Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Written By:
Alfred Dzadey, Jonathan Ebhota, Zuber Khan, Tarek Kherbouche, Amit Ramji, Mozammel, Mohammed
Mohinuddin, Micky Ngouani, Malwenna Malwenna , Hassan Turabi, Osman Sibanda, Mohammed Rayad
Ullah
Project Supervisor:
Ray Wilkinson, Joanna Rawska, Kate Williams, Steve lines
ACKNOWLEDGEMENTS
ACKNOWLEDGEMENTS
We (UAS Challenge MEng Group) would like to thank the supervisors who gave us
their support and unconditional attention throughout the course of the project with
weekly group meetings and off the clock advice. Their expertise in the subject helped in
the successful delivery of this project. Other notable mentions are to the technicians;
Chris Childs and Andrew Curl whose expertise, skill and experience were invaluable in
the manufacture of the components of the UAS.
We would also like to thank Gordon Banks from Ensinger for supplying the materials
use for the project at a discounted prize and very swiftly too; Howard Ash for his
assistance in the procurement of materials and components; Yigeng Xu for giving the
MEng group permission to use E131B for assembly and testing purposes; Clive
Borhem for giving technical assistance to the Propulsion Engineer and also everyone
who supported the group directly and indirectly.
TABLE OF CONTENTS
ii
TABLE OF CONTENTS
ACKNOWLEDGEMENTS............................................................................................... i
TABLE OF CONTENTS ................................................................................................ ii
LIST OF FIGURES ...................................................................................................... vii
GLOSSARY ................................................................................................................ xii
1
Introduction........................................................................................................... 1
1.1 Competition Overview ..................................................................................... 1
1.2 Project Aims .................................................................................................... 1
1.3 The Project Objectives .................................................................................... 2
2
Design Rationale .................................................................................................. 2
2.1 Design Convergence ....................................................................................... 2
2.1.1 Stage 1 Convergence ............................................................................... 2
2.1.2 Stage 2 Convergence ............................................................................... 3
2.2 Further analysis ............................................................................................... 3
3
Project Management ............................................................................................ 4
3.1 Role of the Project Manager ............................................................................ 4
3.2 The Team Structure......................................................................................... 4
3.3 Project Planning .............................................................................................. 5
3.3.1 Milestones ................................................................................................. 7
3.4 Leadership ...................................................................................................... 7
3.5 Team Communication ..................................................................................... 9
3.6 Project Budgeting ............................................................................................ 9
3.6.1 Summary of Project Budget .....................................................................10
3.6.2 Source of Funding ....................................................................................10
3.7 Risk Management ..........................................................................................11
3.8 Conflict management......................................................................................11
3.9 Performance Review ......................................................................................12
3.10 Evaluation ...................................................................................................13
4
Quad-Rotor Design..............................................................................................14
4.1 Design Rationale - Quad-Rotor ......................................................................15
4.2 Payload Box Design and Mechanism .............................................................16
5
UAV Mass Breakdown .........................................................................................17
6
UAV Cost Breakdown ..........................................................................................17
7
Structural Analysis ...............................................................................................18
7.1 Load Case Definition and Free Body Diagrams ..............................................18
8
UAV Stress Analysis ............................................................................................20
8.1 Stress Reduction Techniques .........................................................................20
8.2 Fatigue Awareness .........................................................................................20
8.3 Fatigue due to induced vibration .....................................................................21
8.4 Pressure Loading on Plates............................................................................21
8.5 Load Transfer .................................................................................................22
8.6 Fixed and Movable Arm Stress Maximum ......................................................22
8.7 Simplified Plate Deflection ..............................................................................24
8.7.1 Simply Supported Plate Representation ...................................................24
8.7.2 Analytical Method .....................................................................................25
8.7.3 FEA Simplified Rectangular Approximation ...........................................26
8.8 Plate Deflection - Assembly Contact Model as Built........................................27
8.9 Undercarriage Buckling Calculation ................................................................27
8.10 Undercarriage Bending ...............................................................................27
8.11 Undercarriage Bending - Assembly Contact Model .....................................28
8.12 Undercarriage Torsion.................................................................................29
8.13 Undercarriage Combined Loading - Torsion and Bending ...........................29
8.14 Undercarriage Combined Loading - Assembly Contact Model .....................30
TABLE OF CONTENTS
iii
TABLE OF CONTENTS
iv
TABLE OF CONTENTS
TABLE OF CONTENTS
vi
Appendix. E
Material Properties ..........................................................................179
Appendix. F Load Cases and Load Transfer ...........................................................181
Appendix. G
Stress Analysis ................................................................................182
Appendix. H
Performance & Propulsion ...............................................................219
Appendix. I UAS System Set Up............................................................................261
Appendix. J Systems ..............................................................................................269
Appendix. K
Altitude control .................................................................................281
Appendix. L Verification and validation ...................................................................289
Appendix. M
Telemetry kit Specification ...............................................................302
M.1.
Servo calculation ..........................................................................................307
Appendix. N
Manufacturing ..................................................................................308
N.1.
Machining by milling machine ....................................................................309
N.2.
Machining by XYZ 1330 Lathe ..................................................................309
N.3.
Laser Cutting by Tortec Laser cutter .........................................................310
N.4.
Cutting blocks by vertical bandsaws machine............................................310
Appendix. O
Test Rig ...........................................................................................311
O.1.
Initial Gimbal Test Rig Conceptual Design ................................................312
O.2.
Updated Octagonal Gimbal Test Rig Assembly .........................................314
O.3.
Octagonal Model Mount Frame Technical Drawing ...................................316
O.4.
Octagonal Mid Frame Technical Drawing ..................................................318
O.5.
Octagonal Outer Frame Technical Drawing ...............................................320
O.6.
Octagonal Gimbal Test Rig Stand Technical Drawing ...............................322
O.7.
Gimbal Test Rig Weight Estimation ...........................................................324
O.8.
Gimbal Test Rig Manufacturing Cost .........................................................326
O.9.
Qualification test plan ................................................................................326
Electrical Performance Tests (Initial, In-Process, Final) .........................................326
Storage Temperature Cycling ................................................................................326
Thermal Shock ......................................................................................................326
Random/Sine Vibration..........................................................................................327
Operational Temperature Cycling ..........................................................................327
O.10. Initial Involvement in the MEng Team Project ............................................327
O.11. Tri Angular Bracket Technical Drawing......................................................328
O.12. T-Bracket Technical Drawing ....................................................................330
Appendix. O
Design features for business case ...................................................332
LIST OF FIGURES
vii
LIST OF FIGURES
Figure 1 - Initial Concepts for Stage 1 convergence ..................................................... 2
Figure 2 - Concepts considered in the stage-2 convergence ........................................ 3
Figure 3 - Project Organization Chart ........................................................................... 5
Figure 4 - Progress (to date) of the project ................................................................... 7
Figure 5 - Leadership area of priority Semester A (Left), Semester B (Right) ............ 8
Figure 6 Performance Charts for Jonathan (a) and Zuber (b) ...................................12
Figure 7 - Quad-rotor design .......................................................................................14
Figure 8 - Stowage Instructions ...................................................................................15
Figure 9 - Quad-rotor in Stowed Configuration ............................................................15
Figure 10 Removable Lightweight Payload Box .......................................................16
Figure 11 - Removable Lightweight Payload Box ........................................................16
Figure 12 - Payload Box with simple construction and failsafe mechanism .................16
Figure 13 Payload Box with Payload Clearance .......................................................16
Figure 14 Free Body Diagram - Flight and Landing Cases .......................................18
Figure 15 - Free Body Diagram - Landing Cases ........................................................18
Figure 16 - Free Body Diagram - Flight and Gust Load Cases ....................................19
Figure 17 Fixed Arm Cross Section See also Appendix G.7 ..................................22
Figure 18 Mesh for Fixed-arm Assembly Values as per Appendix G.6 ..................23
Figure 19 - Deflection of Fixed-arm Assembly (Flight Loads) with 7.6mm Deflection ...23
Figure 20 - Stress of Fixed-arm Assembly (Flight Loads) with Stress 15.8MPa
(Contact) and 20MPa (Peak) .......................................................................................23
Figure 21 Stress (Close-up) of Fixed-arm Assembly (Flight Loads) with Stress
15.8MPa (Contact) and 20MPa (Peak) ........................................................................24
Figure 22 - Simplified Plate Representations ...............................................................25
Figure 23 - Simple Plate Deflection Carried out on CATIA showing 4.54mm deflection
....................................................................................................................................26
Figure 24 - Flight and Gust condition of Main Body with 0.13mm Deflection................27
Figure 25 - Lateral Impact Case on Single Leg - 60.6MPa Stress ...............................28
Figure 26 Stress Element A with Principal Stress for - Analytical Undercarriage
Combined Loading Bending, Buckling and Torsion (G.13) .......................................29
Figure 27 - Arm and Mass for Rayleigh Method ..........................................................31
Figure 28 Mass Representation of Motors, Blocks, Plates, Fasteners and ESC .......33
Figure 29 Simplified FE analysis with 1st Nat freq as 19.64Hz 69.3mm Deflection
(Left) and 164MPa Stress (Right) ................................................................................33
Figure 30 Simplified FE with 2nd Nat freq as 20.06 Hz (Left) and 3rd Nat freq as 134.6
Hz (Right) ....................................................................................................................33
Figure 31 Simplified FE with 4th Nat freq as 224.1 Hz (Left) and 5th Nat freq as 411.9
Hz (Right) ....................................................................................................................33
Figure 32 As Built FE Analysis - Mass Representation of Motors, Fasteners, Cables
and ESC......................................................................................................................34
Figure 33 As Built FE analysis with 1st Nat freq as 451 Hz 69.0mm Deflection (Left)
and Stress (Right) .......................................................................................................34
Figure 34 - As Built FE analysis with 2nd Nat freq as 736 Hz (Left) and 3rd Nat freq as
1707 Hz (Right) ...........................................................................................................34
Figure 35 - As Built FE analysis with 4th Nat freq as 2 KHz (Left) and 5th Nat freq as 4.1
KHz (Right) .................................................................................................................34
Figure 36 - Prototype Quad Rotor ...............................................................................44
Figure 37: Waypoint Command File ............................................................................47
Figure 38: Telemetry Information transmitted to ground control station .......................50
Figure 39: Transmission Link Statistics (Serial Connection) ........................................51
Figure 40: Transmission Link Statistics (Telemetry Kit) ...............................................51
Figure 41 PID System (Oscar, 2013) ........................................................................55
LIST OF FIGURES
viii
LIST OF FIGURES
ix
LIST OF FIGURES
Figure 136 - Contact model Flight Case for Main body assembly - Equivalent Stress
with predicted locations .............................................................................................204
Figure 137 - Resolving Component to Determine Vertical Load ................................205
Figure 138 - Undercarriage Leg Under Pure Bending................................................205
Figure 139 - Undercarriage Leg Under Pure Torsion .................................................206
Figure 140 - Stress Element A (Warren C. Young) ....................................................207
Figure 141 - Plan View of Stress Element A ..............................................................207
Figure 142 - Stress Element A with Principle Stresses ..............................................208
Figure 143 - Undercarriage Mesh for Contact Model with values as per G.6 .............209
Figure 144 Lateral Landing on Single Undercarriage Leg with 53.6mm Deflection .209
Figure 145 - Lateral Landing on Single Undercarriage Leg with 60MPa Bending Stress
..................................................................................................................................210
Figure 146 - Lateral Landing on Single Undercarriage Leg with 60MPa Bending Stress
(Close-up) .................................................................................................................210
Figure 147 - Tip Landing on Single Undercarriage Leg with 60MPa Bending Stress .211
Figure 148 -Tip Landing on Single Undercarriage Leg with 66mm Combined bending
and torsion deflection ................................................................................................211
Figure 149 - Tip Landing on Single Undercarriage Leg with 71MPa Combined bending
and torsion stress ......................................................................................................212
Figure 150 Entire Quad-Rotor Flight Deflection of 7.9mm at Motor Arm Tips .........213
Figure 151 - Entire Quad-Rotor Flight Deflection of 7.9mm at Motor Arm Tips (Closeup).............................................................................................................................213
Figure 152 - Entire Quad-Rotor Flight Stress of 28.8 MPa at Motor mount plates .....213
Figure 153 - Entire Quad-Rotor Flight Stress with Plate Stress peak at 14.42Mpa ....214
Figure 154 Downward Load - 1kg Payload and 10N Additional Load onto PB-005
Plate ..........................................................................................................................215
Figure 155 - Side Load - 1kg Payload and 10N Additional Load onto Hinge Plate at
45deg to horizontal ....................................................................................................215
Figure 156 - Side Load - 1kg Payload and 10N Additional Load onto short edge 45deg
to horizontal...............................................................................................................216
Figure 157 - Side Load as per Figure 156 - Showing Pre-mature Release due to global
deflection...................................................................................................................216
Figure 158 Downward Load as per Figure 154 - new design showing 0.73mm
Deflection ..................................................................................................................217
Figure 159 - Side Load as per Figure 155 new rigid design and Deflection of 1.56mm
..................................................................................................................................217
Figure 160 Side Load as per Figure 156 and Figure 157 with new design and
deflection of 0.41mm*................................................................................................217
Figure 161: Proof of Connection ................................................................................261
Figure 162: Mission Planner top menu ......................................................................262
Figure 163: Initial Setup for all components ...............................................................262
Figure 164: Mission Planner Waypoint Entry Point ....................................................262
Figure 165: Secondary Commands ...........................................................................263
Figure 166: Area for writing flight plans into Pixhawk's Memory ................................263
Figure 167: Stability Tuning for Quad-rotor Control ...................................................264
Figure 168: Mission Plannner environment for changing parameters ........................264
Figure 169: Fail Safe parameters ..............................................................................265
Figure 170: Typical Set Fail Safe Values ...................................................................266
Figure 171: Monitoring System Values ......................................................................267
Figure 172: Flight ready monitoring system ...............................................................267
Figure 173: Quad-rotor Acceleration and Velocity parameters ..................................268
Figure 174 Minim OSD V2.1 (unmannedtechshop, 2015)..........................................276
Figure 175: 3DR uBlox GPS with Compass Kit (unmannedtechshop, 2015) .............278
Figure 176 CG calculations for the x and y-axis ........................................................281
Figure 177 CG calculations for z-axis ........................................................................281
LIST OF FIGURES
xi
GLOSSARY
3D
AFS
Atl
BEC
BOM
CAA
CAD
CCW
CG
CNC
COTS
CPR
CW
D
EMI
ESC
EU
FBD
FE
FEA
FEM
FPV
ft
GPS
Hz
I
IAS
IMechE
km
knots
KV
Li-PO
m
MEng
mm
MPa
MTOM
N
OSD
P
PA
PDR
PVC
PWM
Three Dimensional
Advanced Failsafe
Altitude
Battery Eliminator Circuit
Bill of Material
Civil Aviation Authority
Computer Aided Design
Counter-Clockwise
Cenre of Gravity
Computerised Numerical Control
Commercial of the Shelf
Cardiopulmonary Resuscitation
Clockwise
Derivative
Electro-Magnetic Inteference
Electronic Speed Controller
European Union
Free Body Diagrams
Finite Element
Finite Element Analysis
Finite Element Method
First Person View
Feet
Global Positioning System
Hertz
Integral
Indicated Airspeed
Institution of Mechanical Engineers
kilometer
Nautical Miles
kilo-volts
Lithium Polymer
metres
Masters of Engineering
Millimeter
Mega Pascals
Maximum Take-Off Mass
Newtons
On Screen Display
Proportional
Polyamide (Nylon)
Preliminary Design Review
Polyvinyl Chloride
Pulse Width Modulator
GLOSSARY
xii
Quad
RC
RC
RPM
RTL
SCA
SUA
TX
UAS
UAV
VAT
VLOS
W
WBS
WP
Quadcopter
Radio Controller
Receiving (Radio)
Revolutions Per Minute
Return to Launch
Sudden Cardiac Arrest
Small Unmanned Aircraft
Transmission (Radio)
Unmanned Aircraft System
Unmanned Aerial Vehicle
Value Added Tax
Visual line of Sight
Watts
Work Breakdown Structure
Waypoint
GLOSSARY
xiii
Introduction
1 Introduction
The Unmanned Aircraft system (UAS) challenge is being introduced by the Institution of
Mechanical Engineers (ImechE) for the first time. Teams entered by universities will only constitute
of members from the undergraduates cohort. The competition will provide students from different
universities to develop and demonstrate leadership, teamwork and technical competencies. Its
being held during the academic year 2014 till 2015. During this period the universities participating
in the competition will follow a structure of designing, developing and demonstrating. It will also
include design reviews, presentations and flight demonstration that will contribute to point scoring.
