MET2011_Louderback_David

HOVERCRAFT THRUST SYSTEM AND DRIVETRAIN
A thesis submitted to the

Faculty of the Mechanical Engineering Technology Program
of the University of Cincinnati
in partial fulfillment of the
requirements for the degree of
Bachelor of Science
in Mechanical Engineering Technology

at the College of Engineering & Applied Science
by
DAVID LOUDERBACK
Bachelor of Science University of Cincinnati
May 2011
Faculty Advisor: Dr. Ahmed Elgafy

ABSTRACT
The thrust system and drivetrain for the hovercraft had to be designed and constructed to
enable adequate acceleration and a top speed of 50-60 mph. In the end, the thrust to weight
ratio puts this craft’s acceleration in the “racing craft” category and the top speed has been
calculated to be 68.5 mph.
The drivetrain had to be designed to efficiently and reliably transfer the power from the 105
hp automotive engine to the 42” fan. A synchronous belt was chosen to reduce the likelihood
of belt slippage and to efficiently transfer the power.
Since a single engine/fan integrated hovercraft setup was chosen, the engine and drivetrain
for the thrust system also had to power the lift system. Due to this, some compromises had to
be made, such as a variable blade fan, which can accept 6, 9, or 12 fan blades. Six blades
would be better strictly for thrust, while 12 blades would better suit a lift system. The
available adjustment gives room for compromise.
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ACKNOWLEDGEMENTS
I would like to thank Professor Elgafy for his support and encouragement throughout this
project. Also great thanks goes out to John Calder of Dorsey Alexander, Inc. and Scott
Hartman of Onvio for their generous donations to the Hovercraft. John and Scott provided
all of the power transmission components for this project. Without the donation of materials
and use of the shop at Blue Ash Tool and Die, this project would not have been possible. I
would also like to thank Jeremy Brewer for his donation of the Mazda engine and his
assistance in getting it running, as well as all of our additional sponsors.
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TABLE OF CONTENTS
HOVERCRAFT THRUST SYSTEM AND DRIVETRAIN .................................................... 1

ABSTRACT ............................................................................................................................. II
ACKNOWLEDGEMENTS .................................................................................................... III
TABLE OF CONTENTS ........................................................................................................ IV
LIST OF FIGURES .................................................................................................................. V
LIST OF TABLES .................................................................................................................. VI
INTRODUCTION..................................................................................................................... 1
PRODUCT RESEARCH .......................................................................................................................................... 2
CUSTOMER FEEDBACK AND SURVEY ANALYSIS ....................................................... 5
INTERPRETATION OF SURVEY RESULTS ............................................................................................................. 6
PRODUCT OBJECTIVES ........................................................................................................................................ 7
DESIGN .................................................................................................................................... 9
DESIGN ALTERNATIVES AND SELECTION ........................................................................................................... 9
SELECTION OF AN ENGINE: .............................................................................................................................. 10
FAN SELECTION: .............................................................................................................................................. 13
TOP SPEED CALCULATIONS: ............................................................................................................................ 16
POWER TRANSMISSION: ................................................................................................................................... 18
THRUST DUCT AND STATOR BLADES:.............................................................................................................. 25
SCHEDULE AND BUDGET ................................................................................................. 26
FABRICATION ...................................................................................................................... 27
TESTING ................................................................................................................................ 38
CONCLUSION ....................................................................................................................... 39
REFERENCES ........................................................................................................................ 40
APPENDIX A – RESEARCH DOCUMENTATION .............................................................. 1
APPENDIX B – SURVEY RESULTS ..................................................................................... 1
APPENDIX C – QFD AND PRODUCT OBJECTIVES ......................................................... 1
APPENDIX D – SCHEDULE AND BUDGET ....................................................................... 1
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LIST OF FIGURES
Figure 1 - Single-engine craft.................................................................................................... 2
Figure 2 - Dual-engine craft ...................................................................................................... 2
Figure 3 - Economical "kit" hovercraft ..................................................................................... 3
Figure 4 – Reverse buckets stored to side ................................................................................. 3
Figure 5 – Reverse buckets activated ........................................................................................ 4
Figure 6 – Universal Hovercraft – Hoverwing.......................................................................... 4
Figure 7 – Thrust System Design .............................................................................................. 9
Figure 8 – Calculated Hump Drag .......................................................................................... 11
Figure 9 – Engine Donor – 1995 Mazda MX-3 ...................................................................... 12
Figure 10 – Fan Tip Speed ...................................................................................................... 14
Figure 11 – Blade Pitch vs. HP Absorbed ............................................................................... 15
Figure 12 – Dynamic Thrust vs. Speed ................................................................................... 16
Figure 13 – Total Drag vs. Speed ............................................................................................ 17
Figure 14 – Total Drag vs. Dynamic Thrust = Top Speed ...................................................... 17
Figure 15 – Power Transmission Components ....................................................................... 18
Figure 16 – Belt Profile ........................................................................................................... 19
Figure 17 – Layout of sprockets and belt ................................................................................ 20
Figure 18 – Drive Shaft Layout............................................................................................... 21
Figure 19 – Side Profile of Fan Shaft ...................................................................................... 21
Figure 20 – Shear Force and Bending Moment Diagram for Fan Shaft ................................. 22
Figure 21 – Pillow Block Bearing ........................................................................................... 23
Figure 22 – Jaw coupling shell................................................................................................ 24
Figure 23 – Jaw coupling spider ............................................................................................. 24
Figure 24 – Thrust Duct and Stator Blades ............................................................................. 25
Figure 25 – Hovercraft Basic Frame ....................................................................................... 27
Figure 26 – Hovercraft Frame ................................................................................................. 28
Figure 27 – Hovercraft being relocated................................................................................... 28
Figure 28 – Thrust Duct Mold ................................................................................................ 29
Figure 29 – Thrust Duct with Inner Flashing Removed.......................................................... 30
Figure 30 – Completed Thrust Duct ........................................................................................ 30
Figure 31 – Engine Frame Pieces ............................................................................................ 31
Figure 32 – Engine Mounted on Frame .................................................................................. 32
Figure 33 – Fan Frame being Welded ..................................................................................... 33
Figure 34 – Completed Fan Frame Mounted with Engine ...................................................... 34
Figure 35 – Trailer Base .......................................................................................................... 35
Figure 36 – Trailer Modifications ........................................................................................... 35
Figure 37 – Completed Trailer with Hovercraft being relocated again .................................. 36
Figure 38 – 42” Fan Mounted to Hub ..................................................................................... 36
Figure 39 – Fan being test fit on Hovercraft ........................................................................... 37
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LIST OF TABLES
Table 1 – Customer Importance 5
Table 2 – QFD Importance 6
Table 3 – Fan Shaft Spreadsheet Calculations 23
Table 4 – Milestone Dates 26
Table 5 – Condensed Budget 26
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Hovercraft Thrust System and Drivetrain David Louderback
INTRODUCTION
There are many options for personal recreation vehicles, from snowmobiles to dirt bikes
and 4-wheel ATVs to jet skis and personal boats. These vehicles are all great at what they
were designed to do. The problem with each, however, is that they are quite limited in the
terrain that each can travel on. Dirt bikes and ATVs are limited to travel on land, while jet
skis and boats are limited to travel on water.
The greatest advantage of a hovercraft is its ability to travel over all types of terrain,
from paved asphalt to grassy fields to the open water. Hovercraft operate by creating a
cushion of air below the craft. This cushion of air supports the weight of the craft and
enables a fan or propeller to easily propel the craft in the desired direction. In addition to
recreational uses, hovercraft can also be used for emergency use. In fact, a hovercraft is the
only vehicle available which can safely maneuver across thin ice on a frozen lake or pond,
enabling rescue teams to safely reach a victim who has fallen through the ice.
While hovercraft do exist, their poor maneuverability and lack of an effective braking
system have prevented them from gaining widespread acceptance. High cost and a lack of
knowledge and understanding by the general public have also kept them out of the spotlight.
To satisfy the requirements of this Senior Design Project, a 3-person capacity, fully
functional hovercraft will be designed and built. Besides the obvious challenge of creating
an operational hovercraft, the main goals of this project are to improve upon some of the
hovercraft limitations mentioned in the above paragraph. The project will be divided into
three parts. Jeremy Siderits will be responsible for the body and frame of the craft. Kelly
Knapp will be responsible for the lift and steering systems. Lastly, David Louderback will
be in charge of designing the propulsion system. While these three parts of the project are
separate, they are also highly dependent upon and integrated within one another. No one
team member can do much work without first consulting with the other team members, to
ensure that the overall design still functions as a whole.
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PRODUCT RESEARCH
Compared to other recreational vehicles, there is relatively little information available on
hovercraft, due to their rarity. In addition, few manufacturers exist. Two of the largest
manufacturers in the United States are Neoteric Hovercraft, and Universal Hovercraft.
Neoteric Hovercraft is focused more towards selling fully built hovercraft, while Universal
Hovercraft mostly sells kits, to be assembled by the customer.
There are two main classifications of hovercraft: single-engine and dual-engine. With a
single-engine craft (Figure 1), a single engine and fan provide the airflow necessary for both
lift and propulsion. This is achieved by directing the airflow rearward of the craft. A splitter
is then used to redirect approximately 30% of the airflow underneath the craft to provide the
lift power. The remaining 70% of the airflow is used to propel the craft.
Figure 1 - Single-engine craft
On a dual-engine craft (Figure 2), one engine and fan provide the lift power, while a 2nd
engine and fan provide the forward thrust. Usually the lift engine and fan are mounted
towards the front of the craft, with the thrust engine and fan mounted towards the rear.
Figure 2 - Dual-engine craft
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A single-engine craft is generally cheaper, and easier to construct than a dual-engine

