Integrated Maintainability in the Structural and System Design of Fixed-Wing UAVs

This paper introduces an overall design approach to a fixed-wing unmanned aerial vehicle (UAV) with an emphasis on the incorporation of maintainability into structural and system-level designs. Conceptual design was established using CAD software, following which aerodynamic performance was analyzed by external flow simulations based on the finite volume method. The outcome of the above analyses was used to finalize the external shape, resulting in detailed structural and layout designs. Mechanical behavior of critical structural components was analyzed through finite element analysis (FEA) to determine stress distribution, deformation, and vibration characteristics under simulated operational loading conditions. A distinctive feature of this research is the prioritization of maintainability as a primary design criterion from the outset. The inner arrangement of components; batteries, electric ducted fan motors, avionics, and control surfaces, was carefully planned to provide maintainability access for both personnel and tools. Sensor and control systems were also embedded with the aim of facilitating condition-based and predictive maintenance over UAV’s operational life. This involved choosing sensor points of attachment and providing access to areas expected to need regular inspection, adjustment, or replacement. The completed UAV prototype optimizes aerodynamics, structural strength, and maintainability. The design strategy not only satisfies performance and production demand but also helps to reduce maintenance downtime and lifecycle costs. This maintainability-driven design philosophy serves to increase the UAV's viability for actual world deployment in environments in which reliability, serviceability, and operational readiness are vital.