to reach this point. By adding the two new rods in the kite two more connectors have to be made to connect the vertical carbon fiber rods in the back of the kite to the diagonal supports. The front connector also has to be redone since there are now five rods going into the front of the kite instead of three.
Next week, we are going to be very busy. Last week, we started to put together a plan to complete a rough draft of our final design brief, which we have to put into action this week, so that the draft is complete before class next week. We also plan to create 3D models of the new connectors and print them on either Daniel's or the Innovation Studio's 3D printers. Hopefully, these will be finished early enough in the week so that we are able to outfit the kite again in nylon. Since the actual profile of the kite is not changing with the new design, we hope to be able to use the same cut out of the nylon to conserve material. We do not expect any major problems to arise this week other then having to deal with the limited supply of 3D printers, as more and more groups try to use the printers. We also didn't get set off of our schedule for the next week and we will remain on schedule unless any nightmares may arise. Hopefully, this week will be smoother sailing then last week as long as we saddle up, keep it reined in for the next week, and make sure we continue to hoof it till the end. By doing this we will remain in a stable position to finish the race strong like Always Dreaming did.
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