sakai

 Sakai Kiwame

date:08/09/2025
day:Monday
activity/photo:
We gathered at 9:15.
We learned about airplane mechanism. 
I knew Drone means model airplane has a GPS.
Drone is a UAV(Unmanned Aerial Vehicle ).
Also, I understood how to control height and direction.

Figure 1 Lecture content

After that we made a paper plane and a paper helicopter.
We measured their flying time. 
Sir Zihad's things are the best.

Figure 2 Our plane and helicopter

We varnished the table.
One table painted twice, the other once.

Figure 3 before and after the table

date:09/09/2025

day:Tuesday

activity/photo:

We started to repaint CH750 metal mount at 9.am.
It is for airplane fuel tank. 

We painted it twice.

Figure 1 before and after the airplane base

Sir Zihad made a our schedule.

We have to complete 5 project during September.
TB1 is to make a mount for LED light.

TB2 is to make a display stand for static model.
TC1 is to make a F5E gas turbine engine mount.
TC2 is to remodel plane fuselage assuming it is destroyed.
TC3 is to make drone's monitor and antenna mount.

Figure 2 our project

After that, we repaint metal support for mb339 stand.

Figure 3 repainted mb339 stand

date:10/09/2025
day:Wednesday
activity/photo:
We waxed Aermacchi MB339 wing.

It was restored shine and brilliance.

Figure 1 before and after the wing

We repainted metal support for gas turbine engine stand 3 times.

It became a great monkey yellow. It's so cool.

Figure 2 before and after the engine mount

We designed a display stand for static model while it's drying.
It's still in progress.
It needs to add dimensions.

Figure 3 display design

date:11/09/2025
day:Thursday
activity/photo:
We played a air plane simulater.
It was difficult to control airplane, but I could control it well.

Figure 1 airplane simulation

After that we measured a model plane fuselage.
We made the measurements considering the design and construction.
However we couldn't measure the inside of it.

Figure 2 measurement result 

Also we measured the F5E gas turbine engine mount and sketched.

Figure 3 engine mount sketch

date:12/09/2025

day:Friday
activity/phote:

Today, we were introduced to the laboratory's drones.
This black drone is made of carbon, making it lightweight and foldable. 
So it provides the advantage of easy portability.
It is also capable of carrying objects up to 2kg.

Figure 1 foldable drone

There are two types of aircraft, one with wings, and another drone equipped with both wings and four propellers.
The advantage of drones is to require only a small space for takeoff and landing.
On the other hand, airplane's advantage is more stable flight compared to drones.

Figure 2 two types of aircraft

The aircraft in Figure 3 made by USM students, showing receiver and microcontroller.
The micro controller is a device capable of detecting altitude and the inclination of the fuselage.

Figure 3 aircraft made by USM students

The device mounted at the tip of the airplane is a Pitot tube, which can measure airspeed by comparing the pressure received from the front-facing opening with that from the side openings.

Figure 4 The device mounted at the tip of the airplane

We discussed about our project.
In Remodeling plane fuselage (TC2), the way of the plane are connected has been charged from glue to bolts.
It is a new way of connecting. If success, it will make replace parts easier than with glue.
Display stand (TB2) will be used metal plate and cork board. It is possible to use pins because of cork board. 

Figure 5 discussion of our project

We assisted to start CH750 experimental airplane engine.
However it didn't start. It started before, but I guess things like this happen.

Figure 6 removing the propeller

date:17/09/2025
day:Wednesday
activity/photo:
I made a model plane fuselage 3D model.
Due to the limitations of the laser cutter, the hull was created in four blocks.
This time, holes were provided to allow bolts to be inserted into the fixing points of the important connection parts.

Figure 1 4blocks of airplane

Figure2 is overall view.

Figure 2 overall view

The rudder and elevator in part 4 did not fit together properly, so it was not possible to confirm their operation on the assembly. However, in reality, there should be no interference and it should work normally.
The hinge thickness was designed to be 1 mm, but if it is different, the design will be changed.

Figure 3 part 4 of airplane

The 3D design is almost complete, so we will move on to 2D drawing.

date:19/09/2025
day:Thursday
activity/photo:
Today, we went to USM main campus to apply for a visa and pay USM fee.
We finished it at 3p.m.
After that,  I continued to make  a model plane fuselage 3D model.
I cut holes in the wall at each connection point to run the rods and servo cables through, and as I can see from the nose to the back of the plane I should be able to run them through without any problems.

Figure 1 View from the nose of the plane

Tool holes were then drilled into each connection on the upper side of the aircraft to allow for bolt tightening.

Figure 2 overall view

At the same time, we also started creating blueprints for laser cutting. I created the blueprints by laying out as many parts as possible to avoid wasting resources.

Figure 3 Laser cut blueprints (block1)

date:19/09/2025
day:Friday
activity/photo:
I made a lazer cut blueprints of a model plane fuselage 3D model.
I finished to make it, It will take four laser cuts.
I also created a file in Dxf format.