craft. A single-engine craft is a bit more limited, however. For example, with a dual-engine
craft, it is possible to only turn on the lift engine, so as to manually maneuver the craft into
and out of a trailer, or in other tight situations. In addition, dual-engine craft are generally
able to go faster and hover higher, due to their dedicated engines for each task.
The cheapest hovercraft, such as those offered from Universal Hovercraft (Appendix
A) can be purchased for about $2000. These are sold in “kit” form (Figure 3) and must be
built and assembled by the customer. Most of the parts are provided and the buyer must
provide additional materials to assemble the unit. The cost of the additional materials, such
as wood and skirt material, can easily increase the cost of the hovercraft to $3000 or more.
While units like this do hover, they are typically very basic and lack many of the advanced
features found on more expensive craft, such as: increased payload/seating capacity,
increased top speed and acceleration, and the ability to travel in reverse.
Figure 3 - Economical "kit" hovercraft
About $20,000 will buy a much more sophisticated craft, such as the Neoteric
Hovertrek (Appendix A). This craft comes fully assembled and offers one main advantage
over most other hovercraft: it has reverse thrust buckets. When the reverse buckets are not
being used, they store neatly off to the side (Figure 4).
Figure 4 – Reverse buckets stored to side
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When activated, the reverse buckets swing into position to redirect the thrust airflow
towards the front of the craft (Figure 5). If used while in motion, the craft is slowed down,
but if used while stopped, reverse travel is enabled.
Figure 5 – Reverse buckets activated
Highly advanced hovercraft such as the Universal Hovercraft 19XRW-Hoverwing

(Appendix A) are available which continue to push the envelope of the hovercraft’s abilities
by enabling the craft to take flight (Figure 6). This low level flight is made possible by the
combination of a high power engine with airfoils on either side of the craft. This craft is
incredibly expensive; priced at $85,000.
Figure 6 – Universal Hovercraft – Hoverwing
While there is quite a wide range of hovercraft available, there does not seem to be a
mid-priced option with attractive features. The prices jump from only a couple thousand
dollars with minimal features to twenty thousand dollars and more for the most technically
advanced features. One goal of this project is to bridge that gap with a well featured,
$10,000 hovercraft.
4
CUSTOMER FEEDBACK AND SURVEY ANALYSIS

A hovercraft survey was distributed among peers, recreational vehicle enthusiasts, and
professionals in the hovercraft industry. A total of 13 responses were received. Table 1
shows a sorted list of what was most important to what was least important.
Table 1 – Customer Importance
Survey Question Average Rating

Durability 4.54
Reliability 4.54
Maneuverability 4.31
Speed 4.23
Safety 4.15
Effective brakes 4.15
Cost 3.92
Ability to travel in reverse 3.15
Low noise 2.92
Cargo space 2.23
Ability to tow skiers/tubers 2.00
The survey results show that the top features are durability, reliability, and
maneuverability. Surprisingly, the results show that the ability to tow skiers/tubers is not a
highly desired feature. Cargo space and low noise also rated low on the list. If any features
will need to be eliminated, it will be the lowest two.
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INTERPRETATION OF SURVEY RESULTS

Table 2 Shows the QFD Importance. The customer importance column came directly
from the survey results. This was how the Product Objectives were identified.
Table 2 – QFD Importance
Warning labels/fire extinguisher
4 cycle engine powered at 85%
Hull constructed with fiberglass

seamed marine grade plywood
Ability to seat 3 passengers

Screen to cover the fans
Reverse thrust buckets
Customer importance
Aerodynamic design
Sturdy construction
Relative weight %
Rearview mirrors
Proper tip speed
Emergency stop
2ft3 cargo space
Relative weight
Crash bumper
Tow rope
Mufflers
Durability 3 9 3 9 9 9 4.5 0.11 11%
Reliability 3 9 9 9 1 9 4.5 0.11 11%
Maneuverability 3 1 9 1 1 4.3 0.11 11%
Speed 3 1 1 3 9 1 4.2 0.11 11%
Safety 9 9 9 3 9 9 9 9 9 1 9 4.2 0.10 10%
Effective brakes 3 9 9 4.2 0.10 10%
Cost 1 1 1 3 3 1 9 3 1 3 1 3 1 1 3.9 0.10 10%
Ability to travel in reverse 3 9 3 3.2 0.08 8%
Low noise 9 3 9 2.9 0.07 7%
Cargo space 1 9 2.2 0.06 6%
Ability to tow skiers/tubers 3 9 9 9 2 0.05 5%
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PRODUCT OBJECTIVES
The following is a list of product objectives and how they will be obtained or measured to
ensure that the goals of the project are met. The product objectives will focus on the various
aspects of the hovercraft.
Reliability (11%):
1. A four cycle engine will be used, instead of the unreliable 2 cycle that is used on
many hovercraft.
2. All electrical connections will be soldered and then covered with heat wrap to ensure
no bare wires will be exposed to water and corrosion.
3. All fasteners will be fastened with locknuts and/or Loctite for sturdy construction.
4. Engine will be powered at 85% during normal operation in order to obtain longer
engine life.
Durability (11%):
1. A rubber crash bumper will be placed around the craft and attached to the exterior
frame.
2. The hull will be constructed using ½” marine grade plywood coated with an epoxy
primer and an enamel grade finish for waterproofing.
3. All seams will be joined by fiberglass for superior strength and waterproofing.
4. All metal used for engine mounts or frame support will be primed and painted to
prevent corrosion.
Speed (11%):
1. The craft will be designed to travel in excess of 40 mph on calm water.
2. Sloped shapes will be used to reduce drag.
Maneuverability (11%):
1. Reverse thrust buckets can be used in addition to the normal rudders to control the
movement of the craft.
2. A turning radius of zero is achievable with minimal thrust but increases with speed.
Safety (10%):
1. A screen will cover the thrust and lift fans.
2. Fan tip speed will be kept below the manufacturer’s maximum tip speed in order to
keep the fan blades from breaking and possibly injuring people.
3. Warning labels will be placed on:
a. Any electrical device to prevent shock
b. Around the fans to prevent injury
c. Near engines to prevent burns
4. A fire extinguisher will be placed on board in the event that the engine catches fire.
5. All other safety requirements will be upheld based on part manuals.
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Effective braking system (10%):