For the competition, the UAS can have a maximum take-off mass of 7kg with Commercial Off The
Shelf (COTS) products not exceeding 1000. The UAS will need to perform a series of tasks such
as take-off, climb to an altitude between 100-400ft, cruise, follow a predefined route, drop two
payloads (Bag(s) of flour) weighing 1kg each at any reachable location and land back completely
autonomously.
Design Rationale
2 Design Rationale
This section begins to discuss the solutions to the mission requirement outlined in the previous
chapter. It assesses various design options and converges to an ultimate solution. Upon evaluation
of various design concepts, it was conclusive that the best approach to tackle the problem was by
going forwards with a Quad-rotor and ground control station.
Design Rationale
The results from the Stage-1 convergence demonstrated that a multi-rotor would be the best option
to meet the product design specification.
Quad-Copter
Hex-rotor
Octacopter
3 arm 6 rotors
Project Management
3 Project Management
To achieve the project objectives, effective organisation, planning, budgeting and management
styles were adopted. This section describes the organisational structure and the key management
tasks undertaken to deliver the project successfully. It describes the leadership, organisation
structure and role selection, project planning, budgeting, people and conflict management, finally a
review on both team leads is discussed.
Project Management
Alfred Dzadey
Project Manager
Zuber Khan
(Chief Signatory - Quality)
Jonathan Ebhota
Systems Team Leader
System Engineer
Osman Sibanda
Marketing/Bussiness
Specialist
Amit Ramji
(Chief Engineer)
Structural / Stress / Design /
Hardware & Electrics
Integration and Assembly
Engineer
Mozammel
Manufacturing Engineer
Mohammed Mohinuddin
Micky Ngouani
Kasun Malwenna
Hassan Turabi
Project Management
needed to complete the project. Major objectives were subsequently listed and implemented into a
Work Breakdown Structure (WBS) as shown in Table 1 below.
The WBS details the main steps that are required to complete this project. Stages involving design,
manufacture, purchasing and delivery of products may involve several delays that creates
difficulties and hence prevents the scheduled delivery. Strict time management and contingencies
such as overestimating time frames for completion of such tasks have been implemented into the
project plan to account for these delays.
Work Breakdown Structure
1 Scope
4.3 Structural material and sizing ready for purchase
1.1 Determine project scope
4.4 Design purchase readiness
1.2 Define resources
5 Order parts
1.3 Scope complete
5.1 Send out order list for components and delivery
2 Design Specification/System Requirements
6 Manufacturing & Assembly
2.1 Create Design specification for a UAV
6.1 Machine structural frame
2.2 Review system specifications
6.2 Integrate systems components
2.3 Create system requirements
6.3 Integrate structural frame, system and propulsion
components
2.4 Obtain approvals to proceed (concept, timeline, 7 Testing and Validation
budget)
2.5 Analysis complete
7.1 Develop unit test plans using design specifications
3 Preliminary Design
7.2 Develop integration test plans using design
specifications
3.1 Review specifications
8 Integration Testing
3.2 Payload Delivery System
8.1 Test system integration
3.3 Propulsion System design
8.2 Integration testing complete
3.4 Systems design
9 Critical Design Review (CDR) and Flight Readiness
Review (FRR)
3.5 Concept Structural design
9.1 Draft CDR report
3.6 Preliminary Safety Case consideration
9.2 Deliver CDR report
3.7 Preliminary Weights estimation
9.3 Draft FRR report
3.8 Obtain approval to proceed
9.4 Deliver FRR report
3.9 Preliminary Design complete
10 Competition
3.10 Deliver PDR to IMeche
10.1 Design Presentation
4 Final Design ready for purchase
10.2 Flight Readiness Review
4.1 System components finalised ready for
10.3 Competition day
purchase
4.2 Propulsion components ready for purchase
10.5 UAS CHALLENGE FINISH
Table 1- Work Breakdown Outline
Once the work breakdown structure was established, the project schedule was created and is used
as a baseline schedule for the whole duration of the project life. Using the project plan, a graph
representation of the current progress has been created and is shown in Figure 4. This is a
simplified overview of the progress made so far which is detailed in the project plan shown in
Appendix A.2. The progress made so far and completion of tasks can be seen in more detail in the
project plan.
UAS CHALLENGE 2015
Project Management
10
20
30
40
50
60
70
80
90
100
Progress (%)
3.3.1 Milestones
The major milestones set for this project are as follows:
30 October - Defining scope of project
16 November - Complete Design Analysis
05 December Deliver PDR to IMechE
16 December Design ready for purchase
1 April Deliver CDR report
30 May - Integration testing complete
12 June Deliver FRR report
1 July Design presentation
July Competition Day and End of UAS Challenge
3.4 Leadership
Leadership involves creating an inspiring vision and managing the delivery of the vision.
Leadership brings together the skills needed to achieve this vision. Therefore, it is vital that the
style of leadership is rightly chosen for team performance and effective quality. The style of
leadership may vary during the duration of the project. The three circle model is a concept that is
used to represent the dynamics of a group displaying the percentage of effort in terms of team,
task and individual. (Adair, 2012) It is critical for the leader to monitor these areas to ensure that
one area doesnt needlessly become dominant. An example is where the group may take long to
make decisions due to the size of the group and differences of opinions. This is mitigated by
creating a cut of point whereby the group is no longer being effective in the decision making
process.
Project Management
Consequently, the leader will conclude what has been discussed and make the final decision. In
Figure 5 the three circle diagrams depicts in which area leadership was stressed during the
academic year.
TASK
TASK
TEAM
INDIVIDUAL
TEAM
INDIVIDUAL
Project Management
Types/Techniques
Description
Agendas are always sent out 24 hours before our official meetings
with our supervisors and also minutes are also sent out 24 hours
after the meeting as a follow up of what was discussed and agreed
in the meeting.
WhatsApp
It is used a form communication where all group members can
discuss about findings or issues
Google drive
An account was made for sharing files between members in the
group. Each individual in the group has a folder with their name and
hence can share their work to the group
Text messages and phone
For contacting individuals in the group privately for any needs
calls
regarding the project
Group meetings
Its used as a way to meet up face to face to discuss and updates or
issues and to check progress of work and make decision.
Table 2 - Forms of communication used in project
Project Management
10
Budget Estimation as of
01/11/2014
Part
Unit Price
Flight controller
Telemetry kit
GPS Module
ESC
Propellers
Brushless Motors
Camera
OSD
Batteries
RC Transmitter
Air frame including landing
gear and payload box
Extra cable and connectors
Test Rig*
Unplanned Quad Parts
Delivery Costs*
Total:
C. Factor (x1.2)
Current Total:
*Not Part of COTS
Quantity
Actual as of
23/04/2015
Unit Price
Quantity
Difference
150.00
40.00
50.00
30.00
5.00
20.00
50.00
30
90.00
30.00
1
1
1
5
6
5
1
1
2
1
159.98
35.80
53.94
27.16
3.95
19.16
56.41
29.99
60.40
14.99
1
1
1
5
6
5
1
1
3
1
-9.98
4.20
-3.94
-2.84
6.30
0.84
-6.41
0.01
-1.20
15.01
150.00
146.30
3.70
50.00
150.00
0.00
100.00
1,157.63
1389.16
1
1
0
1
20.95
132.08
21.02
125.06
1
1
1
1
29.05
17.92
-21.02
-25.06
Remaining:
Percentage:
Table 3 - UAS Challenge 2015 Budget
1,100.94
231.53
79.252438
Project Management
11
competition. The team decided to invest in the project extending the budget to 1500 with the aims
of winning an award and being reimbursed.
Project Management
12
appointed as team leaders to overlook specific sections; structural and systems. For these two,
three further criterias were included; Coaching, Managerial skills and Motivational skill. The
breakdowns of each criterion are as follows:
Enthusiasm: passion and interest for the role and subject
Coaching: training and guiding other team members through their work performance and
subject knowledge
Managerial skills: ability to plan and delegate workload, communicate between team
members, and solving issues between members fairly and objectively
Motivational skills: being able to understand what motivates each member and keeping
them motivated
Team value: quality and information being passed on, insight in topics, availability for help
when asked and general team sportsmanship
Planning: time management, planning for delays and possibly additional workload
Execution: method of execution, holding up other members
Delivery: quality of final work produced for individual role
Contribution: overall workload taken, experience and insight provided and contribution to
the team
Zuber Khan
Jonathon Ebhota
5
Project Management
13
Figure 6 presents the performance chart of the two sub team leaders. It describes on a scale from
0 to 5 how they are rated against each category, where 5 is classed as the best and 0 is classed
as the worst. On average it can be seen that Zuber was excellent in most of these categories
whereas Jonathan mostly was good all round and both lacked in motivating team members. A
more detailed individual performance review of each team members can be seen in Appendix A.5.
3.10 Evaluation
Self-evaluation allows one to reflect on how effective their performance was during the project.
During this process, the performance of the leader can be assessed to see how effective it was,
noting areas that need improvement. It should also list the skills developed and what skills need to
be worked on in order to be a better leader if they were to do the project the second time round.
Using the Project manager evaluation form in the Appendix A.6, it was possible for me to evaluate
my performance. It was found that the team scored me 5 in regards to management of the
team/project, having the ability to work with others, ability to present options and reach decisions
and the ability to locate and utilize resources effectively. As a leader of the team and project these
were my strongest areas. An area in which I was marked to be average was the ability to anticipate
and analyse problems. It seems like this is an area in which I need to focus on if I were to manage
a project again. Moreover, as part of the evaluation there were phrases regarding the likelihood to
work again with the project manager on another project. It was reported back that they would be
willing to work with me again on another project with some changes applied.
Further points were asked for regarding any specific strong points/ weak points about my
performance. The positives were: Firstly, I had good form of communication skills and
persuasiveness. Secondly, I was always going the extra mile and continuously standing up for the
team in front of supervisors and I was very supportive. Evidently, it is clear that I possess essential
skills such as good communication, persuasiveness and Im very supportive of the team member
because I believe as the leader of the team it is my duty to be the voice of the team and the person
held accountable for the team. The negatives were: primarily, I need to keep within deadlines and
secondly, I am far too lenient. These are areas that need to be worked if Im to manage another
project. Im apparently too lenient when it comes to deadlines. During the period of the project, we
have had team members that have had personal issues outside the academic work. It meant that if
I had set deadlines for work to be completed and a team member said they couldnt complete the
task due to personal problems, I would be reluctant to give them more time. This could potentially
cause delays in the initial time plan and hence maybe keeping to a strict deadline regardless of the
personal background situation might be necessary and something I could consider next time.
Overall, I would say I have done a good job in managing this group so far and I have learnt some
vital lessons regarding what to do and what not to do as a project manager.
UAS CHALLENGE 2015
Quad-Rotor Design
14
4 Quad-Rotor Design
A Hex-Rotor had been considered during the early stage of the design convergence process,
however during the detail design stage this had been changed to a Quad-rotor design. The reason
for such a dramatic design change is due to mass and cost constraints and is detailed in Appendix.
C and Appendix. D respectively.
Upon detailed consideration of the mass and materials involved with the Hex-rotor, it had been
decided to significantly modify the design and produce a Quad-rotor. As detailed in Appendix. C,
the reduction in mass by alterations in geometry, reduction of parts and optimising the use of
materials results in a very lightweight structure as shown in Figure 7 below. The use of extruded
Nylon 6 main body plates (Appendix B.7) allows for a lightweight structure that is fastened together
into a sandwich design to provide a significantly rigid structure. The use of Carbon Fibre has been
entirely eliminated due to financial constraints; hence a suitable strengthened alternative is
selected. The use of M3 bolts and Nylon 66 blocks (Appendix B.7) allows for a rigid main structure
with multiple load paths. Using the machined Nylon 66 blocks in compression allows for the
majority of the loads to remain in-plane of the main body plates and allows the fasteners to take up
most of the load.
Details of the design architecture and in-depth features are found in Figure 7 through Figure 9 and
Appendix B.7.