Figure 1 all of laser cut blueprints

After that, we started working on designing the display stand, and the 3D design was completed.
I haven't had time to work on 2D yet.
I created an LED mount and attached the LED to the display stand.
Therefore, the LED mount for TB1 should be completed by modifying this.
The LED mount consists of two parts that are bolted to the display stand to support the LED.
The display stand is a rectangular pillar, but if the mounting point is made circular, it should be possible to fix it to a cylinder as well.

Figure 2 display stand

Figure 3 How to fix the LED mount

date:22/09/2025
day:Monday
activity/phone:
The display stand (TB2) was modified as shown in Figure 1.
The metal plate was replaced with a steel frame, and the LED mount was modified to allow the attachment of a 50 mm screw.
In addition, the LED mount (TB1) was also modified to allow the attachment of a 50 mm screw, similar to TB2 (Figure 2).

Figure 1 TB2 after change

Figure 2 TB1 after change

TC2 was modified as follows:

• The corners of the square frame should be filleted to improve strength.

• The space for connecting bolts is too large, which may increase fluid resistance.

• The horizontal stabilizer and elevator were redesigned as a single part, since they might bend when separated.

• The vertical stabilizer does not require holes.

• A slot needs to be added to improve structural strength.
  
  

Figure 3 how to make a slot

Figure 4 redesigned horizontal stabilizer and elevator

After that, we tried to fly the airplane.
It was difficult for me because it was not the same as playing a simulator.
When I actually tried it, the controls felt lighter, and I wasn’t sure which way to move the stick while flying.

Figure 5 airplane and battery and remote controller

Figure 6 operating airplane

date:24/09/2025
day:Tuesday
activity/phote:

Modifications were made to TB1 and TB2.

TB1 was improved so that 50mm screws can be used.

Figure 1 Improved TB1

The TC2 also features a slot to increase the fixing force, and the design has been changed so that the vertical stabilizer and elevator are made from a single part.
Due to design changes, it was necessary to correct the matches, which took time.

Figure 2 Improved TC2

Figure 3 Modified vertical stabilizer and elevator 

Figure 4 After installing the slot

We are still considering ways to reduce the space required for using tools as we have not yet found a good solution.

date:24/09/2025
day:Wednesday
activity/photo:

We started building the TC2.

First, we cut a 25mm x 25mm piece of steel according to the parts diagram.

Figure 1 Grinder

After that we used a power saw to cut the parts that needed to be cut at an angle into the square pillar.

Figure 2 Power saw

Then we confirmed that the layout was as designed and removed the burrs.
Finally, we welded the base and finished today's work.

Figure 3 Welding process

During his spare time, he also made some improvements to the plane's design.

He fixed a previous problem where the space above the plane for bolt fastening was too large, resulting in wind resistance.

He reduced the space above in two places, and added a sliding plate to the top in one place.

Figure 4 overall view

Figure 5 Sliding plate

date:25/09/2025
day:Thursday
activity/phote:
Today we continued on from yesterday's TC3, finishing up the drilling and welding of the parts in the morning.
Before welding, the unevenness of the welding part of the base was removed.

Figure 1 Drilling the holes

Figure 2 Welding process

Figure 3 Removal of unevenness

In the afternoon, we also painted the assembled drone stand yellow.

We will continue painting tomorrow to make sure there are no uneven areas.

Then I started cutting the TB2 parts. I'm running low on materials, so I'll resume work tomorrow if I can get them ready.

date:26/09/2025
day:Friday
activity/photo:
We continued painting TC3 from yesterday.
Also, since we were able to procure the materials, we cut the TB2 parts.
After confirming that the cutting was accurate, the welding was carried out and assembly was completed.

Figure 1 painting continues

Figure 2 TB2 after cutting

Figure 3 TB2 after assembly

In the afternoon, the LED mount for TB2 was also completed.
The TB1 LED mount should have had the part through which the screw passes shortened so that shorter screws could be used.

Also, we went to buy screws, but the screws we wanted were not available in the store, so we decided to buy them online.

Figure 4 Making LED mount of TB2

Figure 5 LED mount of TB1 and TB2 

date:30/09/2025
day:Tuesday
activity/photo:

Today we started by painting the display stand.

Figure 1 display stand after painting

Then, while that was drying, we started working on building the plane.

We changed the connections between each block of the plane from eight bolts to four, and created the parts with a laser cutter.

After cutting, the parts were fastened with bolts and assembled.

Figure 2 Using a laser cutter

When we actually tried to attach the boat with bolts, it was extremely difficult, so we thought of ways to improve it, such as ensuring there was enough space to reach in with our hands.

Figure 3 Assembled airplane

I was pleased with the TB2 LED mount as it fixed the LED securely when I actually installed it.

Figure 4 Installing the LED mount (TB2)

Today, my internship at USM ended. At USM, I was able to have a variety of experiences that are hard to come by in Japan.
I would like to conclude this blog by expressing my gratitude to Mr Zihad for giving me such a valuable experience.

ARIGATOU Mr Zihad