1. The hovercraft will feature reverse thrust buckets that cause the hovercraft to reduce
speed.
2. Fifty percent of the thrust airflow will be redirected for braking allowing a
deceleration equal to one half of the acceleration rate.
3. An emergency stop feature will be used to cut power to the lift fan. Pads on the
bottom of the hull will prevent damage when this feature is used.
Cost (10%):
1. The hovercraft will be priced similar to an ATV or Jet Ski, around $10,000 new.
Ability to travel in reverse (8%):

1. The hovercraft will be equipped with reverse thrust buckets to allow the craft to travel
in reverse by pulling a lever.
Low noise (7%):

1. Normal operation will be at less than 85 decibels.
2. The engines will be equipped with mufflers.
3. The fan tip speed will be below the manufacturer’s maximum tip speed. This will
minimize excessive sound.
Cargo space (6%):

1. The design will allow at least 2 ft3 of cargo space, located under the seat or in the
front of the hull.
Ability to tow skiers/tubers (5%):

1. A tow rope will be able to be attached to the back of the craft.
2. In order to legally tow a skier, the craft will be able to seat 3 passengers.
3. It will have rearview mirrors so the operator can verify the safety of the skier.
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DESIGN
DESIGN ALTERNATIVES AND SELECTION

The craft was originally designed to be a dual engine craft, with a separate engine and
fan for the lift and thrust systems. Due to the increased cost and reliability concerns of
having two separate systems, the decision was made to use a single engine and fan for the
thrust and lift systems. The completed thrust system can be seen in Figure 7.
Figure 7 – Thrust System Design
Also, due to the rising cost and complexity of the project, the decision was made to
remove the thrust buckets from the hovercraft. Alternatively, the hovercraft will slow by
spinning 180 degrees and applying thrust to act in the opposite direction of travel, which will
effectively slow the craft. The power to the engine can also be reduced to produce some skirt
drag which will also stop the craft. If the engine is turned off completely, there will be a loss
of pressure underneath and the craft will stop almost immediately. Due to the potential of
injury to the occupants and damage to the craft, this procedure should be used in an
emergency situation only.
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SELECTION OF AN ENGINE:
As with all things related to hovercraft, weight is very important. The first thing I did
was look at different types of engines and how much horsepower they produced per pound.
Diesel engines typically produce 0.1 HP per pound. Four-cycle gasoline engines typically
produce 0.4 HP per pound, while two-cycle gasoline engines produce about 0.8 HP per
pound. Turbine engines are far too expensive and impractical for the design of this craft.
Aircraft piston engines are often used in hovercraft, but they are not readily available and are
too expensive for this craft. From this information, it was obvious that either a two-cycle
gasoline or four-cycle gasoline engine would be used.
2-Cycle Engines:
• Advantages:
o Very light per HP
o Small size per HP
o Usually air cooled (therefore less weight and complexity)
• Disadvantages:
o High noise levels
o Less reliable and requires more maintenance
o Small overall HP output
o Fuel-oil mixture required
o High vibration
o More pollution
o High RPM with narrow power band
o Poor fuel economy
4-Cycle Engines:
• Advantages:
o Quieter operation
o More reliable with less maintenance
o Larger overall HP output
o No fuel-oil mixture required
o Low vibration
o Less pollution
o Lower operating RPM with wider power band
o Better fuel economy
• Disadvantages:
o Heavier per HP
o Larger size per HP
o Usually liquid cooled (therefore more weight and complexity)
o More expensive
From the information above, it was decided that a 4-cycle automotive engine would be
used. These engines are readily available from junk yards for a few hundred dollars.
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Horsepower Required:
Since our hovercraft is to be operated on land and water, a phenomenon known as

“Hump Drag” had to be considered. When a hovercraft is hovering in a stationary position
over water, the force of the lift air displaces a volume of water equal to the craft weight. This
depression creates a mound around the craft, which exerts tremendous drag on the craft as it
tries to start moving. The maximum drag du during
ring this stage is known as “Hump Drag.” Up
until the craft reaches Hump Drag, the craft will be extremely sluggish and unresponsive.
Once the craft has successfully climbed over the mound and is past Hump Drag, then the
friction will be greatly reduced and the craft will begin to accelerate. If enough power is not
available to overcome Hump Drag, the craft speed on water will be limited to 55-10 mph. It is
recommended to have at least twice as much static thrust as there is Hump Drag (1). As can
be seen from Figure 8,, our craft will experience a Hump Drag of 92.6 lbs at 8.1 mphmph.
According to Perozzo’s recommen
recommendation,, we will need a minimum of 185 lbs of static thrust.
Figure 8 – Calculated Hump Drag
Additionally, hovercraft are generally categorized into two categories: cruising and
racing craft. Cruising craft have fan static thrust to weight ratios of 10% or more, while
racing craft have ratios of 25% or more. To go along with our customer objectives of having
a craft which is fun to operate, we would like our craft to fit into the racing category, which
means we’ll need a minimum of 300 lbs of thrust, based on a 1200 lb craft (including the
weight of 3 passengers). Also, top speed on a ho hovercraft
vercraft is limited only by drag and
available horsepower. We wanted our craft to be able to travel a minimum of 50 50-60 mph.
Based on our requirements for horsepower and top speed, I ended up choosing to use a
B6ZE engine out of a 1995 Mazda MX
MX-3, as shown in Figure 9.. This is a 1.6 liter, dual
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overhead cam, fuel-injected 4-cylinder engine. This engine produces 105 HP at 6200 RPM
and 100 ft-lbs of torque at 3700 RPM.
Figure 9 – Engine Donor – 1995 Mazda MX-3
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FAN SELECTION:
Fan vs. Propeller:
Once the engine was selected, it was time to determine the propulsion device which
would be driven by the engine. A decision had to be made as to use either a fan or a
propeller.
Propeller:
• Advantages:
o More thrust per HP – generally 5-8 lb/hp
o Faster throttle response
• Disadvantages:
o Very loud due to higher tip speed
o Higher thrust line due to larger size
o If damaged, entire prop must be replaced
o High blade erosion
Fan:
• Advantages:
o Quieter operation
o Lower thrust line due to smaller size
o Individual blades can be replaced if damaged
o Less blade erosion
• Disadvantages:
o Less thrust per HP – generally 3-6 lb/hp
o Slower throttle response
Based on the information above, I chose to use a fan instead of a propeller. This would
allow us to meet our customer needs of having a quiet craft which is reliable and easy to
maintain.
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Diameter:
The next decision to be made was the diameter of the fan. In terms of efficiency, the
larger the fan, the better – as long as power is available ttoo spin the fan at the proper rpm. The
horsepower required to rotate a fan increases as the cube of the rpm. Too small of a fan will
allow the engine to over rev, while too large of a fan will cause the engine to bog down. One
downside of using a large fan an is that it raises the thrust line of the craft. This force causes the
nose of the craft to dive under acceleration. Larger diameter fans will typically operate at
lower rpm, thereby reducing the tip speed and noise. It is recommended to keep tip spee speed
under 600 ft/sec (1).. This limit results in reduced noise, reduced danger from high speed
rotation, and reduced blade erosion.
Based on all of the information above, the fan that I have selected is 42” in diameter and
has a max rpm of 2500. The fan is manufactured by Hascon Engineering
Engineering.. Figure 10 shows
that at 2500 rpm, our fan tip speed will be 458 ft/sec. This number is far below the
recommended 600 ft/sec maximum.
Figure 10 – Fan Tip Speed
Number of Fan Blades:
The next thing to be determined was the number of fan blades on the fan. The number
can vary anywhere from 3 to 16. More blades are better for creating static pressure for lift
purposes. Fewer blades are better for creating thrust. With our single engine craft, a
compromise had to be made to accommodate both the thrust and lift systems. A 12 12-blade
hub with 12 blades was chosen for our craft. This gives the option to use all 12 blades for
maximum lift pressure, or we can ususee 6 or 9 blades for increased thrust, so long as the
minimum lift pressure is still maintained.
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Blade Pitch:
An additional variable with the fan is the pitch of the blades. The pitch on the chosen
fan can be adjusted from 20° to 50°. Altering the pitch is one way of properly loading the
engine so that it doesn’t over rev. Increasing the pitch increases the CFM output of the fan,
but it also drastically increases the amount of HP to drive the fan. As shown in Figure 11, at
a 40° blade pitch, our engine will have enough HP to spin the fan its full 2500 RPM.
Increasing the pitch to 45°, however, means that we’ve only got enough power to spin the fan
to 2250 RPM. Increasing the pitch further to 50°, and our 105 HP engine can only spin the
fan 2000 RPM. It would take nearly 200 HP to spin the fan 2500 rpm with a 50° pitch.
Figure 11 – Blade Pitch vs. HP Absorbed
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TOP SPEED CALCULATIONS:

Now that the engine and fan have been selected, the top speed of the hovercraft can be
estimated. The top speed of is determined when the available thrust cannot overcome the
increasing drag. The fan generates the most thrust with the craft at rest. The dynamic thrust
decreases as the speed of the craft increases, due to the air hitting the blades at a smaller and
smaller angle. Figure 12 shows the decreasing dynamic thrust with relation to craft speed.
Figure 12 – Dynamic Thrust vs. Speed
To determine the top speed, the drag must also be determined. When operating on a
smooth surface, there are two main types of drag: form drag and momentum drag. Form drag
is the most dominant type of drag and is determined by the physical size and shape of the
craft. A form factor of 0.5 is assumed (1). The momentum drag is caused by static air under
the craft coming into contact with the moving ground underneath. Figure 13 shows the types
of drag vs. the craft speed. Momentum drag is the linear red line. Form drag is the higher,
green line. The total drag (form + momentum) is depicted by the blue line at the top.
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Figure 13 – Total Drag vs. Speed
Now that the total drag and dynamic thrust have been plotted, the graphs can be
combined to show the theoretical top speed, as shown by Figure 14. The intersection of the
two lines shows that our top speed should be 68.6 mph.
Figure 14 – Total Drag vs. Dynamic Thrust = Top Speed
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POWER TRANSMISSION:
The power transmission system consist of the belt and sprockets, drive shafts with
keyways and retaining ring grooves, bearings, and the jaw coupling. These components are
shown in Figure 15.
Figure 15 – Power Transmission Components
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Belt and Sprocket Design:
A synchronous belt tooth was chosen because it offers many advantages over V-belts,
such as a higher torque capacity and resistance to slipping, even when wet. Within the
synchronous belt family, many options further exist. Standard timing belts have a
trapezoidal tooth design and are prone to jumping teeth. The HTD curvilinear belt design
was certainly an improvement over the standard timing belt, but still was not ideal for high
power applications. The belt that I have chosen, due to its high strength and superior features
(such as greater flexibility and moisture resistance), is the Gates Poly Chain GT Carbon belt.
This belt is so strong that it is advertised as being a full replacement for roller chains. Based
on the hp and rpm requirements, an 8mm tooth pitch will be used. Figure 16 shows the
dimensions of this belt profile.
Figure 16 – Belt Profile
Engine power is 105 HP, so based on a service factor of 1.4, the design HP is 147 HP.
The service factor of 1.4 was chosen due to the fact that the power source is a multiple
cylinder internal combustion engine, the system will experience intermittent service (up to 8
hours daily), and the system is used to power a fan.
The max engine rpm is 6500 and the max fan rpm is 2500, so a 2.6 reduction ratio will
be needed. Due to the availability of standard parts, a reduction ratio of 2.54 is being used.
The smaller sprocket will have a pitch diameter of 2.81” and the larger sprocket will have a
pitch diameter of 7.12”. The center distance between these two sprockets will be 20.44” and
the belt will have a pitch length of 56.7”. The two sprockets and belt can be seen in Figure
17. Based on the 2.81” sprocket rotating at 6500, the maximum belt speed has been
calculated to be 4777 ft/min. This is far below the manufacturer’s recommended maximum
of 6500 ft/min. Using the manufacturer supplied charts, a 36 mm width was chosen for the
sprockets and belt. The smaller sprocket would have the lowest hp capacity (due to the
tighter radius and subsequent fewer teeth in engagement), so taking a 36 mm wide sprocket
and correcting for the speed down ratio and belt length correction factor, the rated power is
161 HP. This is higher than the design hp of 147, so the system has been proven to be
sufficiently strong.
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Figure 17 – Layout of sprockets and belt
Drive Shaft Calculations:
Three separate, solid steel drive shafts will be used in the drive train. Figure 18 shows
the layout of the drive shafts. The first drive shaft (blue/green in the picture) will be used to
connect the engine flywheel to the jaw coupling, and will be 1.125” in diameter. The other
two drive shafts (red and yellow in the picture) will be stepped from 1.125” up to 1.5”. The
purpose of the step is to locate the shafts against the bearings. There is a 0.03” sharp fillet at
radius of step, producing a stress concentration factor of 2.5. Power is transmitted from the
drive shaft to the sprockets via a 3/8” sled runner key and keyway, producing a stress
concentration factor of 1.6. Lastly, the sprockets are held in place axially with retaining
rings. The retaining ring groove in the shaft produces a stress concentration factor of 3. All
of these different stress concentration factors at different locations were taken into account
when determining the drive shaft sizes. Additionally, a design factor of 2.0 was used, due to
an average level of confidence in the data for material strength and loads.
20
Figure 18 – Drive Shaft Layout
At 6500 RPM, the engine generates 1018 in-lbs of torque. Acting on the smaller, 2.81”
sprocket, this creates 724.3 lb of tension in the belt. When this tension acts on the larger,
7.12” sprocket, it creates 2578.6 in-lbs of torque on the fan shaft. The maximum bending
moment on the fan shaft is 1000.2 in-lb. Figures 19 shows a side profile of the fan shaft and
Figure 20 shows the shear and bending moment diagram for this shaft.
Figure 19 – Side Profile of Fan Shaft
21
Figure 20 – Shear Force and Bending Moment Diagram for Fan Shaft
1020 cold rolled steel was chosen for the drive shafts due to its high strength and
relatively low cost. A reliability factor of 99% was used = 0.81. A size factor of 0.875 was
used. Due to the three separate shafts and numerous times the drive shaft size had to be
calculated (due to varying stress concentration factors at various locations), a spreadsheet
was made to ensure consistency across the numerous calculations. The fan shaft calculations
can be seen below and a view of the spreadsheet is in Table 3.
1/3
32 2
3
= + ( )2
4
1/3
32 ∗ 2 3 ∗ 1000.2 3 2579 2
2
= + ( )
21262.5 4 64000
= 1.436 "
22
Table 3 – Fan Shaft Spreadsheet Calculations
Input Data:
Shaft material specification 1020 Cold rolled steel
Tensile strength Su 75000 psi
Yield strength Sy 64000 psi
Basic endurance strength Sn 30000 psi fig 5-8
Size factor Cs 0.875 fig 5-9
Reliability factor Cr 0.81 table 5-1
Modified endurance strength s n' 21262.5 psi
Stress concentration factor Kt 3 retaining ring groove
Design factor N 2
Shaft loading Data: Bending and Torsion