Quad-Rotor Design
15
Sandwich Design to
minimise bending effect
with rigid links (M3 bolts)
Quad-Rotor Design
16
Figure 10 through Figure 13 show the design of the payload housing with a simple trap-door type
design activated by gravity with release of a servo. The design can be adapted to use either rotary
servo motors or linear actuators. The structural analysis of the payload compartment and its
development is carried out in Appendix G.15 and G.16. Dimensions of the payload compartment,
component parts and BOM can be found in Appendix B.7.
17
Initially a Hex-rotor was considered, which would inherently have increased cost compared to a
Quad-rotor due to increased structural, electronic and propulsion components. It was therefore
unequivocal that a Quad-rotor was the tactic forward to achieving a solution within budget
requirements.
A detailed cost calculation for the Quad-rotor (Appendix. D) has been carried out to ensure the
UAV is within IMechE budget limits (IMechE, Jan 2015). The total cost of COTS items within the
Quad-rotor is 824.84, structure cost of 81.34, hence a total cost of 906.18 with an itemised
breakdown provided in Appendix. D. The above cost summary is inclusive of VAT, less delivery
and is accurate to retail prices at the time of purchase.
Structural Analysis
18
7 Structural Analysis
7.1 Load Case Definition and Free Body Diagrams
Structural Analysis
19
20
21
tolerances of fit. Fasteners with tighter tolerances will load the local structure during
repeated flexure more than a loose tolerance fastener due to the miniscule freedom of
movement of the joint.
In fatigue critical areas, interference fit fasteners shall be used whenever possible in
preference to clearance fit. A close tolerance for clearance/transition fit fasteners will
improve the fatigue performance of the joint, as this will minimize the risk of individual holes
being over-loaded. For the current Quad-Rotor design, fasteners are loaded axially hence
introducing a bolt pre-load and reducing the miniscule movement if any existed.
22
D1
F
2
D2
F
1
The maximum bending stress experienced on the Fixed-arm is 14.42MPa as shown in Appendix
G.7 and the maximum bending stress experienced by the Movable-arm is 15.26MPa as shown in
Appendix G.8. Refer to Appendix B.7 for parts list, Appendix. E for material properties, G.4 for
boundary conditions, G.5 for Finite Element solver method, G.6 for mesh types and properties and
G.7 - G.8 for results of the contact model for bending case of the UAV Arms. A Sample calculation
for the Fixed-arm is shown below:
0.016
25 0.17 2
=
=
= 14.42
(0.0164 0.01154 )
64
23
Figure 20 - Stress of Fixed-arm Assembly (Flight Loads) with Stress 15.8MPa (Contact) and
20MPa (Peak)
UAS CHALLENGE 2015
24
Figure 21 Stress (Close-up) of Fixed-arm Assembly (Flight Loads) with Stress 15.8MPa
(Contact) and 20MPa (Peak)
FEM Verification: Tube Stress Comparison
One can observe the results from the above analytical stress calculation being 14.42MPa and the
stress level as seen in the far field stress contour of the tube in Figure 21 (15.8MPa) being very
close. Substantiation of the numerical modelling and contact constraints can be deemed as
accurate as a very small difference is observed between the methods.
Plate deflection has also been calculated analytically to enable comparison to an FEA model,
ensuring the modelling techniques are correct and establishing meshing and connection properties
to be used on the entire UAV FEA model. The analytical method calculated a deflection of
4.555mm, whereas the FEA package calculated 4.54mm (Appendix G.11). These results are in the
same order of magnitude and are marginally different; therefore the modelling technique is deemed
correct and usable throughout.
A simple plate deflection was determined of a 2mm thick Nylon plate with dimensions of 315mm by
280mm. This was the largest the plate would go to on the UAV if necessary therefore was used for
the purpose of this analysis. The reason for this was to compare the analytical results with the
results produced by the FEA model. If the results were similar or close to the analytical method, the
modelling method could be applied to the whole UAV model where the plates are used.
25
X = a = 315mm
Y = b = 280mm
3
12(1 2 )
(, ) = sin
=1 =1
= 11 sin
sin
2
2
sin
+ 12 sin sin
+ 21 sin
sin
+
160
2
1
4
2
2
[( 2 ) + ( 2 )]
33.8445
=
=
383.72
88200 106
2
Followed by calculating the flexural rigidity
=
16383.72
112
= 622.063
13 = 207.35
31 = 207.35
33 = 69.12
26
w11 =
w13 =
w31 =
33 =
1
2.61905
1
2.61905
1
2.61905
1
2.61905
622.063
12
12
)+(
)]
[(
2
0.315
0.282
= 4.67689 103
= 5.21215 105
= 7.59333 105
= 6.41566 106
207.35
12
32
)+(
)]
[(
2
0.315
0.282
207.35
32
12
)+(
)]
[(
2
0.315
0.282
69.12
32
32
)
+
(
)]
[(
0.3152
0.282
The coefficients were then input into the Navier solution equation to calculate the deflection at the
centre.
0.1575
0.14
0.1575
(, ) = 4.67689 103 sin (
) sin (
) + 5.21215 105 sin (
)
0.315
0.28
0.315
3 0.14
3 0.1575
sin (
) + 7.59333 105 sin (
)
0.28
0.315
0.14
3 0.1575
3 0.14
sin (
) + 6.41566 106 sin (
) sin (
)
0.28
0.315
0.28
w(x, y) = 4.67689 103 5.21215 105 7.59333 105 + 6.41566 106
w(x, y) = 4.555 103 m = 4.555mm
Figure 23 - Simple Plate Deflection Carried out on CATIA showing 4.54mm deflection
From the FEA model (Figure 23) it was found that the deflection has been calculated to be
4.54mm.
UAS CHALLENGE 2015
27
The mesh used was set to a size of 2mm with absolute sag of 1.5mm. Therefore any further plate
bending analysis carried out on CATIA, should be set to the same mesh size and constraints as it
has been substantiated to provide accurate answers.
Method
Deflection
Analytical (Rectangular Plate)
4.555mm
FEA CATIA (Rectangular Plate)
4.54mm
Table 4 Comparison of Simplified Plate Deflection for Model Substantiation
G.4
for
boundary
2
2 2
( )
2
2 0.18
(
)
4.926 103
= 556.78
Analysis on pure bending has also been carried out in Appendix G.13, to represent a pivot jam or
lateral sideward landing on a single undercarriage leg. With the applied 1.5 global load safety
factor the stress experienced by the undercarriage leg was in the region of 62.2MPa, being higher
than the yielding properties of the PVC material (Appendix. E). However this analysis has assumed
UAS CHALLENGE 2015
28
a worst-case scenario with the UAV landing on a single leg, which can now be avoided. The UAV
would also share multiple load paths if a misbalanced landing were experienced therefore reducing
the stress. Additionally, the entire Quad-rotor structure would deflect as a result of such bending
impact, highlighting that a parent non-linearity has not been considered. To further analyse such
parent non-linearity on a single undercarriage leg, spring constraints at the Lug bracket (LB-003)
bolt holes with the stiffness of the main body structure can be modelled
Figure 25 (60.63MPa). From this similarity in analytical and numerical methods, it is conclusive that
the analytical modelling techniques are substantiated and can be relied upon for further analysis if
required. Refer to Appendix B.7 for parts list, Appendix. E for material properties, G.4 for boundary
conditions, G.5 for Finite Element solver method, G.6 for mesh types and properties and G.13 for
results of the contact model for bending case of the undercarriage.
29
Torsional analysis has also been carried out to determine the twist the undercarriage would
experience if the UAV landed on the tip of one horizontal leg (UH-001 - Appendix B.7). Appendix
G.13 calculates a pure torsion case to be used for a combined loading effect in section 8.13 and
8.14. The calculated twist angle is 0.6257rad or 35.85, the twist angle being of such high
magnitude indicates a high stiffness constraint at the boundary condition or a significantly high load
due to single leg impact assumptions. However the assumption of a single leg impact is a rare
occasion and can now be avoided. The shear experienced by the undercarriage due to the twist is
calculated to be 30.57MPa which is significantly low compared to the PVC yielding properties in
shear being 1099.3MPa (Appendix. E).
1.059798 6.34 1
+ (1.059798 6.34)2 + 4 30.5722 = 27.1
2
2
-34.495
27.095
30
Description
Deflection (mm) or
(deg)
Equivalent Load
(N) or Stress
(MPa)
393.7N
62.2MPa
60.63MPa
30.57MPa
34.495MPa
71.76MPa
31
8.16.1
Modal analysis was carried out to determine the natural frequency of the UAV arm with the full
assembly of parts with their corresponding weights. Once the natural frequency is known, one can
program the autopilot system (Pixhawk) and ESCs to ramp through the primary natural
frequencies to ensure excessive vibration is not encountered. The ESCs can control the motors to
have a soft/ medium/hard start to idle for this reason and the modal frequencies can be avoided
to protect the structure (loosening fasteners, fatigue and instability during flight).
m = 0.36846Kg
L = X = 0.234m
2
2
0 ( 2 ) +
=1 ( )
2
=
0 2 + =1 2 ( )
To be able to calculate the natural frequency using Equation 6, the static deflection equation
requires to be differentiated twice.
1 ()
= 1 (6 3 2 )
2 1 ()
= 61 ( )
2
2 =
92 2 6 6 7
256
6 + 7 ] + 64
5
0
2
=
+ 7 ]+
6
64
5
32
2 =
(1.4
9.7 105
1.124131676
1.124131676
=
3
5
5.361854627 10 ) + 2.362901004 10
2.43571499 105
1.124131676
=
= 214.83/ = 34.19 = 2041.93
2.43571499 105
From this it can be concluded that the natural frequency of the simplified arm is 34.19Hz.
Rayleighs method usually always over predicts, therefore in reality the natural frequency will be
slightly lower.
33
8.16.2
Figure 29 Simplified FE analysis with 1st Nat freq as 19.64Hz 69.3mm Deflection (Left)
and 164MPa Stress (Right)
Figure 30 Simplified FE with 2nd Nat freq as 20.06 Hz (Left) and 3rd Nat freq as 134.6 Hz
(Right)
Figure 31 Simplified FE with 4th Nat freq as 224.1 Hz (Left) and 5th Nat freq as 411.9 Hz
(Right)
34
Figure 33 As Built FE analysis with 1st Nat freq as 451 Hz 69.0mm Deflection (Left) and
Stress (Right)
Figure 34 - As Built FE analysis with 2nd Nat freq as 736 Hz (Left) and 3rd Nat freq as 1707 Hz
(Right)
Figure 35 - As Built FE analysis with 4th Nat freq as 2 KHz (Left) and 5th Nat freq as 4.1 KHz
(Right)
UAS CHALLENGE 2015
35
2nd Nat
Freq (Hz)
N/A
3rd Nat
Freq (Hz)
N/A
Simplified
Analytical (8.16)
Simplified FEA
19.64
20.06
134.6
(8.16)
As-built FEA
451
736
1707
(8.17)
Table 6 Summary of Modal Frequencies for Fixed Motor Arm
411.9
2000
4100
As predicted from the Rayleigh method in Section 8.16, the actual natural frequency will be slightly
lower between the 34.19 Hz Vs the 19.64 Hz. From this simplified analysis, one can substantiate
the modelling techniques used in the FEA for more complex assemblies. The As-built cases have
significantly higher modal frequencies and was also predicted due to the increased stiffness when
considering fastened motor plates and blocks. Additionally it is worth noting that the higher less
important frequencies have modal excitation closer to the motor mount plates, hence the reason
for selecting Aluminium Alloy plate as a mounting material for the motors (Appendix B.7 and
Appendix. E). Aluminium Alloy compared to the cast mild-steel motor brackets which are supplied
with the motors are less susceptible to fatigue damage due to repetitive vibration.
36
Below is a margin of safety table which has maximum loads and stresses which could be applied
onto the Quad-rotor and also the maximum allowable loads and stresses. Using the maximum and
allowable loads and stresses, safety factors were obtained.
Part No.
(Appendix
B.7)
Case /
Calculation /
Section
FA-001
Case 1 (G.7)
MA-001
Case 1 (G.8)
UV-001
Case 2 (G.13)
UV-001
BP-001 &
BP-002
Assembly.
Maximum
Thrust from
Motors
Maximum
Thrust from
Motors
Undercarriage
Pipe Under
Buckling
Safety
Factor,
SF=
Allowable
/Applied
14.42MPa
55MPa
3.81
15.26MPa
55MPa
3.60
10.5Kg
56.76Kg
5.41
Undercarriage
Pipe Under
30.57MPa
1099.3MPa
Torsion
(G.9)
Undercarriage
Lug Under
72.84N
1765.15N
Maximum
Loading
Analytical
Combined
Undercarriage
Loading
Combined
27.09MPa
55MPa
1 on
Loading
Undercarriage
Bending,
Vertical Leg
Buckling and
Combined
Torsion (G.13)
Loading
34.5MPa
55MPa
2 on
Undercarriage
Vertical Leg
Appendix G.12 Main Body
Deflection due
to Maximum
5.83MPa
55MPa
Thrust and
Gusts
Table 7 - Summarised Margin of Safety Table
Case 4 (G.13)
LB-003
Loading
Description
Maximum
Maximum
Allowable
Applied
Load/Stress
Load/Stress
Appendix. E
35.96
24.23
2.03
1.59
9.43
37
Section by Hassan
Dzadey
As a practicing performance and propulsion engineer the key parameters that were vital within this
report was to investigate and identify possible propeller, motor, esc (electronic speed controllers)
and power supply combinations that are efficient and also cost effective with the ability to achieve
the mission objectives set by the IMechE UAS challenge. It is also within the interest of this report
to point out the work that has been conducted as a systems engineer to improve the navigation of
the UAS (Unmanned Aircraft Systems) and target tracking.
At the start of the MEng project IMechE had set specific limitations to which partly involved the
performance of the UAS along with mission details. These specifications are identified below which
were strictly followed:
Maximum Take-Off Mass (MTOM) must be equal to, or less than 7kg
Must have the capability to fly under 20knots wind and 25knots gust conditions
Maximum airspeed of 60knots (IAS) must not be exceeded
Must be capable of operating within altitude range of 100ft-400ft
Must have the ability to complete 2km round mission
On top of the IMechE specification there were specifications set by the MEng group, which are
listed below and also strictly adhered to.
