Skills Applied: Transportation Design (Sketching & CAD (Rhino3d, SW)), Composites Design, Rendering (Keyshot), Concept of Operations Design
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Process Outline:
Elroy Air’s Cargo Modularity
Product Mission
Pod Prototypes
Fabrication Documentation
Cargo Pod Packing Instructions
Cargo Pod Product Family
Elroy Air’s Cargo Modularity
Chaparral’s cargo handling system lifts and latches cargo securely without the need for human assistance. Using proprietary hardware, the aircraft can accommodate unlimited payload types.
Product Mission
Develop a family of modular aerial cargo systems compatible with the existing Elroy Air Chaparral Aircraft.
The development of a versatile product line of cargo pods marks a pivotal stride in bolstering the capabilities of our aerial platform to execute a myriad of missions seamlessly.
Whether deployed for logistical operations, emergency response, or surveillance missions, these pods are meticulously engineered to accommodate various payloads with optimal efficiency and security.
Support 300lbsAerodynamic SurfacingAutonomy Interface
Autonomy Interface
The aircraft is equipped with an expanding frame and latch receptacles. Each pod contains mirroring features for optimum modularity.
Configuration CFD
Aerodynamics and configuration drive design. CFD analysis was used to identify the best configuration to lead the pod design process.
Cargo SpaceClaim
This “keep out zone” is a stand-in for the types of cargo the vehicle will be carrying. Structures should be designed around this geometry.
Geometric Requirements
Design drivers that every pod configuration must satisfy.
Cardboard POC
To test the configuration, we built a cardboard proof of concept to marry with the ground autonomy robot for customer feedback.
Fiberglass Prototype
To kickoff the team’s understanding of composites, a fiberglass prototype was fabricated to work with the ground autonomy bot.
Carbon Canoe Pod
In 2019, Elroy Air built its first full-scale flight-capable vehicle. A carbon fiber pod was developed to carry 150 lbs of cargo at the designated flight loads all while maintaining an empty weight of 30lbs.
Carbon Palletized Pod
Following on-site customer demonstrations for customers, the addition of a palletized cargo pod was added to the product family.
Pallet Configuration
The Palletized Pod uses a fairing-on-pallet design to ease loading of heavy cargo. This configuration features a standardized L-Track system for securing shipments, ensuring simple loading and safe travel for hefty items.
Canoe Configuration
The Express Pod features an open-top design for easy loading of smaller cargo items. With quick release buckle snaps for securing shipments, this configuration enables rapid loading and unloading operations.