Bending moment components Mx 0 My 1000.2
Combined bending moment M 1000.2 lb in
Torque T 2579 lb in
Minimum shaft diameter D 1.436 in
Bearing Selection:
Two pillow block bearings will support each sprocket shaft. They were originally
spaced 4” on each side of sprocket, but reduced to 3” to minimize the bending moment on the
drive shaft. Due to high rpm of shafts, ball bearings will be used. Selected bearings have
radial capacities of over 1500 lbs and axial capacities of over 500 lbs. Figure 21 shows the
selected bearings.
Figure 21 – Pillow Block Bearing
23
Jaw Coupling Selection:
A jaw coupling was chosen to dampen some of the vibrations from the engine and also
to absorb any small variation in shaft alignment due to engine torque. This jaw coupling will
help to reduce stress on the bearings. The coupling is composed of two shells with a 7/8”
urethane spider on the inside. This will be able to transmit 1850 in-lbs of torque at 7500 rpm,
which is more than the 1018 in-lbs of torque at 6500 rpm generated by the engine. Figures
22 and 23 show the jaw coupling in more detail.
Figure 22 – Jaw coupling shell
Figure 23 – Jaw coupling spider
24
THRUST DUCT AND STATOR BLADES:

The thrust duct not only serves as a blade guard, but also increases the thrust by 15-20%,
if done properly. The inlet radius of the duct needs to be about 12% of the duct diameter to
ensure smooth airflow (2). Additionally, the fan blade tip clearance must not exceed 1/2”. I
am aiming for a tip clearance of 1/8” in this craft.
The stator blades are placed close behind the fan blades, and they help to straighten out
the airflow after passing through the fan. There must be either one more or one less stator
blade than there are fan blades. If the number of blades were equal, each time a fan blade
passes a stator blade, there would be a pressure disturbance. Having a different number of
stator blades helps to break up this vibration. The thrust duct and stator blades can be seen in
Figure 24.
Figure 24 – Thrust Duct and Stator Blades
25
SCHEDULE AND BUDGET

The schedule begins on November 24th, with the Proof of Design Contract. The project
takes place over 28 weeks and ends on May 30, when the final report is due. Table 4 shows
some of the key milestone dates.
Table 4 – Milestone Dates
Task Team Member Responsible Target Date

Determine Engines to Be Used All December 13th
Determine Fans to be Used All December 20th
Finalize Gear Ratio Design David Louderback December 27th
Finalize Lift System Design Kelly Knapp January 3rd
Finalize Thrust/Braking System Design David Louderback January 10th
Finalize Steering System Design Kelly Knapp January 17th
Finalize Throttle/Controls Design Jeremy Siderits January 24th
Finalize Hull Design Jeremy Siderits January 31st
Order Components with Extended Lead Time All January 31st
Design Freeze All January 31st
Finalize Design and BOM All February 7th
Order Remaining Components All February 28th
Oral Design Presentation All February 28th
Design Report All March 7th
Complete Component Fabrication All March 14th
Complete Assembly of Hovercraft All May 9th
Demo for Advisor All May 9th
Demo to Faculty All May 16th
Oral Final Presentation All May 23rd
Final Report Due All May 30th
A preliminary budget was prepared which included all materials and parts which would
be purchased. Table 5 shows a condensed version of the preliminary budget. After any
sponsor money is used, the remaining cost will be divided equally among the three team
members. Due to the complexity of the project, this budget ended up being grossly
underestimated. We actually spent about $4000, with an additional $3000 in parts and
materials donated, making the grand total $7000, nearly three times our original estimate.
Table 5 – Preliminary Condensed Budget
Lift System 525

