CARBON FIBER WING - Proof Load Test Setup! (Wing Load Test)

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The DarkAero 1 utilizes a carbon fiber wing that is constructed using a unique structural approach called Hollow Grid. Before flying this wing, we needed to prove it can handle the stresses generated by aerodynamic loads in flight. In this video, Ryan talks through some of the hardware and other details of the setup for the positive G proof load test.

We had to built a test fixture to support the wing in an inverted position and then level it in the roll direction. The inverted orientation allowed us to use the weight of sand bags to simulate aerodynamic lift loads. The support fixture was designed to hold the wing at a specific pitch attitude to replicate worst case loads for the wing structure. We chose to build the test stand out of wood because it is easy to work with and cost effective. However, we had to install some localized aluminum and steel reinforcements into the test stand where the wing attach bolts interfaced.

Mechanical scissor jacks were positioned under the wings to help control the wing load and wing deflection during the test. We had to make pads to distribute the reaction forces from the jacks into the wing. The pads were made from sections of CNC cut foam.

We also made foam pads to sit on top of the wing in between the sand/concrete bags and the wing skin. The foam pads were marked to guide the position of sand bags that were stacked on the wing. The sand bag distribution was generated and tracked with a spreadsheet tool we created.

Around the perimeter of the wing was an aluminum frame with rulers attached to it to measure the deflection and the twist of the wing. FAR Part 23 states that the wing must sustain limit loads without detrimental or permanent deformation. While the wing was deflected, we confirmed that the ailerons were able to still move freely.

For the next test we plan to add station labels on the wing to more clearly organize the position of weights.

Thank you for watching!

00:00 - Intro
00:29 - Test Fixture
02:15 - Load Control
03:34 - Load Pads
06:28 - Measurements
08:20 - Lessons Learned

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Видео CARBON FIBER WING - Proof Load Test Setup! (Wing Load Test) канала DarkAero, Inc