Proteus Plus PW51

Last crawled date: 4 years, 2 months ago

This is a 1.8 m span version of the Proteus wing, with flaps, using the PW51 airfoil and designed to print in a 200 x 200 x200 mm build volume.
Following Peter Wick's advice, the flaps and elevons are bottom hinged.
This version is designed to be an improvement on the 1.65 m span version (which uses the MH45 airfoil) shown in this video:https://www.youtube.com/watch?v=2Ngxi2U_f7g
It has now flown successfully, exhibits excellent efficiency, and handles well (video coming).
It uses two swept 1x10x715 mm carbon fiber half - spars and a rear 5 mm OD x 500 mm long tube spar (the same as the Proteus).
For transport, the design allows the outer halves of the wing to be slid off the spar after disconnecting the elevon clevises. Be sure to use a strong cross-hatch glass reinforced tape 2.5 cm wide for joining the wing sections, e.g.:https://www.aliexpress.com/item/33040897587.html?spm=a2g0o.productlist.0.0.11566b91frQ3BL&algo_pvid=30557374-9691-486b-9e65-163e8c47de83&algo_expid=30557374-9691-486b-9e65-163e8c47de83-14&btsid=d6647c72-a085-42a8-9fb5-d9c117668db3&ws_ab_test=searchweb0_0,searchweb201602_3,searchweb201603_55
otherwise the gears in the elevon servos could be stripped if the outer half of the wing comes loose during a crash or bad landing.
Printing instructions are similar to the original Proteus: https://www.thingiverse.com/thing:2086413
Note: the hatch is designed to be printed on its side.
The spar joiner is printed in PLA+ at 240 C with no fan, 5 perimeters and 65% infill.
Zip ties are used to reduce the risk of it splitting and a section of 1x10x120 mm strip is used to connect the spar joiner with the fuselage.
The flap and elevon are each comprised of 2 pieces that need to be glued together with a 2 mm OD carbon fiber rod and CA glue, after a little sanding of the mating ends.
I have included Simplify3D factory files. Note that the starting scripts might need adjustment as I use Marlin's Unified Bed Levelling system (G29 etc) and volumetric extrusion mode.
The temperature is set to 240 C, suitable for PLA+.
A rear tube spar 500 mm long is used close to the CoG to increase the wing stiffness.
The reason thin 1x10mm strip is used for the spars is so they flex rather than ripping the fuselage apart in a crash/hard landing.
I highly recommend printing the nose using a (semi-) flexible filament.
All up flying weight: 960 g
Wing area: 30.4 dm^2 , 3.27 sq ft
Wing loading: 31 g/dm^2
Printed Parts weights and approximate print times:
Nose: 43 g, 7 hours
Rear fuse: 96 g, 10.5 hours
Spar joiner: 18 g, 1.5 hours
Hatch: 17 g, 2 hours
Fin: 21 g each, 6.5 hours for 2
Root wing: 81 g each, 6 hours each
Mid wing 0: 63 g each, 10 hours for 2
Mid wing 1: 45 g each, 7 hours for 2
Tip wing: 37 g each, 5.5 hours for 2
Flaps: 56 g for 2, 6 hours for 2
Elevons: 47 g for 2, 6 hours for 2
Total weight printed parts: 770 g
Total print time (approx): 74 hours
Vitamins:
The 1x10 mm CF strip can be found here: https://www.aliexpress.com/item/32720654666.html?spm=a2g0s.9042311.0.0.27424c4dea5VT9
The 5 mm OD tube spar can be found here:https://www.aliexpress.com/item/32242824992.html?spm=a2g0s.9042311.0.0.27424c4dea5VT9
The 2 mm and 3 mm joiner dowels can be found here:https://www.aliexpress.com/item/32573564619.html?spm=a2g0s.9042311.0.0.27424c4dea5VT9
The dowels for joining the nose to the rear fuselage should be cut to 13 mm from 2 mm rod.
The dowels for joining the wing sections should be cut to 35 mm from 3 mm rod
The dowels for joining the flap and elevon sections should be cut to 55 mm from 2 mm rod.
The hinges should be cut to 14 x 27 mm from 0.3 mm hinging film, e.g. :https://hobbyking.com/en_us/ca-hinge-sheet-180mmx140mmx0-3mm.html
I don't bother gluing the hinging sheet into the wing or elevon. I just insert the hinges then apply a single layer of Blenderm hinging tape on the bottom surface only, to seal the join.
Servos (4 needed):https://hobbyking.com/en_us/hxt900-micro-servo-1-6kg-0-12sec-9g.html
2x 30 cm long servo extension leads for elevon servos.
Elevon linkage : 70 mm (horn to horn, including clevises)
Flap linkage : 65 mm (horn to horn, including clevises)