Optimization and analysis of composite sandwich box beam for solar drones

Abstract Solar drones have garnered considerably research attention in recent years due to their continuous cruising capability, and the feasibility of design schemes is sensitive to the weight of structure. Sandwich box beam composed of carbon fiber and polymethacrylimide (PMI) foam is conducive to realize the lightweight of structure. In this study, a two-stage optimization design methodology for sandwich box beam is proposed. This methodology is primarily based on a low-order analytical method for evaluating stress/deflection and the linear buckling analysis method combined with experimental correction factor for predicting the buckling eigenvalues. Subsequently, a case study was conducted using an 18-m wingspan solar drone, where the results of mechanical test verified the optimization results. For validating the use of sandwich box beam in solar drones of other scales, additional analysis was conducted based on three aspects: a) effects of stiffness and stability constraints on the design of sandwich box beam; b) crucial role of the weight of foam inter layer and application scope of sandwich box beam; c) best method to improve the buckling eigenvalue of sandwich box beam. Overall, the methodology and general rules presented in this paper can support the design of light wing beam for solar drones.