King Abdul Aziz University of Saudi Arabia (KAU) and Tokai University in Japan have collaborated to design and manufacture a solar powered unmanned air vehicle (UAV), Sun Falcon, which has capability of continuous one day fight with intended design extension towards night flight. The project is a student-driven endeavour involving some 30 students. Both universities are equally involved in the actual design studies of the performance characteristics, aerodynamic design, propulsion and structural analysis. Tokai University is in charge of the actual on-site supervision and examination of on-going manufacturing processes and ultimate fabrication of the prototype model.

The conceptual design of the Sun Falcon was meticulously worked out in consideration of the operational mission, which included such flight characteristics as the cruising velocity, flight altitude, payload, flight time, rate of climb, power requirements and so on. The weather condition patterns in Saudi Arabia, which remained fairly supportive of the solar cell performance, were also deemed crucial in the design process. However, the design of a solar plane had other challenges in terms of power unit accommodation and payload consideration in comparison to other conventional UAVs. In this paper, an outline of the design features of the Sun Falcon is presented and other notable design features particular to solar UAVs are discussed. It was learnt in this exercise that the selection of the base aerofoil is perhaps one of the most important design items, as the Reynolds number for such UAVs understandably drops notably lower than conventional aeroplanes and such features as the camber curvature and wing area must cater for the installation of solar panels whose size, strength and quantity must respect local weather conditions. For the Sun Falcon, the actual design process examined two candidate aerofoils FX74-CL5-140 (FX74) and SD7037-092-88(SD7037) both of which were abundantly suitable for furnishing the required aerodynamic characteristics. SD7037 was ultimately chosen as it provided the best geometry and camber line in terms of accommodation and placement of the solar panels. Further scrutiny demonstrated that this latter aerofoil provided better take-off performance and superior L/D behaviour under cruise conditions. In order to check out the aerodynamic performance in general and overall stability and control characteristics, a preflight test under battery power (a 2,500 mAh li-po 4-cell 14·8v) was achieved on 4 June 2013. Other solar powered based tests are currently under way at present.