Initial cost limitation of 550 after taking into account structural other electrical components
Initial propulsion and power supply weight limitation of 3.7kg was set after taking into
account structural, payload and electrical components weights
At the start of the MEng project various design concepts such as aeroplane, helicopter, Quad-rotor,
Hex-rotor, octocopter and osprey tilt rotor were put forward and analysed and after careful
alliteration the Hex-rotor was chosen as the design that the group would like to construct and put
thought to the IMechE UAS Challenge. Hence for the PDR the performance and propulsion
calculations were based on Hex-rotor as shown in appendix A. During mid-January it was identified
that while the cost would be under the 1000 limit set by the IMechE, the maximum take-off mass
of 7kg would be exceeded by 500g. From this point it was decided to change the design to Quadrotor, hence from Appendix H.2 onwards the calculations will be based on and around the Quadrotor design.
Most of components that are investigated in this report involves two unknown variables that are
required e.g. a propellers two variables involves its diameter and pitch, the RC motor has KV and
power, and the power supply requires voltage and capacity calculations. For this reason this report
has been split into sections which address one variable per component at a time by process of
elimination.
38
3.5 ()
()
39
Now that a RPM range 6,200 to 20,000 is identified in Appendix H.2 1.2, the power versus RPM
graph can be produced to identify the power required from a specific RC brushless motor. Equation
10 (S, 2014) is used to establish the power vs RPM graph:
() = 4 () () 3 (1 109 )
From figure: 1.3 in Appendix H.2 it identifies that a propeller with dimensions 7*6 rotating at
20,000RPM is an appropriate match for having the lowest power consumption of 473W for
efficiency coupled with highest RPM value for high speed. But now looking at figure 1.2 lift vs RPM
it can be seen that a propeller with dimensions of 7*6 will not produce the required lift of 34.34N
but only attain 17.34N. Although this propeller would be great for speed and efficiency it would not
have the required lifting capability to sustain flight. This process is repeated for every propeller and
the results are shown in Appendix H.2 table 1.2 shows the results for different propeller dimensions
together with RPM, power consumed and lift produced which is obtained from figures 1.2 and 1.3.
The maximum RPM used for each propeller to calculate its lift capability is 20,000RPM as
mentioned earlier, but even though the propeller is spinning at 20,000RPM there are still certain
propellers that cannot achieve the minimum lift required per motor of 34.34N and therefore
assigned with the letter N in the acceptability section of the table. This represents that the propeller
performance is not acceptable, this range falls from propellers 7*6 to 9*3.8.in Appendix H.2 Table
1.2 also shows the some propellers at 20,000RPM can produce in excess of 34.34N of lift and
therefore it was required to reduce the RPM to obtain the required lift, one example of this would
be propeller 9*6 at 20,000RPM produced 39.84N of lift and required 1265W to achieve this. As
there this no need to have the excess 4.82N of thrust the RPM can be reduced down to 18,750
which in turn makes the whole system run more efficiently and the power consumption reduces
down to 1042W which in turn results in reduced current draw. The results can be seen on table 1.3
in Appendix H.2
This type of analysis can be seen in larger propeller dimensions such as 17*10, table 1.4 in
Appendix H.2 has the results for this propeller size and it can be seen that a propeller of this size
would achieve well in excess of the 34.34N lift required, 476.45N with 20,000RPM while requiring
2685.2W. This would results in excess thrust of 442.11N which is not required, therefore the RPM
can be reduced down to 5,450 which in turn produces the lift required of just over 34.34N, hence
less current draw making the whole system more efficient.
40
Looking at the two propellers sizes in tables 1.3 and 1.4 in Appendix H.2 it can be clearly seen that
having a larger propeller definitely increases the endurance time of the Quad-rotor because the
power consumption required is reduced by half from 1042W to 543W which in turn means lower
current draw for the same amount of lift produced. Lower current draw results in longer flight time.
One of the disadvantages of increased propeller diameter is the fact that the RPM is reduced
therefore effecting the velocity of the Quad-rotor. Finding the best propeller combination between
these two propellers that would give the lowest current draw with the highest velocity while
maintaining the lift required of 34.34N was the key engineering challenge that was faced though
out this project.
41
By analysing the data obtained from table 1.5 in Appendix H.3 the maximum RPM that these RC
motors can achieve is identified, therefore any propeller that requires higher RPM than what the
motors can achieve is eliminated, this is certainly true for propellers have small diameters and
require high RPM to attain the lift required. From table 1.5 in Appendix H.3 it can also be seen that
the maximum RPM that can be achieved is 14,800, therefore by looking at Appendix H.3 in table
1.2 it can be seen that propellers that are in dimension range of 7*6 to 10*7 and 11*3 can be
eliminated as they require higher than 14800 RPM. Therefore table 1.2 can be reduced down to
1.2.1 in Appendix H.3
()
2000 ()
( ) =
=
= 16.6/
()
120 ()
42
()
cos()
Using trial and error When = 10; F= 69.7N = 20; F=73.0N = 30; F=79.29N = 40; F=89.6N =
44; F=95.4N
From this trial and error section it can be seen that a maximum angle of 44 degrees can be
achieved, but if this angle is exceed than there is the possibility that the Quad-rotor will stall
therefore it is advisable to use an angle setting of less than 44 degrees, in this case 32 degrees is
used.
Now that the maximum flight angle is obtained Quad-rotor maximum speed in straight flight can be
calculated using Equation 14 (Andy, 2014).
max & = 0.000954 0.44704
Equation 14 - Quad Rotor Maximum Speed
Equation 14 assumes that the Quad-rotor will be travelling parallel with the x-axis like an aircraft,
but for a Quad-rotor Equation 14 has to be modified to take into account the angle setting that the
Quad-rotor will be travelling at. Equation 15 shows this modification.
=max & * Cos( )
=( 0.000954*0.44704) * Cos( )
Equation 15 - Quad Rotor Maximum Speed at Angle Setting
Where
( ) = , 29.46/
=
() = 3.8 13
Equation 15 must be rearranged to calculate the maximum RPM required at different pitch to
achieve 20.46m/s
(
)
0.000954 0.44704
=
Cos( )
From table 2.0 in Appendix H.4 it can be seen that as propeller pitch increases, RPM required
reduces to obtain 29.46m/s. As calculated earlier the maximum RPM that can be obtained from the
brushless motors is 14,800RPM, this shows that any propeller that has a propeller pitch setting that
is under 6 inches can be eliminated. Table 1.2.1 in Appendix H.4 can now be modified to table
1.2.2 in Appendix H.4
UAS CHALLENGE 2015
43
()
()
44
() =
Table 1.7 in appendix H.5 has been updated and documented as table 1.7.1 in appendix H.6 to
show addition information such as total cost and total weight that the battery capacity required is
known. Also as mention earlier 3s and 4s lithium-ion cells has been disregard due to high current
draw. From table 2.6 in appendix H.6 it can be seen that 5s lithium-ion power supply will be ideal
for this project were its lowest is weight and also the cost is one of the lowest.
45
table 2.7, appendix H.7. Table 2.7 can be further reduced to table 2.8 in appendix H.7 when only
5s lithium-ion power supplies are considered.
From table 2.8 it can be seen that there are three closely matched motors that can be used for this
project, power 46, Quantum MT 3510 V2 and EMax GT2826-06. Power 46 although has some of
the specs that are required it cannot be considered for this project because the maximum RPM
while using 5s lithium-ion power supply is too lower to consider. Quantum MT 3510 V2 has very
attractive specs such as lowest cost out of the three and also the lowest weight but one of the main
issues any the reason for why it cannot be considered for this project is the fact that the power
consumption value if very low. EMax GT2826-06 is a motor that has most of the specs that are
required for this project, power consumption is perfect, 5s lithium-ion cell and propeller range from
10-14 can be used without a problem, cost and weight are ideal when compared to others that
weigh 200-290g. The only issue with this motor is that the maximum RPM cannot be used when
flying and the thrust setting will be based on 83% therefore the RPM will drop from 12987RPM to
11168RPM. Which in this case a shortage of RPM will occur (12,901RPM-11,168RPM =
1,733RPM) therefore recalculating based on 11,168RPM new maximum thrust and velocity
obtained. Results are presented in table 2.9, appendix H.7by using equation 1.3 maximum thrust is
calculated as 34N per motor As the maximum thrust has changed so does the maximum angle
using equation 1.7, 43. Using equation 1.9 maximum velocity can be calculated 20.9 m/s. Power
consumption using equation 1.4 696W, with power consumption 15% extra has to be added 800W.
Using equation 1.6 current draw can be calculated 43A. Finally by using equation 1.7 flight time
can also be calculated 5.6 minutes which more than the expected 5 minutes.
46
Section by Jonathan
10.1 Introduction
This chapter would discuss the different systems on board the UAS such as navigation and
communication systems as well as schematics showing detailed information on how the system
components are integrated with each and with other systems. A detailed specification sheet is also
provided in the chapter below. A list of systems aboard the UAS is shown below:
Communication system
Details on how to configure and operate all systems on-board the UAS through the autopilot
system are shown in Appendix. J.
The function of the navigation system of the UAS is to provide the information need for the flight
controller to control the UAS to its mission destination. In this case, the mission is to deliver a
payload at a particular spot at pre-specified GPS coordinates. The GPS unit on board is used to
get the GPS lock on the co-ordinates, the on board compass gets the direction of the co-ordinates
and the gyro on board the flight controller determines motion on the relevant axis and then this
information is fed to the motors through the ESCs which regulate the voltage supply to the motors
to control the attitude of the UAS by either reducing or increasing the RPM of the motor. The GPS
coordinates are programmed into the navigation system with the use of waypoint files. The
navigation commands can be entered into the notepad and then loaded to the autopilot system as
shown in Figure 37: Waypoint Command File.
47
10.2.1
Another issue that can affect the performance of the navigation system is the
transmission rate and range of the telemetry kit as there may be a lag in the
transmission of data between the UAS and the ground control station.
Electromagnetic
interference
(EMI)
from
electrical
components
affecting
the
10.2.2
Solutions
To correct the flight condition for the HDOP accuracy of the UAS, the UAS flight control
can be switched from automatic flight control to manual flight control and the UAS can
be flown to the exact position where the payload is to be deployed.
The compass and the GPS unit that would be affected by EMI would be placed away
from components that generated magnetic fields.
48
would then be sent to the servo and the payload release mechanism would then be activated and
the payload released.
The main issue with the mission control system is the accuracy of the navigation control system
and also the autopilot where the command to deploy is stored. If any problem is encountered, the
UAS can be flown manually and the payload can also be deployed manually with the use of a radio
controller.
Selecting the right PID values for the different flight conditions.
When the simulation is run, the Matlab model is then put through a series of different
flight conditions and data is collected from these simulations.
The PID gain values are changed constantly in order get the control system to respond
the right way to disturbances in flight conditions, Table 8 shows the guiding principles for
choosing PID Values.
The simulations are monitored in forms of graphs and hence the values can be changed
when they are needed to be.
49
Set the Quad-rotor inside the test rig and make sure everything is correctly bolted and
connected for safety and all the propellers are fixed and not within the reach of the test rig
arms
Use a high airflow fan to replicate strong gusts to see how well the Quad-rotor responds
to extreme flight conditions.
Start with simply manoeuvres before moving onto more extreme manoeuvres
The autopilot control system on board the Quad-rotor is capable of learning and during
the first flight test which would also be used for auto-tuning the control board, the Quadrotor would learn the appropriate response time and record it.
This method is used to program in the PID values for flight readiness.
Controller
Rise time
Overshoot
Settling time
S-S error
Kp
Decreases
increases
No change
decreases
Ki
Decreases
Increases
Increases
Eliminates
Kd
No change
Decreases
decreases
No change
Response
Table 8 Effects on the close loop response from PID (University of Michigan, 1996)
To create the MATLAB model, the physics behind Quad-rotor behaviour is modelled such as the
torque and forces produced by the motors, the Quad-rotors inertial frame in relation to non-linear
dynamics. With the above information equations of motion can be generated by using a rotation
matrix to simulate the motion of the Quad-rotor. An appropriate controller can then be designed to
reduce any error produced by the Quad-rotor system. The model is not a 100 percent accurate
representation of the Quad-rotor due to different assumptions made in the course of modelling the
Quad-rotor. For this reason, a test rig will be used to improve the PID gain values as a simulation
on MATLAB will only take us so far without. The test rig will be used to fine-tune our close-to-final
PID values before we can actually test the Quad-rotor in actual flight.
An integral part of the flight control system is the autopilot system. The autopilot system comprises
of three layers of ware:
Firmware
Software
Hardware
To fully utilise the capability of the autopilot system, the firmware and software aspects are edited
to make the application flexible in terms of navigation and mission control. The autopilot system
used is Pixhawk which is built on the open source px4 platform. The autopilot system is capable of
carrying out functions such as autonomous flight, computer vision operations and robotic functions.
UAS CHALLENGE 2015
50
The autopilot system has enough processing power to carry out the above mentioned functions at
the same time.
The autopilot systems also has on board sensors which generate and provide information about
different systems on board the UAV and also data about flight performance, this information
(Figure 37) is transmitted to the ground station for observation and control with a telemetry kit
operating at 433Hz. To improve flight conditions of future flights, telemetry data is logged by the
autopilot system and the data gathered can be analysed to make adjustments to any system to
raise the performance of the UAS.
The communication system is used to transmit telemetry data from all components on the UAS to
the ground station for observation and control. There are three methods of connecting the UAS to
the ground control station:
Serial Connection
Telemetry Kit Connection
Radio Connection
The different connection methods have different transmission rate and therefore different functions.
The UAV and the ground control station communicate using a protocol called MAVLINK. This
communication protocol is the main protocol for the Pixhawk unit and this determines the
transmission rate for different types of transmission methods and format of data transmitted.
10.5.1
51
Serial Connection
The serial connection is used to connect the Pixhawk autopilot to a ground control station through
a Universal Serial Bus connection. The baud rate for the transmission is 115200 bits per second
and this connection is used to configure the autopilot system for the first time. The extremely fast
connection is used to load the firmware and software needed to run the autopilot system and also
to calibrate all on board sensors for the first time. Other components of the UAV can be connected
and also configured through the serial connection. The serial connection is also useful when
running diagnostics on the autopilot or any connected component as the transmission rate and
quality would prevent loss of data or useful information through data packet loss in transmission.
The transmission rate can be monitored by the link statistics as shown in Figure 39.
