Weight estimation

Weight estimation is one of the crucial processes in designing an aircraft and it must be done early in
the design process. To get the best approximation, this particular process must be checked,
rechecked and updated frequently. Thus, this section will be discussing about the approximation
method that is used in estimating weight of our UAV and assumptions made to simplify the
calculations. Generally, the weight of an aircraft is made up as follows:

Gross weight = standard empty weight + usable fuel + payload + crew + ballast
Standard empty weight = (power plant weight + structure weight + weight of controls +
weight of equipment and services) + (weight of unusable fuel, full operating fluids and full
oils)
Structure weight = weights of wing(s) + fuselage + engine nacelles + tail unit + landing gear

However, since we are designing a UAV, there are some components that can be neglected such as
seats, de-icing gear, crews and air-conditioning system, which can simplify the estimation process.
Firstly, the gross weight is estimated by using graphs in preliminary design, in which we compared
around 20 models of existing UAVs in the market. Next, that particular weight is then compared with
the approximation methods from Stintons book, entitled The Design of the Aeroplane and the
calculations are shown as below:

1) Power plant weight estimation

Since we are designing a small UAV, we have decided to use a 2 stroke piston engine with
single cylinder because it is lighter and has simple construction, in comparison with 4 stroke
engine. This particular engine is made by UAV Factory Ltd. Europe and its specifications are
shown in table 1.1. As for installation factor, Fp, the value is depending on types of engine,
which can be determined by using figure 1.4.

Figure 1.1: Engine model of UAV28-EFI (1) Figure 1.2: Engine model of UAV28-EFI (2)

Figure 1.3: Engine model of UAV28-EFI (3)

 Table 1.1 : UAV28-EFI specifications

Figure 1.4: Engine Installation Factor, Fp

 Thus, the power plant weight is;

= Fp( )( )

1.74
= 1.3( )( )
25 25

= 2.26

Wp= weight of power-plant, kg

We= weight of engine, kg

Fp = installation factor

P = power rated, W

Wo= gross weight, kg

2) Wing group weight estimation

The weight of wing(s) is a result of combinations between many components such as spars,
booms, struts, wires and other attachments and the value is varies, depending on wing loading,
wing area, wing span and other characteristics. In this approximation, the value of cantilever
wing weight ratio is gotten from figure 2.1 and the ultimate load factor is assumed to be 4.

Figure 2.1: Relative surface weight per unit area of wings and tails
 Thus, the wing group weight is;

(1000)( )
= Fw

4 25
(1000) ( 2 ) 4
= 1.0
25 25

= 2.236

Ww = weight of wing group, kg

Fw = cantilever wing weight ratio

N = ultimate load factor

b = wingspan, m

AR = Aspect ratio

W = wing loading, kg/m2

3) Fuselage weight estimation

The weight of fuselage is another large part in the UAV. The value is affected by the aircraft
group and type of fuselage as shown in figure 3.1 and 3.2, respectively.

Figure 3.1: Ratio of fuselage weight/surface area

 Figure 3.2: Fuselage weight factor

Since we are using single engine and it is mounted at the rear of the fuselage, the metal fuselage
weight per unit surface area and design factor is 6.2 kg/m2 and 1.04, respectively. By using those
factors, the weight of fuselage can be calculated as follows;

= ( )( )

= 1.04(6.2)(0.02)
25

= 3.224

Ff= design factor

= ratio of fuselage weight/surface area

= ratio of surface area/gross weight

4) Stabilizer and tail unit estimation

For this section, the approximation is including the elevators, fin, rudder and various kinds of
tabs, if applicable. From the theory, the total weight of this particular unit is about 2 to 4 percent
of the gross weight. By assuming the fraction is 3%, the weight of tail can be determined as
follows;

= 0.03

= 25 0.03 = 0.75

5) Undercarriage weight estimation

The fraction of landing gears weight to the gross weight is a little bit higher than the tail unit,
which is about 4 to 6 percent and it is depending on type of aeroplanes and landing gears. For
light aeroplanes with nose wheel landing gears, the weight ratio is given as follows;

= 0.055

= 25 0.055 = 1.375

6) Fuel and oil supply estimation

In this approximation, the system is divided into two categories, which is the fuel systems and
fuel tank. The unknown ratios are determined by using figures below;

Figure 6.1: Power/gross weight ratios of propeller-driven aircraft

 Figure 6.2: Fuel Tank weights ratio

For fuel systems (cocks, pipes and pumps):

= 0.05

= 25 0.05 0.07 = 0.0875

For fuel tanks (rigid fibreglass):

7 0.4
= +

= 0.18 = 4.5

7 0.4(4.5)
= +
25 25 25

= 8.8

Total weight of the fuel system:

+ = 8.8 + 0.0875 = 8.875

7) Fuel load

For single engine light aeroplanes, the design fuel load can be estimated as below;

= 0.13 = 3.25
8) Weight of systems

There are several systems involved as we designed the UAV, which are flying controls (including
telemetry for fully autonomous flight) and electric systems and the value of system weight ratio
is ranging from 0.06 to 0.12, in general. Assume we take 0.08, the weight of systems is;

= 0.08

= 25 0.08 = 2.0

9) Payload

For our UAV, the payload is detachable camera from Octopus ISR Systems, which is a subdivision
of UAV Factory Ltd. The model is Epsilon 135 and the specifications are shown below;

Figure 9.1: Dimensions of Epsilon 135

Figure 9.2: Specifications of Epsilon 135

Total weight estimation:

Structure weight = weight of wing+ fuselage+ tail unit+ landing gear

= 2.236 + 3.224 + 0.75 + 1.375

= 7.585 kg

Empty weight = weight of power plant+ structure weight+ weight of systems+ weight of fuel systems

= 2.26 + 7.585 + 2.0 + 8.875

= 20.72 kg

Gross weight = Empty weight+ Usable Fuel+ Payload+ Crew

= 20.72 + 3.25 + 0.9 + 0

= 24.87kg 25 kg

From the calculation above, it can be observed that the estimated gross weight is almost similar to
gross weight from preliminary design.

***reference***

1) http://octopus.uavfactory.com/uav-payloads-equipment/epsilon-135-hd-day
2) http://www.deepscience.com/articles/engines.html
3) http://pdf.aeroexpo.online/pdf/uav-factory-ltd-europe/uav28-efi-turnkey-engine-
system/174156-6722.html#open
4) The design of the aeroplane, darrol stinton