Thust System 600
Body 520
Steering System 150
Electrical 200
Miscellaneous 375
Total 2370
26
FABRICATION
First the entire team worked to construct the Hovercraft body and frame.
Figure 25 – Hovercraft Basic Frame
27
Figure 26 – Hovercraft Frame
Once the frame was mostly complete, the craft was relocated out of my garage and up to
Blue Ash Tool and Die, where Jeremy Siderits and Kelly Knapp would finish the frame and
steering systems.
Figure 27 – Hovercraft being relocated
28
This enabled me to build the drivetrain components separately in my garage. First I set out to
construct the thrust duct. Two cylinders were made out of aluminum flashing and a
expandable liquid foam was poured in place. After the foam hardened, the flashing was
removed and the foam was sanded and shaped to the final dimensions of the thrust duct.
Figure 28 – Thrust Duct Mold
29
Figure 29 – Thrust Duct with Inner Flashing Removed
Figure 30 – Completed Thrust Duct
Then I got to work welding and painting the engine frame. This was made primarily of 1”
square tubing with 1/8” wall thickness, 1020 cold rolled steel.
30
Figure 31 – Engine Frame Pieces
Once I was able to mount the engine on the frame, I constructed a mock platform with the
exact dimensions available for the engine bay and started working on getting the engine
running. This was a very challenging task because the car’s computer had to be fooled into
thinking the engine was still inside the car. Every connection and sensor had to be hooked up
just right.
31
Figure 32 – Engine Mounted on Frame
Once the engine was running I began to construct and weld the fan and drivetrain frame.
Again, this was made primarily 1” square tubing with 1/8” wall thickness. The material is
1020 cold rolled steel.
32
Figure 33 – Fan Frame being Welded
33
Figure 34 – Completed Fan Frame Mounted with Engine
The engine was then installed in the craft and final connections were made. The next thing
that I did was constructed a trailer to transport the craft. I started with a 4x8 foot trailer and
modified it to be 7x12 feet. It is a tilt trailer so the bed can be tilted for easy drive off. To be
loaded, a winch will be added to pull the craft onto the trailer backwards, for better weight
distribution.
34
Figure 35 – Trailer Base
Figure 36 – Trailer Modifications
35
Figure 37 – Completed Trailer with Hovercraft being relocated again
Figure 38 – 42” Fan Mounted to Hub
36
Figure 39 – Fan being test fit on Hovercraft
37
TESTING
Unfortunately the craft has not yet been tested. The bag skirt still needs to be installed in
order to make the craft operational.
The thrust of the hovercraft will be tested by tying the craft to a tree with a spring scale and
operating it at full throttle. Based on these results, we can then experiment with the number
of fan blades and the pitch of each blade to achieve the best results.
38
CONCLUSION
The thrust system was designed sufficiently powerful enough for this craft. Acceleration is
adequate and the top speed goal of 50-60 mph was exceeded and increased to 68.5 mph.
This project ended up being a tremendous amount of work and we simply ran out of time to
get it finished. The amount of work to go is rather small, however, so it should be up and
running soon.
39
REFERENCES
1. Perozzo, James. Hovercrafting as a Hobby. Bend, OR : Maverick Publications, 2001.
2. Fitzgerald, Christopher and Wilson, Robert. Light Hovercraft Design. Foley, AL : The
Hoverclub of America, Inc., 1995.
3. Mott, Robert L. Machine Elements in Mechanical Design. Upper Saddle River : Prentice
Hall, 2004.
4. Caldwell, Laura. Course Documents by Professor Laura Caldwell. [Online] July 2007.
[Cited: August 16, 2007.]
http://homepages.uc.edu/~caldwelm/Courses/SrSeminar/overview.docx .
5. Neoteric Hovercraft. 4 Passenger Recreational Specifications. Neoteric Hovercraft.
[Online] Neoteric Hovercraft. [Cited: 09 20, 2010.]
http://neoterichovercraft.com/specifications/4Lspecifications.htm.
6. Universal Hovercraft. 19XRW Hoverwing. Universal Hovercraft. [Online] Universal
Hovercraft. [Cited: 09 29, 2010.]
http://www.hovercraft.com/content/index.php?main_page=index&cPath=2.
7. —. UH-10F Entry Level Hovercraft. Universal Hovercraft. [Online] Universal Hovercraft.
[Cited: 09 29, 2010.]
http://www.hovercraft.com/content/index.php?main_page=index&cPath=33_40.
8. Ohio Department of Natural Resources, Division of Watercraft. The legal
requirements of boating: towing a person with a boat or PWC legally. BOAT-ED. [Online]
Ohio Department of Natural Resources, Division of Watercraft, 04 02, 2010. [Cited: 09 29,
2010.] www.boat-ed.com/oh/course/p4-15_reqspectotowing.htm.
9. Springer, Ryan. Hovercraft Manufacturer. Rockford, IL, 09 29, 2010.
10. Baker, Larry and Kathleen. Power Sports Enthusiasts. Cincinnati, OH, 10 01, 2010.
11. Simons, Chuck. Power Sports Sales Specialist. Cincinnati, OH, 10 01, 2010.
12. Puerto Penasco, Rocky Point. [Online] 10 12, 2010. [Cited: 11 26, 2010.]
http://www.puertopenasco.org/hovercraft.htm.
13. Hoverstar LC. Hovertechnics, Inc. [Online] 2007. [Cited: 11 26, 2010.]
http://www.hovertechnics.com/recreation/hoverstarlcfeatures.htm.
40
APPENDIX A – RESEARCH DOCUMENTATION
Problem:
Owners of recreational vehicles such as ATVs, boats, and jet-skis are limited to travel
depending on whether they are on land or water. The hovercraft is a recreational vehicle that
can travel on any type of surface including land or water. While several companies
manufacture hovercraft, they are very expensive and usually include minimal features. A
hovercraft will be developed that would entice the power-sports enthusiast by offering the
features of all the other recreational vehicles. This hovercraft will be a total replacement.
Also the hovercraft to be developed will be built for less than $10,000 in order to compete
against present-day recreational vehicles.
Closest MET Projects:
OCAS 1:4 Jet Propulsion Boat

Joseph Duffey, Douglas Weber, Adam Patterson, 1987
One-Man Propeller Driven Airboat

Sean Nguyen, 1990
These two projects are similar to a hovercraft in that they both use the propulsion of air
to move the craft, rather than using a propeller in the water. However, these two projects
differ from ours because they are still boats, and being so, they are limited to use only on
water. Our hover craft will float on a cushion of air and as a result, will be able to easily
travel on nearly any terrain, whether it is land or water.
Appendix A1
Interview Notes:
Interview with power sports sales specialist, Oct. 1, 2010
Chuck Simons (513-752-0088)
Beechmont Motorsports, 646 Mount Moriah Drive, Cincinnati, OH, 45245.
Sells recreational vehicles including ATVs, Jet-Skis, and Dirtbikes.
All vehicles offer excitement but are limited by either land or water.
Chuck stated that the reasons why people buy recreational vehicles are:
• Fun and enjoyment
• Hunting
• Farm Help
• Convenience (carrying big loads)
Features or specifics that most customers are interested in include:
• Automatic Transmission
• Fuel-Injected Engine
• Speed
• Noise Levels
• Cargo area
• Carrying racks (For ATVs)
Interview with power sports enthusiasts, Oct. 1, 2010

Larry and Kathleen Baker (did not want to give contact number)
Beechmont Motorsports, 646 Mount Moriah Drive, Cincinnati, OH, 45245.
Owners of an ATV and a Jetski.
• Larry and Kathleen said that the newer engines are very electrical and their
brand new ATV and jet-ski models had broken down several times and were
difficult to repair. They stated they would never buy a newer model again and
that older style engines were more reliable and much simpler.
• They stated that their jet-ski was fun because they could tow their children on a
tube. (In our research, we found that in the state of Ohio, a motorsports vehicle
is only capable to pull a third party if it is rated to carry at least three people
on-board and it has mirrors to see behind the vehicle).
Interview with hovercraft manufacturer, Sept. 29, 2010

Ryan Springer (815-963-1200)
Universal Hovercraft, 1218 Buchanan Street, Cincinnati, OH, 45245.
Ryan stated that:
• The hovercraft’s hull should be slightly tapered and buoyant so that it floats in
water in case of engine failure.
• Universal Hovercraft is proud that they only use four-stroke engines. A two-
stroke engine produces loud winding noise levels and they are less reliable.
• A bag skirt is more customer-friendly since they are thicker than finger skirts
and repairing is easy to do in the field with scrap PVC coated nylon and skirt
glue. Also, the bottoms of the finger skirt deteriorate quickly since they are
typically made of thinner material.
Appendix A2
Related Products:
http://www.hovercraft.com/co Offered in a kit priced at $1,499

ntent/index.php?main_page=in Very reasonable price
dex&cPath=33_40
9/29/10 Price does not include wood,
UH-10F Hovercraft hardware, upholstery, wire, or paint
costs
Only accommodates one person
Only one engine - limits power and
speed
The UH-10F Entry Level Hovercraft is a great design for first time Low HP
builders, high school technology classes and home science projects.
First time builders and students get hands-on experience in
25 – 35 MPH
woodworking, fiberglass, small engines, propellers, as well as gaining Travels on all surfaces
knowledge in engineering, aerodynamics and physics. Very limited design
A single 10 hp Tecumseh horizontal shaft engine turns a two blade 36-
inch ducted propeller that provides both lift and thrust. This single
engine design is both simple and reliable, and has been successfully
built and flown by students in hundreds of schools and colleges
throughout the world. The 10F complies with the Hoverclub of
America Entry Level racing requirements.
It's built from a foam and plywood sandwich construction. The

combination of these materials makes a low cost, high strength
composite structure that is un-sinkable.
Driving the craft is easy as it has only two controls; steering and
throttle. Slowly advancing the throttle will bring the craft up on
cushion. Adding a little more power accelerates the craft. Speed is
easily controlled by increasing or decreasing engine rpm. First time
pilots can learn to operate the craft in a very short period of time.
The craft will operate on land, water, snow, ice, mud, parking lots,
football fields, ponds and rivers. Speed varies over each terrain.
Smoother terrain will allow the craft to achieve higher speeds while
rough terrain will slow the craft.
The Hoverclub of America has designed a racing program specifically

for the 10F & 10F2 Entry Level Hovercraft. The program is designed
to allow close competition between individual competitors, High
Schools and Universities at a very affordable price. See Hoverclub of
America for more information.
Appendix A3
Reverse buckets offer braking
and reverse capabilities
Limited to max 2 foot waves
16.7% slope gradient max
Expensive – 20-30K depending
on options
http://neoterichovercraft.com/specifications/4L
specifications.htm 9/20/10 Hovertrek,
Neoterichovercraft.com, Neoteric Hovercraft
Neoteric is the original light hovercraft manufacturer and

the Hovertrek™ is the culmination of Neoteric’s 40 years
of experience in light hovercraft design, development and
engineering. Its aesthetically appealing design embodies
all the advantages and advances Neoteric has innovated:
side-by-side seating, fully enclosed cabin, highly
developed reverse thrust for braking and maneuverability,
more cockpit room, increased thrust and low weight.
Engineered to satisfy expectations and to give long life
and value for money, the Hovertrek™ is recognized as the
industry standard for recreational personal hovercraft.
• 4 person, 750 lb payload