10.5.2
The telemetry kit is used to connect the Pixhawk autopilot to a ground control station through a
radio connection over a frequency of 433Hz. The baud rate for the transmission is 57600 bits per
second. This is the primary method of connecting to the autopilot for flight purposes and any other
secondary purpose of the UAV. The connection can also be used to configure the autopilot system
to calibrate on board sensors but due to the connection speed, it is advisable to use the serial
connection for that. For autonomous flight, the flight plan is uploaded to the autopilot through this
connection and with the use of a ground control station. During flight, any secondary mission plans
for the UAV are also sent through the telemetry kit connection; this can range from servo activation
to camera functions. The strength in telemetry connection would decrease as the UAV moves
further away from the ground control station. During flight, all the telemetry generated from all
components is sent to the ground control station through the telemetry kit. The transmission rate
can be monitored by the link statistics as shown in Figure 40.
10.5.3
52
Radio Connection
The radio controller is used to connect to the Pixhawk autopilot and the UAV through a frequency
of 2.4 GHz. The radio controller is used to fly the UAV manually without the need for a ground
control station or GPS based command input to the autopilot system. The radio controller is also
used to configure some stability and control criteria such as PID through a method known as autotune. The radio controller has a number of channels that are used to carry a number of secondary
UAV functions such as servo control, camera control etc. The radio controller also acts as a
backup flight controller when the autonomous flight system fails or acts as a safety flight measure
when the UAV flies out of range of telemetry range of the ground control station.
Servo test
Some of the tests listed above are discussed in different chapters such as the propulsion test in the
chapter dealing with propulsion and performance and the servo test in the chapter dealing with
UAS mission delivery. Every other test is explained below:
10.6.1
The tests carried out on the communication systems are of the following types:
Interference tests
Range tests
Altitude Tests
10.6.2
Interference test
To carry out the interference test, the UAS communication systems are operated near areas or
devices of high magnetic interference, near devices that give off radio waves such as Wi-Fi
devices and TV antennas. The UAS communication systems also tested indoors and outdoors but
in close proximity to a building. The result of these tests is shown below:
Test
System Component
Magnetic
Interference
Near
Buildings
Radio Waves
53
Result
Telemetry kit
Radio Controller
The UAS is designed for open field flight and as such the tests carried out above do not affect the
objectives of the UAS mission, the reason for the test is for future use of similar UAVs used for
different purposes as stated in the business case. These tests were done to show the durability of
the UAS control systems and its adaptability to different operating environments.
10.6.3
The telemetry kit to be used on the UAS is designed to be used at ranges of about 1.5 kilometres;
the farthest point on the UAS is approximately 500 metres from the ground control station. The
range of the UAS telemetry was tested in an open field as well as during the interference tests. The
largest open field used for the test was 600m at its farthest point and the UAS remained in contact
with the ground control station during the test. The antennas for the telemetry kit are Omnidirectional and thereby transmit data in all directions and also upwards.
The altitude test for the UAS was carried out by taking the UAS receiver to the fourth floor of a
multi-storey building of approximately 60 feet. The communication system worked well even with
interference with the Wi-Fi in the building. The radio controller was also tested for both range and
altitude and the tests results show that the radio controller is capable at operating distances of the
UAS mission.
10.6.4
The post assembly design checks were carried out after the UAV had been built, assembled and
the electronic components are connected and ready for testing. The post assembly design checks
include the following:
Inspect structure of UAV to make sure that there is adequate space and protection for
electronic components.
Inspect assembly to make sure components are assembled neatly and safely.
Inspect assembly to make sure electronic components are connected to their proper ports
or power sources.
54
Inspect health of all propulsion system components (motors, propellers, Escs, batteries).
Inspect wiring and make sure that wiring on the assembly match the wiring diagrams.
Inspect Assembly to make sure that the design specifications were met by comparing the
UAV to the design specification sheet.
Inspect assembly to make sure that all safety precautions were taken into consideration
during the assembly and manufacture of the UAV
10.6.5
The electronic components were configured when they were bought in order to carry out various
tests but after assembly the memories of the autopilot system and all other components are
deleted. The main reason for reconfiguring the control system equipment is that sensor error as a
result of being calibrated before the component is assembled on the frame. When the assembly is
done and all the components and their sensors recalibrated, such error is reduced. The UAS
recalibration was done with the use of the 3 axis test rig and the following sensors were calibrated.
Accelerometer
Compass
Radio Controller
Joystick
Gyroscope
Fail-safe systems
Arming Checks
After all the calibration was done and all other system integration checks carried out, the UAV was
then set-up to tune its PID values for flight.
55
Section by Malwenna
Quad-rotors can be regarded naturally stable compared to fixed wing aircraft by the nature of their
design. That is mainly due to the thrust being generated by all four corners where the resultant will
act on the meeting point of three main axes. However, natural stability is only achieved if the CG of
the quad is designed to be on above mentioned intersecting point, so that the vertical forces on the
quad will originate from the same point with no moments about the CG when it's stable. Even if the
CG is not at the intersecting point, quad can be stabilized by simply changing the RPM of the
motors so the moments will be balanced. Therefore, the first step of making a Quad-rotor stable is
the placement of CG. Stability about yaw is achieved by having counter rotating propellers to zero
the resultant torque created by rotating propellers.
Controllability on the other hand did require more attention. There are four rotating parts indicating
more control is needed. Only control input will be the thrust change by changing the RPM of the
motors. But the problem lies within the accuracy of the input due to various factors such as human
error, mechanical error and disturbances by outside forces. This is where the control board
(Pixhawk) takes over to minimize the errors and aid the copters controllability in achieving the
desired output. This is done by a system of three independent Proportional Integral Derivatives
also referred to as PID controllers. As shown in Figure 41, it is a closed loop system where the
error is corrected by subtracting the output from input to identify the error and running the error
through three PID gains. This is a very quick process which will be repeated until the error is
corrected.
56
I (Integral gain coefficient) controls the precision of the angular input, especially when
outside disturbances are present such as gust. This controller will identify the disturbance
and minimize the effect caused by it.
D (Derivative Gain coefficient) By having an input on the quad, there can be accelerations
towards the desired output and this gain will dampen if they are unwanted or amplified if
they helps in achieving the output. Therefore, it helps in predicting errors and mitigates
them (Hove, 2013).
Although PID controllers seem simple, the mathematics behind these is complex to grasp. PID
gains will depend on the weight, size and purpose of the Quad-rotor. Therefore, the main
responsibility of Stability and Control role is to obtain correct PID values for particular quad using
mathematical models, MATLAB simulation or PID tuning. Later is regarded as the most reliable
method.
As stability was a joint role between Mohammed and Malwenna, the work was split between these
two and so was the report. Please refer to 14 Stability and Control II for CG placement and
MATLAB model.
11.1.1
Loiter mode
The main purpose of tuning for loiter mode is for Pixhawk to automatically keep the current
heading and altitude, especially at payload deployment until character recognition identifies the
target. During loiter tuning, the pilot would fly the quad manually as in stabilize mode, but releasing
the stick would keep the Quad-rotor in the same position. However, in order to achieve good loiter
characteristics, there are three main requirements to be fulfilled
GPS positioning GPS is normally positioned elevated from the Pixhawk and other electrical
components. This is to lower the magnetic interference caused by
other components so that GPS positioning hold will be accurate.
Ideal position for the GPS will be decided when the GPS protective
case and the mast have arrived.
decided for the quad was 3DR uBlox GPS which also includes the
LEA-6H compass. Since it will be mounted high, magnetic
interference will be minimized. However, given the availability,
timeliness and budget restraints, GPS Crius CN-06 v2 was
purchased which does not have a compass and Pixhawk inbuilt
compass
Figure 42 Loiter PID
values
UAS CHALLENGE 2015
will
interferences.
be
used
instead
which
will
have
magnetic
57
Vibration Analysis has been done by the structural team to minimize the vibrations and
therefore, lower vibrations will help in loiter.
The Loiter PID P value at the top of the Figure 42 refers to the conversion of difference between
desired and actual position as a speed towards the targeted position. Rate Loiter PID values will
then convert the desired speed to desired acceleration towards the targeted position and desired
acceleration would result in quad obtaining a lean angle to correct the position. These values do
not require changing as advised in the Ardupilot tuning guide (Copter.ardupilot.com, 2015), but will
be changed just to observe in later testing.
Loiter speed refers to the maximum horizontal speed achieved by the quad in loiter mode and is in
the units of cm/s. Therefore 500 refers to 5m/s. Max acceleration at loiter mode is limited to half the
loiter speed by Mission Planner.
11.1.2
Engaging in this mode will enable Pixhawk to take control of the throttle and automatically maintain
the altitude present at engaging moment. The pilot will still be keying pitch, roll and yaw to stabilize
the quad. This mode will be useful when hovering to deploy the payload. Correct AltHols tuning
was not possible to obtain so far in the current test rig since the altitude is fixed. Pixhawk uses the
inbuilt barometer to measure the pressure difference in order to correct the altitude. Therefore, its
important to take the Quad out from the test rig and test AltHold in a secured and open area,
according to rules of regulatory bodies and also not on whether sensitive days which can cause
pressure readings to fluctuate. Therefore, this will be conducted in later test stages when Stabalize
mode is properly tuned. When AltHold is engaged, the throttle would be automatically set between
40% -60%. The pilot can take control of the throttle anytime and throttle input over 60% will cause
to ascend and below 40% will cause to descend. However, if the landing is performed in AltHold
mode, it would take a few more seconds than normally to disarm the motors after a touchdown.
Maximum climb and descent rates are set to a lower value of 2.5 m/s during testing since it
requires practice and experience to control the quad manually without causing any damage.
58
into system to further reduce the altitude error. It is notable that in this setting, D value is kept at
zero. D gain dampens the unwanted acceleration toward desired variable and in this particular
case, acceleration is required. Therefore, it will be kept at zero. Further P to I will have a 1:2 ratio
(3DRobotics, Altitude Hold Mode, 2015), which will be maintained during testing. Built quad is more
powerful than a normal therefore, reducing PI values by 50% will be a good starting point to initiate
testing. Hence, better performance is expected at P = 0.5000 and I = 1.0000. See sections 15.2.1
Pitch and Roll tuning, 15.2.2 Yaw tuning and 15.2.3 Waypoint navigation tuning for other flight
modes.
Safety Case
59
12 Safety Case
Section by Malwenna
12.1 Overview
The UAS can possibly cause property and individual damage to its Pilots, spectators and parts of
the overall population and surroundings. The harm may be brought on by the UAS's contact with
the ground or due to equipment falling out. Therefore, UAS is only allowed to fly in UK airspace if
they are considered safe in operation. UAS in this particular competition being less than 7Kg
MTOM, they will fall under SUA (Small Unmanned Aircraft) category and should comply with UK
Air Navigation Order 2009 articles 138, 166, 167 and CAA CAP 722, and CAP 393. (UK CAA
Safety and Airspace Regulation Group, 2014) (Civil Aviation Authority, 2012)
The main requirements extracted from those articles are as bellow;
The UAS should not operate above 400 feet (122 m)
The UAS should always be in Visual Line of Sight (VLOS) since collision avoidance is
primarily based on this
Maintain a "pilot in control", which is to take control and fly the UAS in case of failure of
autonomy
Operate 150m away from congested areas
Should not operate within 50m of person, vehicle or structure except 30m at takeoff and
landing
Apart from this, it is made sure that team is referring to the University UAS Challenge 2015
competition rule book while designing, manufacturing, testing and demonstration of UAS.
12.2.1
Ensuring no personnel are near propellers when they are powered, especially when
performing PID tests.
Terminating the flight before batterys safety capacity is reached.
After landing, ensure battery power to the components has been stopped either by
removing cables or using a switch before handling the UAV.
Prior testing, ensuring the home location shown in the mission planner software is correct.
UAS CHALLENGE 2015
Safety Case
60
Using a staggered flight test approach, increasing speed and height with each test.
Use of checklists for mechanical and electrical components, systems and assembly before
every flight test to ensure they are connected correctly and working.
their
charging
and
temperature
regularly
can
avoid
such
failure
down
percentage.
certain
But
the
be
connected to
power
module.
used to power the motors and ESCs which are not connected to Pixhawk since Pixhawk can only
support up to 4s batteries. Therefore, this fail safe is used only for the system battery which is a
2200MAH 4s Lipo.
Fail safe will trigger at two occasions
1)
If the 4s battery voltages goosed below 12volts Minimum safe voltage for a 4s battery to
operate is assumed to be 3 volts per cell.
2) If the 4s battery remaining capacity goes below 440MAH This is 20% of the capacity of
the battery which is 2200MAH and 440MAH is being set as the configurable Reserved MAH
(reserved for land or RTL)
Safety Case
61
anytime,
however,
there
separate
low
is
battery
appear
ground
Figure 46 Battery monitor settings chosen in Mission Planner
control
on
the
station
goes below 23%. Having 23% will give sufficient time for ground control to prepare for the fail safe
method selected since failsafe will initiate at 20%
Environmental Impact
62
13 Environmental Impact
Section by Malwenna
In order to UAS design to be a success, it is important to assess the environmental impact it has
from the initial concept of the design. One of the aims in the design process was to have minimum
impact on the environment without compromising the performance. This report covers the main
Environmental factors affected by the use of UAS and proposes action taken and will be taken to
lessen them.
Emissions
Air pollution due to UAV usage is primarily from gas emissions during flight. Therefore, Reduction
in emissions was considered in the initial planning of the power plant. The end result was to
discard the use of any fuel and use battery powered motors which will not only minimize air
pollution, but eliminate it. Therefore, this Quad-rotor design will have zero air pollution due to
emissions.
13.2.2
Noise
There are two types of noise originating from a UAS. Aerodynamic noise is the noise due to
vortices at the blade tips. Higher blade loading and speed will result in a higher noise. But the most
significant noise is the noise from the power plant. Specially noise from a fuel engine airplane
where noise arouses due to combustion and exhaust compared with a similar set up electrical
engine, is higher. However, in this case we are using four motors powered by 5s batteries and
provides a lift to carry 2kg payload. Therefore, power requirement and work done is higher, so is
the noise than in a normal Quad-rotor. However the noise is being minimized by proper weight
distribution and propeller balancing to reduce the vibrations causing the noise. In this particular
competition, high noise can be advantageous as well since UAS has to remain at VLOS always
and noise will aid in locating the vehicle. However UAV would be under the permitted noise level of
Elvington Airfield area and would not significantly affect the air quality.
UAS CHALLENGE 2015
Environmental Impact
63
13.3
Infrastructure
Quad-rotor is a small UAS system and therefore, does not require major infrastructure changes.
But upon impact, it can cause serious damage to infrastructures. Also, uncontrolled radio
frequencies can cause interferences for civil operations. To prevent such incidents, the quad will
be operated 50m away from structure, personnel and 150m away from congested areas as
required by the CAA regulations.
