Case Studies

Neural Robotics Corporation

Intake Manifold Design

Left: AutoCopter  -  Right: Initial Intake Manifold

The Neural Robotics Corporation has developed the AutoCopter, a self-stabilized unmanned mini-helicopter that can be used as stable aerial platform in the sky. Applications include aerial photography, surveillance, pipeline and utility line inspection, convoy escort, and mine detection. Among other capabilities it will perform aerial photography and maintain smooth stability and position. The AutoCopter will fly to altitudes up to its design limit of 7000 MSL.

The Challenge

In such a technically sophisticated machine every cubic inch of usable space and each gram of weight impact the performance of the helicopter. NRI came to INERGI Engineering to design an intake manifold that would better manage space inside the craft that was occupied by part of the carburetion system. The repositioning of some internal fuel system components would be of great functional benefit to Neural Robotics. Creating space inside the craft required the design of a new intake manifold.

Manifold SLA

The Solution

The Autocopter uses a Swiss-built, high-output, two cylinder Zenoah engine (a favorite of Ultralite and experimental aircraft enthusiasts worldwide). INERGI Engineers took the stock intake manifold and reverse engineered it. Scanning the existing manifold, pulling the resulting surface geometry into Solid Edge as a template, INERGI Engineers then used Solid Edge to design a new fuel/air mixture channel. The new manifold design was then analyzed using fluid dynamic analysis software. The flow of the digital fuel / air mixture was optimized and the manifold design was tweaked in Solid Edge.

INERGI Engineers (hot rodders at heart) then made a rapid prototype of the intake manifold and tested in INERGI’s “infinite box” flow chamber. The design did not perform as well as expected or as well as the analysis has indicated. Relying on INERGI’s Design- Use-Learn methodology, the project moved back into the design phase to revise the design, pull just a little more flow and improve side to side balance in the manifold.

Manifold Final Product

Back to the Flow Meter

The Rev Three intake manifold was rapid prototyped, tested and performed well. In fact the final version of the manifold performed so well it added 10 lbs of capacity to the helicopter.

The Results

Solid Edge was the tool used to design and refine the aluminum intake manifold. The result: The Autocopter payload capacity was 15-20 pounds, now it is 25 - 30 lbs depending on configuration. That is a 60% increase in payload capacity.

In the words of our client, “I want to give lots of credit to James Bullington (and team) at INERGI Corporation for doing an outstanding job at a very reasonable cost. This company is amazing when you realize all the different things they can do (if you’re in Huntsville you’ll want to take a tour).”

INERGI also made the initial run of aluminum intake manifolds for NRI.

 

ALSO SEE OTHER CASE STUDIES:
ShotSpotter  ::  Quantum3D

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