• 60 mile range
• 45 mph max forward speed on calm water
• 25 mph max reverse speed on calm water
• 83 dB (A)
Appendix A4
Ability to “fly” at very low heights
Extremely expensive - $85K
Must have a skilled operator
Increased level of danger
Very high speeds necessary to fly
Large, open terrain needed to fly
http://www.hovercraft.com/content/index.ph
p?main_page=index&cPath=2 , 9/29/10,
19XRW Hoverwing, hovercraft.com,
Universal Hovercraft
Universal Hovercraft is proud to offer the UH-

19XRW Hoverwing™ ground-effect vehicle for
recreational, industrial, commercial, military sales.
It is available to our customers on a ready to run
turnkey basis. The Hoverwing™, designed as a
high performance hovercraft, is unique because of
the ability to add wings for flight in ground-effect.
Flying in ground-effect enables you to clear
obstacles and fly over rough water at speeds in
excess of 75 mph. Cruise altitude is 2 to 6 feet and
the craft can jump up to 20 feet to clear large
obstacles. Operating in ground-effect does not
require a pilot's license, and the craft is registered
as a boat which brings a wide range of new
opportunities to the commercial and tourism
industry.
Removing the wings from the Hoverwing™ takes
just 10 minutes. With the wings removed the
Hoverwing™ converts into Sport mode, a sleek
high performance hovercraft, able to carry 4 to 6
passengers into areas that can't be reached with
any other vehicle. The Hoverwing™ can be
configured in many different ways to
accommodate your passengers or equipment
needs.
Appendix A5
APPENDIX B – SURVEY RESULTS
HOVERCRAFT CUSTOMER SURVEY
Please fill out this survey so we can get a better understanding of what the public wants in a
hovercraft.
How important is each feature to you for the design of a recreational hovercraft?
Please circle the appropriate answer. 1 = low importance 5 = high importance
AVG
Safety 1 2 3(5) 4(1) 5(7) N/A 4.15
Durability 1 2 3(1) 4(4) 5(8) N/A 4.54
Reliability 1 2 3(1) 4(4) 5(8) N/A 4.54
Maneuverability 1 2 3(1) 4(7) 5(5) N/A 4.31
Effective brakes 1 2(1) 3(3) 4(2) 5(7) N/A 4.15
Ability to travel in
1 2(3) 3(6) 4(3) 5(1) N/A
reverse 3.15
Low noise 1(1) 2(5) 3(3) 4(2) 5(2) N/A 2.92
Cargo space 1(4) 2(4) 3(4) 4 5(1) N/A 2.23
Speed 1(1) 2(1) 3 4(3) 5(8) N/A 4.23
Ability to tow
1(6) 2(2) 3 4(4) 5 N/A
skiers/tubers 2.00
Cost 1(1) 2(1) 3(2) 4(3) 5(6) N/A 3.92
How much would you be willing to pay for this vehicle?
$1000-$2000 $2000-$5000(1) $5000-$10,000(3) $10,000-$15,000(6) $15,000+(3)
AVG Cost Range – High end of $5000 - $10000
Thank you for your time.
Appendix B1
APPENDIX C – QFD AND PRODUCT OBJECTIVES
Jeremy Siderits, Kelly

Knapp, Dave Louderback
Hovercraft
9 = Strong
3 = Moderate
1 = Weak
Screen to cover the fans

Proper tip speed
Warning labels/fire extinguisher
4 cycle engine powered at 85%
Sturdy construction
Crash bumper
Hull constructed with fiberglass
seamed marine grade plywood
Reverse thrust buckets
Emergency stop
Mufflers
2ft3 cargo space
Aerodynamic design
Ability to seat 3 passengers
Rearview mirrors
Tow rope
Customer importance
Relative weight
Relative weight %
Safety 9 9 9 3 9 9 9 9 9 1 9 4.2 0.10 10%

Durability 3 9 3 9 9 9 4.5 0.11 11%
Reliability 3 9 9 9 1 9 4.5 0.11 11%
Maneuverability 3 1 9 1 1 4.3 0.11 11%
Effective brakes 3 9 9 4.2 0.10 10%
Ability to travel in reverse 3 9 3 3.2 0.08 8%
Low noise 9 3 9 2.9 0.07 7%
Cargo space 1 9 2.2 0.06 6%
Speed 3 1 1 3 9 1 4.2 0.11 11%
Ability to tow skiers/tubers 3 9 9 9 2 0.05 5%
Cost 1 1 1 3 3 1 9 3 1 3 1 3 1 1 3.9 0.10 10%
Abs. importance 1.71 4.90 1.03 2.28 3.57 2.27 4.16 3.83 1.96 0.95 0.60 1.06 0.95 1.82 0.55 31.6
Rel. importance 0.05 0.16 0.03 0.07 0.11 0.07 0.13 0.12 0.06 0.03 0.02 0.03 0.03 0.06 0.02
Appendix C1
Hovercraft Product Objectives
The following is a list of product objectives and how they will be obtained or measured to ensure that the goals of the project
are met. The product objectives will focus on the various aspects of a hovercraft. The hovercraft is a recreational vehicle and will
be designed to provide safe enjoyment for its users.
Reliability (11%):
5. A four cycle engine will be used, instead of the unreliable 2 cycle that is used on many hovercraft.
6. All electrical connections will be soldered and then covered with heat wrap to ensure
no bare wires will be exposed to water and corrosion.
7. All fasteners will be fastened with locknuts and/or Loctite for sturdy construction.
8. Engine will be powered at 85% during normal operation in order to obtain longer engine life.
Durability (11%):
5. A rubber crash bumper will be placed around the craft and attached to the exterior frame.
6. The hull will be constructed using ½” marine grade plywood coated with an epoxy primer and an enamel grade finish for
waterproofing.
7. All seams will be joined by fiberglass for superior strength and waterproofing.
8. All metal used for engine mounts or frame support will be primed and painted to prevent corrosion.
Speed (11%):
3. The craft will be designed to travel in excess of 40 mph on calm water.
4. Sloped shapes will be used to reduce drag.
Maneuverability (11%):
3. Reverse thrust buckets can be used in addition to the normal rudders to control the movement of the craft.
4. A turning radius of zero is achievable with minimal thrust but increases with speed.
Appendix C2
Safety (10%):
6. A screen will cover the thrust and lift fans.
7. Fan tip speed will be kept below the manufacturer’s maximum tip speed in order to keep the fan blades from breaking and
possibly injuring people.
8. Warning labels will be placed on:
a. Any electrical device to prevent shock
b. Around the fans to prevent injury
c. Near engines to prevent burns
9. A fire extinguisher will be placed on board in the event that the engine catches fire.
10. All other safety requirements will be upheld based on part manuals.
Effective braking system (10%):