Environmental Impact
64
Once discharging is completed, they should be secured in a stout cardboard box or similar
and clearly labelled with "SPENT LITHIUM BATTERIES FOR RECYCLING" (Smith, n.d.).
Also batteries can be returned to the battery retailers whom are obligated to accept spent batteries
under the National Battery Back Scheme.
Environmental
No Impact
No Significant Impact
Factor
Impact
Hazardous Materials
Emissions
X
X
Noise
Infrastructure
Waste
X
X
X
Table 10 Impact of Quad-rotor on environment
Significant
65
Section by Reyad
Due to the complexity of the Quad-rotor stability, joint roles were required in order to carry out the
complex tasks. The stability testing sections are split, along with the reporting.
Refer to Section 11 Stability and Control and 11.1 PID Tuning for more information on the
introduction of Quad-rotor stability.
66
The z-axis is far less black and white, compared to the x and y-axis. The lower the CG on the zaxis the more stable the Quad-rotor becomes, on the other hand, the more stable the Quad-rotor
becomes, the more thrust will be required to manoeuvre the Quad-rotor. Assuming that the top
plate is the datum (see Figure 47), the CG is at 0.9 cm with one payload and two batteries and -1.7
cm after payload has been deployed. As these points are below the propeller, they should allow for
some level of stability with very little compromise to the manoeuvrability.
Section by Reyad
To get started on MATLAB, an m-file of all size and weight of the main components will be required
as well as the thrust and torque coefficients of the motor. These will be used to create a transfer
UAS CHALLENGE 2015
67
function for the PID values (full model in Appendix. J). Another m-file will be required for the initial
starting conditions.
Once the Quad-rotor parameter and initial conditions file have been created, the files will be loaded
onto the altitude control file on Simulink. At first the PID values will all be set to zero before being
adjusted one at a time, first for the throttle command and then followed by the Roll and Pitch on the
Position Control Simulink file. The test was done in the same fashion as one would do for the
physical test, by pushing the P value (in throttle command) until the throttle response is deemed
acceptable. Without an I or D value this would cause the Quad-rotor to oscillate with little to no
damping, as seen in Figure 49. To introduce damping, the D gain must be increased, and as
Figure 49 once again indicates, after multiple iterations, the D gain allows the Quad-rotor to
stabilise at 100ft, the minimum height for the UAS Challenge, at a reasonable amount of time.
Figure 49 Quad-rotor oscillating with only the P gain (left), with P and D gain (right)
Pitch and Roll should be theoretically be the same as a Quad-rotor in a + or x shape, so should
ideally be symmetrical and therefore the PID values for one mode should be very same for the
other. However, at the time of Simulink testing the Quad-rotor had not been manufactured for
validation but for the test it was assumed that the CG was at the centre for the x, y and z-axis and
all moments were the same for all the arms. For the roll and pitch the P value were increased until
there were oscillations before the D and I values were increased one at a time for the Quad-rotor to
fly with a good response. Full test data can be found in full model in full model in Appendix. J and
also for Throttle/altitude and for pitch and roll .
When it was time to do the yaw tuning, it appeared that regardless of what value the PID were,
even 0, the Quad-rotor would still yaw on the Simulink model and therefore no further attempt was
made on yaw. Fortunately, yaw is less of a concern on a Quad-rotor as it can be manually
controlled without any issues to the Quad-rotors flight path.
After extensive testing on Simulink, the final values for Throttle, Pitch and Roll are shown on the
figure below, Figure 50.
68
69
Stabilise mode, one of the initial recommended modes for tuning the Quad-rotor, as it handles
some level of control over the Quad-rotor over the pilot such as maximum roll and pitch. In acro
mode, the pilot has full control and could therefore push the Quad-rotor to overturn itself and if the
pilot was tuning the Quad-rotor without a test rig then the pilot could cause some serious damages
to the Quad-rotor and if the propellers snap off, damage to anyone nearby like the pilot. In stabilise
modem, the Quad-rotor will automatically try to stabilise itself once the pilot releases the stick,
making it the ideal starting point for tuning. As progress was made, more and more control would
be taken back from Pixhawk before testing it under acro mode.
As its a Quad-rotor, the pitch and roll values can remain the same since it can also be flown
sideways in the same way for forward flight. However, this will be tested later on if they require a
different set of PID values. As Pixhawk does not allow for a P value below 0.08, that will be what
the test will start with. I and D will be set to zero to minimise their effect and will be incorporated
once the P value is satisfactory.
70
For a more detailed version of the test plan, please see full model in Appendix. J.
The test rig was finally completed approximately one week before the submission date which gave
the group two days to do some quick testing. During these two testing days the Quad-rotor
managed to pitch and return to level within a very good time frame, approximately 2.3 seconds,
however, due to the placement of the batteries, the roll took much longer than expected to stabilise
(just over 6 seconds). This is due to the Quad-rotor not being fully assembled as it was designed to
be but put together for testing purposes and the batteries were not closely placed at the centre to
minimise the moments and the placement of the CG. After some realignment, the pitch, roll and
yaw results were much improved and better than expected in some cases. However, Pixhawk has
its own method of providing data on how the Quad-rotor should stabilise, see Figure 53, and
unfortunately there wasnt enough time to improve the result nor could the data be extracted (at the
time) for further analysis.
71
15.2.2
Yaw tuning
The Yaw tuning will involve a similar procedure to the pitch and roll tuning, although unlike the
pitch and roll values, it wont require fine-tuning as yaw has less of an impact on stability. Having
said that, there are still good reasons for improving the yaw PID values to improve the response
(start and stop), reduce the overshoot and add a damping to the yaw acceleration.
Please see section 11.1.1 Loiter mode and 11.1.2 Altitude Hold Mode (AltHold) for other flight
modes.
15.2.3
In auto mode, the Quad-rotor will follow a pre-set path, from Mission Planner, and is capable of
doing certain tasks, such as deploy payload, taking video of flight path and pictures of current
locations. Tuning auto mode includes altitude and position from AltHold and loiter modes and as a
result should only be tuned after those two have been tuned. In the configuration menu the
maximum horizontal and vertical up/down speed can be changed in 10mm/s, so 25m/s will be
written as 2500. There is an issue where Pixhawk cannot maintain control of both altitude and
horizontal speed simultaneously whilst going over certain speeds, which can vary from Quad-rotor
to Quad-rotor. For this to be checked, the groups Quad-rotor must be flown in auto mode to see
how much of a compromise this may be before steps are taken to overcome this issue.
Auto mode can be setup so that the Quad-rotor starts the mission from the ground or whilst flying.
If the Quad-rotor is set on the ground, then the throttle must be set to zero as the moment the
throttle is increased, the Quad-rotor will be set to auto mode and make its way to the first waypoint.
If the Quad-rotor is starting whilst in the air, it will start moving towards its first waypoint once the
controller has been set to auto. If, after it has been to auto, the first command is take-off, it will
recognise that command as completed and move to the next one. While the Quad-rotor is set to
auto mode, Pixhawk will overlook all inputs from the pilot as long as not disable auto mode and
yaw. As some pilots may decide to take pictures of the location, the pilot still has some control over
the yaw control, although Pixhawk will try to regain control once it has reached its next waypoint.
Waypoints can be set up as fast waypoints (Ardupilot, 2015), which operate in the same way as
regular waypoints but without any delay or loitering at that waypoint. For both cases, a radius must
be inputted into Pixhawk, so that Pixhawk can recognise that way point as complete once it is
within a certain range.
72
73
Section by Reyad
The core functionality of the Pixhawk software Mission Planner is to return to launch (RTL) if it
loses contact with the ground station or manual control. If more advanced options are required
then Pixhawk has an on-board Advanced Failsafe (AFS) system. The pilot can setup for failsafe
conditions so that the multi-copter can loiter for a short period of time before RTL, automatic
landing or termination (Plane.Ardupilot, 2014). If termination is chosen, then this will apply to all
modes of flight termination cases, whether that is GPS loss, communication loss, Geofence breach
or altitude breach. Once the aircraft has entered termination mode, it is no longer recoverable so
for this purpose the Quad-rotor will not be set on termination but land as a last resort.
74
Systems Layout
75
17 Systems Layout
Section by Tarek
17.1.1
Hardware Systems
The following block diagram is off the hardware of the Quad-rotor, the diagram has two sections
which operate in their own unique way. The first section is the ground control station which has
two subsystems, the controller and the ground control station computer with the communication
system. The base station computer is what stores the Mission planner, this software allows for the
control of the flight path and the operation of the Quad-rotor. The communication system linked to
the computer communicates with the Quad-rotor which allows for transmitting and receiving data.
The radio control allow for manual control of the Quad-rotor by the pilot.
The second section is of the Quad-rotor consists of motors, flight controller, power distribution,
camera, GPS Module, and video graphics processing unit (VGPU) or the minimOSD along with
pixhawk. The motors flight controller and power distribution resample the systems that of
propulsion systems. The GPS module is for pinpointing the location of the Quad-rotor and flight to
the desired location. Finally the camera and the minimOSD with pixhawk are part of the
transmission of the video and data feed to the ground control station.
Systems Layout
76
Signal name
Description
User input
The user input is to turn the Quad-rotor on/off, toggle on/off video stream, activate/
deactivate the autopilot and arm/disarm the Quad-rotor. This is achieved through
ground control station Mission Planner and using the radio controller allows for
manual flight of the Quad-rotor.
Power
The power supply of the Ground Control Station is from the laptop, where it must
have the battery fully charged before the mission. At the ground station a portable
power supply will be available for the computer to be connected to for recharging.
GPS Satellite
Signal
The GPS system on the Quad-rotor receives a GPS signal from global orbiting
satellites and on the ground station it is connected to WIFI where it updates its
mapping and positioning.
RC Control
Signal
The manual control is through the transmitter and receiver of the radio controller.
Telemetry
Data
The communication between the Quad-rotor and Ground Control Station is through
the 3DR telemetry kit operating at 433MHz.
Video Data
The video data is sent through the video transmitter and receiver kit which is
connected to the minimOSD which includes extra video data such as altitude,
attitude and direction.
Motor Thrust
The motors function is provide thrust in order to lift the Quad-rotor and travel
around the course.
Sensor Data
The flight sensors record various data such as accelerometer, magnetometer and
gyroscope which there information is sent to pixhawk which are then processed to
meet the flight conditions.
17.1.2
Software Systems
The following diagram and table are of the software block diagram of the Quad-rotor systems. This
section also has two subsystems, as there is software running on the ground control station and on
the Quad-rotor. The ground control has two main subsystems and some have further subsystems.
The first subsystem is the Radio Controller (RC) transmitter, which transmits manual pilot control
commands to the receiver on the Quad-rotor to control the flight conditions on the Quad-rotor. The
second subsystem contains the ground control station computer, running operating windows 7
using the Mission Planner for the mission planning. The Mission planner receives video and data
information from the Quad-rotor, the Mission planner then displays that information and stream for
the user. On the Quad-rotor there are three main subsystems. The first is the RC receiver which
receives signal from the radio controller on ground which operates on a tuned frequency for the
receiver and transmitter to operate coherently. The second subsystem is Pixhawk, it receives
signal from RC receiver with command to control the Quad-rotor. The second is the video graphics
processing unit (VGPU), the minimOSD receives data from Pixhawk such as the altitude, attitude,
and heading etc which are processed with the video feed and transmitted to the ground control
UAS CHALLENGE 2015
Systems Layout
77
station. Pixhawk is the main computer or brain on board the Quad-rotor, Pixhawk receives data
through the telemetry kit which contains flight commands such as GPS coordinates or signal when
to release the payload. The table below contains more descriptions on individual systems.
Description
Video
Commands
Video command will be sent through the video link which makes the camera take a
photo of the target for it to then be processed. This will read the alphanumeric
information at the target and display it at the ground control station.
Video Data
The video data is transmitted from the camera on bored the Quad-rotor, with
information from the minimOSD. The video will be displayed on the ground station
Mission planner. The video is transmitted through video transmitter which will be
operating in the same frequency as the video receiver on the ground station.
Telemetry
Command
The telemetry command is sent from the Ground Control Station Mission planner
through the telemetry transmitter to the receiver which then sends the information
to pixhawk to be processed.
Telemetry
Data
The telemetry data sends data from the Quad-rotor with pixhawk data to ground
station. The data from pixhawk includes information such altitude, attitude, location
and speed which are displayed on the Mission planner page.
User Data
The user data is the collection of the flight information which is displayed on the
Mission planner with information regarding current flight conditions.
RC
Commands
Systems Layout
78
17.2 Communication
The range and performance of the radio frequency (RF) link are critically dependent on the
antenna used. The radiation pattern of a quarter wave monopole antenna is heavily dependent on
the design and layout. Therefore selecting the correct antenna and placing in the most efficient
location on the Quad-rotor is crucial. The mounting of the telemetry and the video transmitter, must
take into account of the possibilities of shadowing, as this can be a factor when mounted in an
obstructed area for example between the two structural plates of the Quad-rotor. The effects of
shadowing will hinder the range and coverage of the transmission range. For this reason the most
common set up on a UAV or aircraft is the vertical polarization. As the advantage of a vertical
polarization, waves propagate much more effectively in this orientation near the earth, whereas
horizontal polarized the waves will be cancelled out by the reflection from the earth.
Electromagnetic Interference (EMI) is common issue that occurs with electronic devices as they
might interfere or interrupt the performance of a device, due to radiation and the source could be
from nature or manmade devices. If the EMI intervenes with the aircraft systems it could turn out to
be a very serious issue during flight, especially if a system such as navigation are disrupted this
would lead to a loss of signal and would lead to missing the flight path hence increasing flight time.
Therefore, on the Quad-rotor the mounting of the GPS will be placed on most elevated location on
the Quad-rotor, and the telemetry and video transmitter will be placed some distance away from
each other to avoid interference (Wyatt & Tooley, 2008).
When testing the GPS and telemetry kit loss of performance was identified, and the reason for this
was that the operating frequency of the laptop is up to 400MHz and the telemetry operates at
frequency of 433MHz. During testing the laptop was used as the power source for the GPS and
telemetry kit. This could also be due to path loss as the test was carried out on a long narrow field
with trees obstructing the line of sight signal. Nonetheless a range of more than 400metters was
achieved as this was down to the maximum length of the field. To protect signal strength aluminum
shielded wires are used to protect against EMF to help reduce cable loss. Cable loss is the amount
of signal lost due to the cable, another measure taken to reduce this effect it to have long enough
cables to reach each connection point because the longer the cable the higher signal loss (Bailey,
2003).
