"During the test manufacturing phase, we reconsidered the technology we had chosen, which enabled us to create a highly unusual hybrid wing structure. In the end, this solution became a real technical highlight and even caught the attention of the other engineering teams at the competition. The biggest challenge of all, however, was coordinating the team and simply finding a time when we could all meet in the workshop, as the entire project took place right in the middle of the exam period," said Tra My Vu Nguyen, a second-year bachelor’s student on the Cybernetics and Robotics programme at the Faculty of Electrical Engineering, Czech Technical University in Prague (CTU).
Together with eleven other students, she travelled in July to represent CTU AeroLab at the prestigious international Air Cargo Challenge. The competition takes place every two years at the university whose student team won the previous edition. Participating teams are tasked with developing an unmanned aircraft capable of covering the greatest possible distance within a set time while carrying the maximum possible payload. The objects carried by the aircraft simulate real-world cargo and change with each edition of the competition. This year, the aircraft carried cans of Spezi soft drink, while two years ago the payload consisted of billiard balls. In 2022, for example, the task was to transport medical supplies in the form of blood bags.
Taking risks pays off
The final aircraft was the result of extensive aerodynamic simulations and calculations. The CTU AeroLab team developed a unique loading system. The cans were first placed in specially designed balsa-wood crates, which were then loaded into the fuselage as complete units through a removable nose section. This allowed the team to avoid cutting openings into the sides of the fuselage, which would have compromised its buckling strength.
The aircraft also stood out for its unconventional geometry: the team opted for a relatively short fuselage combined with large tail surfaces to provide the required stability and controllability. For propulsion, they chose a twin-engine configuration, with the two motors having to operate efficiently within a strict maximum current limit of 30 A.
The competition lasted four days. On the first day, the teams presented their models, which then had to pass a technical inspection. This assessed whether each aircraft was fully operational and complied with all the specifications set out in the technical report prepared by the students. The following three days were devoted to flying.
"On the first day, everyone flew conservatively because only the two best flights counted towards the overall score, and at the beginning we had two flights per day," explained Tra My Vu Nguyen. "Once we knew we had two successful flights under our belts, we started taking more risks and pushing the limits of our aircraft further. In one of the rounds, we even managed to score the maximum number of points. Perhaps if we had started taking risks one round earlier, while the weather was still favourable, we might have made it onto the podium," she added.
Putting into practice what they have yet to learn in class
Tra My Vu Nguyen has been a member of the CTU AeroLab student team for almost a year. Although she has to balance her work with the student team alongside the demanding Cybernetics and Robotics degree programme, the experience is helping her progress both academically and professionally. "At CTU AeroLab, I have learnt about areas such as the optimisation of flight parameters and unmanned systems. Optimisation theory is not taught until the fifth semester of the Cybernetics and Robotics programme, but I have already had the opportunity to put it into practice," said Tra My Vu Nguyen.
In addition to drone optimisation, CTU AeroLab students can get involved in areas such as aerodynamic design, CFD simulations, avionics development, structural design and the actual manufacturing of the aircraft. This gives them first-hand experience of everything involved in developing aircraft of this kind.
Team members are also in contact with industry partners who sponsor the construction of the student aircraft. Talented students can therefore gain both valuable experience and professional contacts while still at university, potentially opening the door to interesting career opportunities in the future.
The CTU AeroLab team is based at the Department of Aerospace Engineering at the CTU Faculty of Mechanical Engineering, where it has access to a workshop, laboratories, expert supervision and administrative support. Students from all CTU faculties are welcome to join the CTU AeroLab team. ‘All you need to do is come and see us, take a look at what we do and be keen to get involved,’ concluded Tra My Vu Nguyen.
Photo by CTU AeroLab