4. The hovercraft will feature reverse thrust buckets that cause the hovercraft to reduce speed.
5. Fifty percent of the thrust airflow will be redirected for braking allowing a deceleration equal to one half of the acceleration
rate.
6. An emergency stop feature will be used to cut power to the lift fan. Pads on the bottom of the hull will prevent damage
when this feature is used.
Cost (10%):
2. The hovercraft will be priced similar to an ATV or Jet Ski, around $10,000 new.
Ability to travel in reverse (8%):

2. The hovercraft will be equipped with reverse thrust buckets to allow the craft to travel in reverse by pulling a lever.
Low noise (7%):

4. Normal operation will be at less than 85 decibels.
5. The engines will be equipped with mufflers.
6. The fan tip speed will be below the manufacturer’s maximum tip speed. This will minimize excessive sound.
Appendix C3
Cargo space (6%):
2. The design will allow at least 2 ft3 of cargo space, located under the seat or in the front of the hull.
Ability to tow skiers/tubers (5%):

4. A tow rope will be able to be attached to the back of the craft.
5. In order to legally tow a skier, the craft will be able to seat 3 passengers.
6. It will have rearview mirrors so the operator can verify the safety of the skier.
Appendix C4
APPENDIX D – SCHEDULE AND BUDGET
Schedule (proposed in yellow, actual in orange):
Jeremy Siderits, Kelly Knapp, Dave Louderback Tasks in black text are equally shared by the group members
11/21 - 11/27
12/12 - 12/18
12/19 - 12/25
12/5 - 12/11
11/28 -12/4
12/26 - 1/1
1/16 - 1/22
1/23 - 1/29
2/13 - 2/19
2/20 - 2/26
3/13 - 3/19
3/20 - 3/26
4/10 - 4/16
4/17 - 4/23
4/24 - 4/30
5/15 - 5/21
5/22 - 5/28
1/9 - 1/15
1/30 - 2/5
2/6 - 2/12
2/27 - 3/5
3/6 - 3/12
3/27 - 4/2
5/8 - 5/14
5/29 - 6/4
1/2 - 1/8
4/3 - 4/9
5/1 - 5/7
DATE
TASK
Proof of design contract 24
Hovercraft concept development 6
Preliminary hovercraft design 31

19
Engine 13
15
Fans 20
29
Gearing (sizes, ratios, and type) 27
12
Lift system 3
19
Thrust system 10
19
Steering 17
19
Throttle and controls 24
19
Hull 31
19
Winter Break (CAD drawings only) 2
2
Long delivery components 31
31
Major Component Design freeze 31
31
Final hovercraft design 21
3
Hovercraft BOM 21
18
Order hovercraft components 28
18
Oral design presentation 28
3
Design report 7
18
Component fabrication 14
Assembly 9
Demo to advisor 9
Demo to faculty 16
Oral final presentation 23
Final report due 30
Appendix D1
Original Hovercraft Budget:
Hovercraft Budget
System Component Description Price
Lift Bag Skirt Vinyl coated nylon fabric $125.00
Lift Engine 4-stroke engine $100.00
Lift Fan Multi-blade fan $250.00
Muffler Muffler system $50.00
Thrust Thrust Engine 4-stroke engine (Discounted) $100.00

Thrust Fan Mult-blade fan $350.00
Belt System Belt and pulleys $50.00
Reverse Buckets Fabricated fiberglass shell $50.00
Muffler Muffler system $50.00
Body 1/2" thick marine grade plywood Material used for the bottom of the hull $150.00
misc wood Material used for ribs and top of the hull $100.00
Fiberglass and resin Joint support and waterproofing material $125.00
In-line Seating Fabric and support for seating $40.00
Paint Enamel based paint for superior protection $75.00
Warning Labels Keep hand away, hot, electrical hazard $10.00
Duct Screen Wire sceen for fan protection $20.00
Steel Tube Tube stock for engine support Donated
Steering Handlebars Handlebar system $100.00

Rudders Rudder system $50.00
Electrical Temperature Gauge Temperature guage for lift engine $25.00

Temperature Gauge Temperature guage for thrust engine $25.00
Tachometer RPM guage for lift engine $25.00
Tachometer RPM guage for thrust engine $25.00
Battery 12v Battery $50.00
Alternator System to charge battery $50.00
Misc Misc parts and hardware N/A $375.00
Total $2,370.00
Appendix D2

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HOVERCRAFT THRUST SYSTEM AND DRIVETRAIN

A thesis submitted to the

in Mechanical Engineering Technology

Bachelor of Science University of Cincinnati

Faculty Advisor: Dr. Ahmed Elgafy

HOVERCRAFT THRUST SYSTEM AND DRIVETRAIN .................................................... 1

Figure 1 - Single-engine craft

Figure 2 - Dual-engine craft

A single-engine craft is generally cheaper, and easier to construct than a dual-engine

Figure 3 - Economical "kit" hovercraft

Figure 4 – Reverse buckets stored to side

Figure 5 – Reverse buckets activated

Highly advanced hovercraft such as the Universal Hovercraft 19XRW-Hoverwing

Figure 6 – Universal Hovercraft – Hoverwing

CUSTOMER FEEDBACK AND SURVEY ANALYSIS

Table 1 – Customer Importance

Survey Question Average Rating

INTERPRETATION OF SURVEY RESULTS

Table 2 – QFD Importance

Warning labels/fire extinguisher

4 cycle engine powered at 85%

Hull constructed with fiberglass

Ability to seat 3 passengers

Reverse thrust buckets

2ft3 cargo space

Effective braking system (10%):

Ability to travel in reverse (8%):

Low noise (7%):

Cargo space (6%):

Ability to tow skiers/tubers (5%):

DESIGN ALTERNATIVES AND SELECTION

Figure 7 – Thrust System Design

Since our hovercraft is to be operated on land and water, a phenomenon known as

Figure 8 – Calculated Hump Drag

Figure 9 – Engine Donor – 1995 Mazda MX-3

Figure 10 – Fan Tip Speed

Number of Fan Blades:

Figure 11 – Blade Pitch vs. HP Absorbed

TOP SPEED CALCULATIONS:

Figure 12 – Dynamic Thrust vs. Speed

Figure 13 – Total Drag vs. Speed

Figure 14 – Total Drag vs. Dynamic Thrust = Top Speed

Figure 15 – Power Transmission Components

Belt and Sprocket Design:

Figure 16 – Belt Profile

Figure 17 – Layout of sprockets and belt

Drive Shaft Calculations:

Figure 18 – Drive Shaft Layout

Figure 19 – Side Profile of Fan Shaft

Table 3 – Fan Shaft Spreadsheet Calculations

Shaft loading Data: Bending and Torsion

Figure 21 – Pillow Block Bearing

Jaw Coupling Selection:

Figure 22 – Jaw coupling shell

Figure 23 – Jaw coupling spider

THRUST DUCT AND STATOR BLADES:

Figure 24 – Thrust Duct and Stator Blades

SCHEDULE AND BUDGET

Table 4 – Milestone Dates

Task Team Member Responsible Target Date

Table 5 – Preliminary Condensed Budget

Lift System 525

Figure 25 – Hovercraft Basic Frame

Figure 26 – Hovercraft Frame