Image Processing
79
18 Image Processing
Section by Tarek
The Requirements
Image recognition code will be used to read the letter at the target and displayed letter on the
ground station screen. Earlier competition requirements stated that there would be a mixture of
alphanumeric characters at the target which should be recognized and displayed at the ground
station (Barragan, 2014). However the march 2015 rules state that there will only be one letter at
the target in a target area of 2m by 2m.
18.1.2
Testing
For testing purpose the target has been scaled down to resemble real life operation. The
parameter of the square target is 2m by 2m and the Quad-rotor cruise altitude is at 100ft. To verify
the code ability to recognize the target letter, tests were carried out at different altitudes to compare
the results. The reason for testing at different altitudes is because for payload deployment the
Quad-rotor would need to descend to an altitude to safely deploy the payload at the target. The
altitudes that have been selected for testing are at 100ft, 50ft and 20ft. The target will be elevated
at 1.5 m above the ground.
Scaling
As the delivery box is elevated above ground at 1.5m = 150cm, taking scale at 1/20 therefore
testing is as follows:
For 100ft:
100ft = 3048cm 3048 150 = 2898 cm
2898
= 144.9
20
For 50ft:
50ft = 1524cm 1524 150 = 1374 cm
1374
= 68.7
20
For 20ft:
20ft = 609.6cm 609.6 150 = 459.6 cm
459.6
= 22.98
20
As the altitude was scaled down the target character should also be scaled down. The target is 2m
by 2m.
200
2 = 200
= 10
20
Therefore the target will be 10cm by 10cm with the letter in the middle of the square target.
Image Processing
80
18.1.3
Results
To represent the altitude of 100ft, 50ft and 20ft, the test will be carried out at 144.9cm, 68.7cm and 22.98cm.
For testing only two letters where tested, H and Z.
Altitude (cm)
144.9
144.9
68.7
68.7
22.98
22.98
Alphanumeric Letter
H
Result
1317 characters where
displayed
Z
1400 characters where
displayed
H
2489 characters where
displayed
Z
1568 characters where
displayed
H
H
Z
Z
Table 13 - Alphanumeric processing at different height
18.1.4
Analysis
From the result obtained in Table 13, it shows that when taking a picture above 50ft the results are
not consistent and hence the Quad-rotor is required to descend to an altitude of lower then 20ft to
achieve a more accurate result. Descending to altitude lower than 20ft is beneficiary for the
payload deployment because it allows for greater possibility of a safer deployment.
18.1.5
Shape recognation
The shape recognation code was planned to be used to identify the target during flight, when the
Quad-rotor reaches the coordinate set at the ground station using the Mission planner the program
would be able to identify the target and center itself ontop of it. The code measures the properties
of image regions and will scalar the actual number of pixels in the region of the image, which then
can be identified as a shape, in the figure bellow it demontraights its operation. The setback of
running the code during the mission is its time to process the image, in this case it took more then
30mins as the code removes any connected components pixels that have fewer then 60 pixels.
UAS CHALLENGE 2015
Image Processing
81
Normally it is running at a minimum of 20-30 pixels which takes 2-5 minutes, however as the test
will be in an open field the grass causes a lot of interferance during processing hence a higher
pixel setting is required (Samieh, 2007).
The figure below is taken from a height of 22.95cm to resemble 20ft and the size of the box is
10cm by 10 cm to resemble the target of 2m by 2m:
18.2 Video
The camera model selected for the live feed video to the ground station is through Mobius
ActionCam. The Mobius camera is commonly used on such UAVs, the camera provides a high
quality video feed and the quality can be altered from three possible choices. This can be useful if
needed to transmit over a long range but operating at its highest resolution of 1080p-30fps will be
needed as the ground station is within a reasonable distance and it would need to process the feed
to determine the alphanumeric at the target. The camera is needed to provide a still image of the
target from the Quad-rotor and transmitted to ground station (Mobius, 2015).
The camera has the ability to record while streaming, this would allow for playback of the flight at
another time. However this feature is not crucial but it may be used to analyze the flight condition
of the Quad-rotor. The camera has five video recording cycles time settings they are 3, 5, 10,
15mins or Max. The max will record until the 4GB memory has reached its limit and if recording at
1080p-30fps that would equate to 30mins of footage this can be increased by the use of an
additional memory card.
Initially Boscam TR1 was going to be used as the FPV camera but this was dismissed as the
camera is not compatible with the minimOSD. The camera would require an additional transmitter
for it to transmit video data from the minimOSD. Mobius ActionCam was then selected for its video
quality its size and weight.
Image Processing
82
83
Section by Tarek
The validation and verification stage is from the V model, which is used in all forms of engineering
projects. The V model operates from a hierarchical perspective starting from requirements,
standards to testing. The benefit of the V model allows for easy tracking of the phase where the
product is currently held, for example when the product reaches the verification stage it measures
how the system was built to the system requirements (Monhem, 2010). The flow direction of the V
model is all interchangeable as after one stage is complete one can check if the outcome suite the
previous stage requirements as its a good method of defect tracking. Also its a cost effective
method of making sure the right product is built as once the product reaches the validation or
operation stage and spot that it does not match the requirements or regulations this will hinder the
progress of the project.
Future work
84
20 Future work
Section by Tarek
The following concepts where considered but where not investigated or developed further because
of complexity, time and mainly due to the limitation of remaining funding. The main reason for not
proceeding with these concepts is due to cost, as the spending on the Quad-rotor is very close to
the maximum value of COTS which is set at 1,000. If the component list goes above the
maximum COTS the Quad-rotor will not be allowed to enter the competition, hence these where
not established or expanded on further due to the cost issue.
85
21.1.3
86
their
21.1.4
Others
This design came as the quad was still meant to carry 2 payloads and a set of linear servos.
However, the linear servos was found to be too big, heavy and very expensive. Moreover due to to
weigh restricted it was decided to use only 1 payload at the time.
87
21.1.5
Section by Micky
Conceptual design by Zuber Khan
Actual design by Amit Ramji
A representation of the payload box final designs is as show in Appendix B.7. Once the servo is
powered, it actuates the horn that rotates of an angle of 90 degrees. Subsequently, the movement
release the movable door which lets the bag of flour fall. The detailed design can be found in
section 4.2 and structural analysis in Appendix G.15 to G.16.
Figure 65 to Figure 69 is an illustrative reproduction of the final design carried out in section 4.2,
these aim to show the servo integration.
88
89
21.2 Servo
It was decided to choose the MG90S servo, Metal gear with one bearing for relevant reason
towards the UAV specifications. Tiny and lightweight with high output power, this tiny servo is
perfect for RC airplane, helicopter, Quad-rotor or robot. This servo has metal gears for added
strength and durability. The servo can rotate approximately 180 degree (90 in each direction), and
works just like the standard kinds but smaller. This servo is controllable with any code, hardware or
library to control; these servos. This servo is appropriate to make part moves without building a
motor controller with feedback and gear box, especially since it will fit in small places
21.2.1
Specifications
Weight: 13.4 g
Dimension: 22.5 x 12 x 35.5 mm approx.
Stall torque: 1.8 kgf.cm (4.8V), 2.2 kgf.cm (6V)
Operating voltage: 4.8 V 6.0 V
21.2.2
Rational
This digital servo uses switched mode power which is considerably more efficient than the
analogue power alternative. A small microprocessor inside the servo analyses the receiver signals
and processes these into very high frequency voltage pulses to the servo motor. Instead of 50
pulses per second, the motor will now receive upwards of 300 pulses per second. The pulses will
be shorter in length of course, but with so many voltage pulses occurring, the motor will speed up
much quicker and provide constant torque.
The result is a servo that has a much smaller dead band, faster response, quicker and smoother
acceleration, and better holding power. In order for the servo to operate smoothly, the force it
generates should have be greater that the friction force Ffrict-sliding as its horn slide along the
UAS CHALLENGE 2015
90
payload box door. Thus it should be greater that Ffs = 0.013 Kgf. The calculation can be found in
Appendix M.1
21.3 BEC
They require +5V to power the opto-isolator and while the Pixhawk can be powered from the servo
rail, it does not provide +5V to the servo rail. The ESCs must be powered by a BEC or with a
jumper from an unused connector on the board. In this case, it was decided to use an SBEC to
power the electronic rather than a jumper.
Turnigy 5A SBEC is an advanced switching DC-DC regulator which will supply a constant 5A. It
works with 2 - 7 Cell Lipoly pack and supplies a constant 5 or 6v to your receiver and is
interference-free, perfect for confined spaces
21.3.1
Specification
Type: Switching
Input protection: Reverse polarity protection
Output (Constant): 5v/5A or 6v/5A
Input: 8v-26v (2-7cell lipo)
Weight: 18g
Figure 71 - SBEC26 Turnigy
21.3.2
Rational
There are 3 main types of power regulator or battery elimition circuit which are BEC, UBEC and
sBEC.
The BEC and the UBEC are good power regulator for small specifications such as those involving
curreent bellow 10A and voltage difference across the BEC less than 5V otherwise there is a risk
of short circuit or melting circuit thus damaging the flight control.
In this case the Swicthing sBEC26 has been chosen because it design make it prone for hight
voltage discharge with considerably less heat emanation thus less waste of power. Moreover, it
can a providd more power throught the intensity of curent it supports. The crucial importance of a
voltage regulator for the system is that the high voltage supplied by the batteries (26 - 18V) would
damage the flight control components which opperates below 6V.
91
The Quad-rotor will run with 2 batteries. The battery pack 1 (18.5V, 16Ah, 3s LiPo) will only run the
motors whereas the RC receiver and the payload servo will be run by the battery pack 2 (11.1V,
2.2Ah, 2s cell LiPo). The reason for this arrangement is that once the motors are switched off, the
flight control system Pixhawk is still reading its mission.
UAS CHALLENGE 2015
92
The battery pack 2 will power the servo and other receiver through the SBEC which will drop its
voltage to 5V-6V. The SBEC is connected on the AUX OUT pin 6 and the servo will be connected
on the AUX OUT pins from 1~4 since the platform is Arducopter. The RC receiver is connected at
the RC pin.
On the Config/Tuning > Full Parameter List page, ensure that the RCXX_FUNCTION is set
to zero for the servo thats to say RC9_FUNCTION as the servo is connected to the
Pixhawks AUX OUT 1).
09
Following Create the mission to be fly and add a DO_SET_SERVO command and include the
servo number ( 10) in the Ser No field and with the PWM value (usually between 1000 ~
2000) in the PWM field.
93
The DO_SET_SERVO command is a do command which means that it can only be run between
waypoints so it must not be the first or last command in the mission. It will be executed
immediately after the waypoint that precedes it. After the first payload is dropped, the Quad-rotor
will return to the ground station location to be fitted with the 2nd payload and perhaps a new battery.
Other Involvements
94
22 Other Involvements
Section by Micky
22.3 Challenges
It was particularly challenging to find information related to the system integration for many
reasons. First of all, the use of Pixhawk has made it particularly difficult to find and integrate other
system component because it is relatively new. The majority of information available online are
related to APM (ardupilot Mega) which is the earlier version.
Manufacturing
95
23 Manufacturing
of the project. The manufacturing plan included materials to be used, joining methods, machines to
be used and the best possible way to carry out the tasks on time. Initially composite laminates and
tubes were intended to be used however the complexity in manufacturing and cost restrictions did
not allow this.
Section by Mozammel
Acknowledging the weight and budget limit for the project, the manufacturing process includes
milling, lathe, laser cutting and CNC machining which are available within the lab facility of the
university.
23.1.1
Machines
The following machines are used to manufacture the parts depending on their operating functions.
Machine Type
Functions
Use end mills to obtain precise dimensions
Milling machine
(Bridgeport Series 2)
body plate
Vertical Bandsaws machine
23.1.2
Tools
Tools
Functions
2 End mills
3 Centre drill
4 Slot drills
Manufacturing
96
9 Micrometre
To measure dimensions
23.2.1
Fixed Bracket
The fixed brackets are made of nylon 6.6, which has the favourable
characteristics to hold the arms in place. Also bearing in mind, the
finishing quality is more emphasised and that is why using the milling
machine, the brackets are manufactured. Figure 76: Machined fixed
bracket shows the fixed bracket machined in milling machine.
23.2.2
23.2.3
Movable arm vertical fixed bracket
/support bracket
From nylon 6.6, the brackets are machined in milling machine as per
the technical drawings. All dimensions are carefully machined
according to the technical drawings but the edge fillets of radii of 12.5
Manufacturing
97
23.2.4
Considering the impact of the landing gear, nylon 6.6 (16mm cast sheet)
is used to manufacture the brackets which makes it more reliable to
support the landing gear. The bottom support bracket has a 2 mm
counter bored of 8 mm diameter to attach a spring which has
compression stiffness of 300 N/mm and the damping of 0 N.s/mm. The Figure 79: Machined
spring is considered to withstand the impact from the landing gear which bottom support
bracket
is bridged between landing gear bottom support bracket and the landing
gear pivot.
23.2.5
23.2.6
of nylon 6.6 and the pivotal section respectively. The groove for the spring
was modified by making a counter bored of 2 mm depth.
Refer to 308Appendix. N for the landing gear lug bracket with the landing
gear pivot.
23.2.7
Arm pivot
The arm pivot required two types of machining; centre lathe and milling. The
nylon 6.6 rod was clamped into the four-jaw chuck and the desired length
and diameter was cut by high speed steel tooling; then the rod was
bored 22mm deep and milled 5.5 mm from both sides on the other end.
The remaining flat part was then drilled to make it suitable for pivotal
function for the movable arm.
Manufacturing
98
23.2.8
Due to ease of use in Trotec Laser machine setup, laser cutting was
attempted. Even though accurate dimensions were obtained but during
machining the heat of the laser melted the edges and clear smoke was
observed.
To overcome the challenge of heat damaged edges, the main body
plates were machined in Denford Router 2600 Pro. The advantage of Figure 84: Cutting nylon plate
in Laser machine
such machining has high accuracy and the material properties are not
affected as much by any thermal energy; deburr and polishing of sharp
edges was carried out using hand file.
23.2.9
PVCs tubes
All the tubes were roughly cut down by hand and then by lathe machine precise dimensions were
achieved.
23.2.10
Section by Mozammel
Motor Mounts Manufactured and Assembled by Zuber Khan
The positions of the holes are really important as to align with the motors accordingly. The
machining of motor mounts plates were attempted on the CNC machine but since the thickness of
the aluminium plate is 1mm so clamping was not achieved properly with current tool constraints.
Therefore the holes positions were carefully marked by hand and piloted by a 1.5 mm drill and
finished off by a 3 mm drill. Figure 16 shows the brackets are screwed in with the motor mount
plates.
Manufacturing
99
23.2.11
1.
Overview of Machining
Mostly milling machine is used to obtain precise cutting (by end mills), smooth surface (by fly
cutter), and holes (by centre drill and slot drills). Centre finder complete, precision parallel sets,
micro-meter and metric slip gauges are the usual tools that are used while milling the components.
Refer to Appendix. N for figures of some machined components by milling.
2.
Arms (fixed and movable), arm pivots, landing gear pivot, landing gear strut and stabilizers are
machined in lathe machine. The arms were drilled in 20 mm by a 13mm slot drill on one side to
install the LED lights. The nylon 6.6 rod (diameter of 25mm) was machined to diameter 22 mm by
high speed steel tooling and then bored into 22 mm at the centre of the rod with a diameter of
16mm.Refer Appendix. N for figures regarding lathe machine.
3.
The laser cutter is used to machine the main body plates but it has been identified that the heat
has melted the edges of the plates so subsequently it is decided to machine on CNC machine
Refer Appendix. N for figures on laser machining set up.
4.
Vertical bandsaws machine is used to cut the purchased block or sheet (aluminium alloy) into
required dimensions for the components Refer to Appendix. N
5.
CNC machines are used for machining the main body plate and the turn button for payload box
after several practise sessions. Although simulations were carried out to obtain motor mount
plates, brackets and T-joints but unfortunately due to lack of knowledge at that point of time,
machining was countered with many known and unknown errors. Since the building of the Quadrotor solely depends on the manufacturing timeline so with the supervision of the technicians
majority of the parts are machined in the milling and lathe machines.
Manufacturing
100
23.3 Challenges
Compared to acrylic and wood foam which are mainly used in practise session, nylon and
aluminium are proven to be hard to machine. Alongside desired tools for clamping, machine
planning and drill sizes were not available during manufacturing. Hence manufacturing of the parts
were mostly dependent on milling and lathe machines and as a result constrained some desired
features of the parts. Pace of manufacturing was also affected as supervision was required while
using the milling and lathe machine in the machine lab.
Below show failed attempts on motor mount when tried on VMC 1300 and router 2600 Pro.
Conceptual Payload CAD model Using dimensions of 1 kg flour bag to propose potential
designs
Test Rig
101
24 Test Rig
This section comprises intensive testing and manufacture of a 3-axis gimbal test rig. As with any
project of this type, practical testing is vital to collaborate with the theoretical data determined for
the designed product. In general, testing during design of a new product is mandatory to reflect its
key performance factors and capabilities. It is most commonly known that manoeuvrability of a
multi-copter predominantly affects the flight performance. Therefore controlled flight during
manoeuvrability is a major factor to be achieved. In real world applications, achieving a stable
multi-copter during its flight regime is an issue of concern. Design of a test rig would aid in the
demonstration of multi-copter flight within a controlled environment and significantly add advantage
during the testing phase of this project. The test rig will be adopted to demonstrate safe control of
the UAV functions. Hence the design stage of the test rig began with rigorous brainstorming
activities bearing its effectiveness in mind.
To solely rely on systems to operate as efficiently as possible is not good practice, hence testing
the operation of individual system components and post integration would validate the testing
processes. The gimbal test rig would be a beneficial tool for the verification of sub-system tests in
controlled conditions. As part of the competition requirement, the chosen Quad-rotor design is
required to be able to carry two payloads (1kg each bags of flour) and deploy each payload
independently. This independent deployment of payloads at any given time could cause instability
post deployment and hence would affect the weight distribution on the UAS. The stability of the
multi-rotor after imbalance can be verified during testing within the gimbal design discussed later
on. It is anticipated that the test rig will aid to define PID control numbers which will hugely benefit
in the monitoring system and stability side of the project. Although the UAS design specification
does not require building a test rig, it was noted that fabricating a gimbal test rig would be
worthwhile as manoeuvrability and stability of a Quad-rotor is tremendously complex. Therefore a
safe testing method would have to be implemented to avoid damage on such a costly design. The
initial phase of testing using the gimbal test rig aided in the calibration of various sub systems such
as compass, magnetometer, Pixhawk, RC controller, GPS, etc.
Test Rig
102
Test Rig
103
instruments. (Project, 2015) The gimbal test rig would utilise gyroscopic motion and is a device that
would be used to measure, maintain orientation and most importantly stabilise the Quad-rotor
under investigation.
Moreover the gimbal test rigs operation is mainly based on the principle of preserving angular
momentum. The outer gimbal or ring (green coloured frame in Figure 91 which is the gyroscope
frame, is mounted so as to pivot about an axis in its own plane determined by the support from the
stand. This outer gimbal possesses one degree of rotational freedom and its axis possesses none.
The middle gimbal or ring (red coloured frame in Figure 91) is mounted to the outer gimbal so as to
pivot about an axis in its own plane that is always perpendicular to the pivotal axis of the gyroscope
frame (outer gimbal). This middle gimbal has two degrees of rotational freedom. The axle of the
spinning inner most gimbal (blue coloured frame in Figure 91) defines the spin axis. The motors
mounted on the Quad-rotor are coupled to spin about an axis, which is perpendicular to the axis of
the middle gimbal. Overall the entire gimbal test rig is meant to allow freedom of movement in all
yaw, roll and pitch axis. (Turner, 2015) See appendix O.2 for the general arrangement for the
updated octagonal gimbal test rig assembly with its bill of materials.
24.2.1
The figure shown above validates the required inner length of each of the boxes used to construct
the model mount frame. An internet based octagon edge length calculator was used to obtain the
dimensions during the entire design.
UAS CHALLENGE 2015
Test Rig
104
The
figure
dimension
alongside
of
the
shows
Quad-rotor
the
final
between
24.2.2
entire Quad-rotor.
The figure shown above validates the required inner length of each of the boxes used to construct
the mid frame.
Test Rig
105
24.2.3
The figure shown above validates the required inner length of each of the boxes used to construct
the outer frame.
Test Rig
106
Structural Testing
107
25
Structural Testing
was
individually
quality
Structural Testing
108
Considering the conservation of energy, the potential energy possessed by the bag of flour will be
converted to kinetic energy on impact neglecting air resistance and heat. The following calculations
denote the possible results to be anticipated.
mgh = 0.5mv2
1x9.81x0.98 = 0.5x1xv2, therefore v= 4.4m/s
Hence it can be concluded through above calculation that the payload remains intact and free from
any substantial damage.
Section by Osman Sibanda
Business Case
109
26 Business Case
The main part of this report is the business case of our UAS with accordance to the iMechE
requirements. The rest of this report will focus on the business case of our Quad-rotor the
Odonata-XV. Our company name is Autoquads Inspection Ltd.
Business Case
110
Business Case
111
There is less risk involved with the crew and the surrounding environment including animals
Lesser environmental disturbances etc. noise pollution
A costs analysis carried out by Europa that using UASs for inspections compared to the other
methods can significantly reduce the costs involved by about a third. (European Commission,
2014)
26.5.1
Sudden Cardiac Arrest (SCA) - is a condition where the heart suddenly stops beating and
blood to the brain and other organs stops flowing. Abnormal heart beat rhythms are called
arrhythmias; this is when a heart beats too fast, too slow or at irregular rhythms. 95% of people
who suffer Sudden Cardiac Arrest (SCA) die within minutes and for every 1 minute a persona
suffers cardiac arrest their chance of survival is decreased by 10%. (NIH, 2011)
Cardiopulmonary resuscitation (CPR) can be performed on individuals experiencing SCA but
they are not as effective as AEDs. Automatic external defibrillators (AED) are lightweight,
battery operated; portable devices used to measure heart rhythm and can send electric shocks
to restore the heart to normal rhythm.
UAS CHALLENGE 2015
Business Case
112
instructions as well as voice commands to alert the user when to send electric shocks. Using
our UAS AEDs can be transported to the patients quickly to deliver the services before the
medics arrive to the scene.
Product
Size (H x W x D) (cm)
Weight (kg)
Average Cost ()
3.1
1194
19 x 21 x 7
1.5
1199
20 x 18.4 x 4.8
1.1 kg
1175
22 x 30 x 7
1245
AED
Defibtech Lifeline AED
Table 16 shows the potential AED products with the dimensions, weights and the average
costs. This option was not chosen for various reasons including the prices of the AEDs
themselves which are very expensive. The other reason was the time it would take to reach the
patients, the Odonata XV would have been able to reach some patients a little time before the
emergency staff get there but in most cases the emergency staff are improving their response
time therefore this market would not have proved to be profitable over time.
26.5.2
The emerging UAV technology is to become key in the future competitiveness of the European
aerospace industry compared to other parts of the world. According to (European Commission,
2014) the common European market will offer a solid base to compete globally with other
leading competitors in the world e.g. USA, Israel, Brazil, China and Russia. It is predicted that if
an enabling legal framework is adopted it will furthermore allow the operations and the
manufacturing of the UAVs to grow from simple operations to more complicated operations
thus allowing the current businesses to gain valuable practical expertise while developing their
businesses. For example in France the number of approved operators rose from 86 to 400
after the introduction of an initial regulation.UK and Sweden has also seen similar growths in
different markets because of an enabling regulation (QinetiQ, 2013).
Industry experts believe it is really difficult to predict the potential UASs have globally but it is
currently predicted to be worth about $5.2 billion and it is expected to grow to about $11.6
billion per year in 2023 (QinetiQ, 2013). Further to boosting businesses across Europe the UAV
market is set to increase jobs globally as well. In Europe around 150,000 jobs are forecasted
by 2050 (European Commission, 2014). According to the Scottish Enterprise, the UK has the
most ambitious project for wind farm plans. This therefore means more market for inspection
since operations and maintenance accounts for over a quarter of the lifetime cost of a wind
farm. Analysis by UK Government predicted that the number of wind turbines will increase to
over 5500 by year 2025 with the operations and maintenance claiming 2bn per year from this
business boost.
UAS CHALLENGE 2015
Business Case
113
26.5.3
Regulation restriction
Since this UAS is less than 7Kg MTOM, they will be categorised as a SUA (Small Unmanned
Aircraft) category and should comply with UK Air Navigation Order 2009 articles 138, 166, 167
and CAA CAP 722, and CAP 393. (CAA, 1995)
The following chapter summarizes the UK legal requirements for flying UAVs in the UK
(Austin, 2010):
The craft should not endanger anyone or anything, including the pilot of the UAV. The pilot
holds the responsibility for the operations to be conducted safely.
The UAV must be in VLOS (visual line of sight taken to be at 122m vertically and 500m
horizontally) of the pilot at all times. For any uses beyond these distances, the pilot must
seek CAA permission and prove the craft can be flown safely at that distance.
CAA permission is required for any aerial work
Should not be flown within restricted airspace
The craft should not be flown;
Above or around 150m of any congested area
Above or around 150m of an assembly of more 1000 people
Around 50m of any vessel, vehicle or structure which is not under the pilots control
Within 50m of any person during take-off or landing and within 30m of any persons
during flight except for the pilot
26.5.4
A lot of factors will heavily affect entering the inspection sector. The biggest challenge would be
the initial capital that would have to be invested in mass production of the Odonata XV. The
subsequent chapters give some details into technological challenges that the organisation
could face;
Safe operation
EU aviation policy defines safety as the paramount objective. The current regulatory system for
UAS based on fragmented rules for ad hoc operational authorizations is an administrative
UAS CHALLENGE 2015
Business Case
114
bottleneck and hampers the development of the European UAS market (Austin, 2010). Either
to produce or to operate UAS national authorizations do not benefit from mutual recognition
and do not allow for European wide activities. The principle that safety will not be compromised
is hugely followed by the European aviation system for the integration of UAS. UAS operations
must demonstrate an equivalent level of safety in contrast to manned aviation.
Security
UAS is not resistant to probable unlawful actions. The potential uses of the UAS could be for
military purposes, the navigation or communication system signals of other UAS could be
jammed or ground control stations hijacked. Any identified security requirements needs to be
translated into legal obligations for all relevant players, such as the air navigation service
provider, UAS operator or telecom service provider, under the oversight of the competent
authorities. (Austin, 2010)
Data protection
Fundamental rights must not be trespassed by the UAS operations, including the respect for
the right to family and private life, and the production of personal data. Amongst the wide range
of potential civil UAS applications a number may involve collection of personal data and raise
ethical, privacy or data protection concerns, in particular in the area of the surveillance,
monitoring mapping or video recording.
UAS operators would need to comply with the applicable data protection provisions, notably
those sets out in the national measures established pursuant to the sat protection Directive
95/46/EC and the Framework Decision 2008/977. (Austin, 2010)
26.5.5
Competition
Knowing your competition is a crucial process of a successful product, therefore this chapter
will look into present competitors strengths and weaknesses and how the Odanata XV can
gain a competitive advantage.
Existing competitors
Product: Aibot X6 UAS
Aibot uses the X6 UAS to carry out inspections on power lines, wind turbines, bridges, train
paths and oil and gas pipelines. Our company will respond to Aibot by having a much smaller
UAV and providing the service much cheaper than them. (Aibotix, 2015)
Product: Md4-200
Micro drones uses the Md4-200to carry out inspections on oil pipelines, power cables, cooling
towers, forestry, radiation and wind turbines . The Md-200UAS has a very good flight time of
about 30 minutes but our company will respond to MicroDrones by having a heavier payload
capability since the Falcon can only carry 200g. (Micro Drones, 2015)
Product: Asctec Falcon 8
Asctec uses the Asctec Falcon 8 to carry out inspections solar parks, offshore/onshore
turbines, structural integrity and wind parks. Autoquads inspection Ltd will respond to this
UAS CHALLENGE 2015
Business Case
115
competitor by having thermal imaging cameras and by providing our service cheaper because
of the cost of the Odonata XV. (AscTec, 2015)
2% share
st
1 year
Wind farms
Overhead
power lines
Rail
Bridges
4%
nd
share
6%
rd
year
share
8%
share
th
year
10% share
th
4 year
year
()
4338 (+3000)
4470 miles
(National Grid)
20
50
80
110
140
89
178
268
357
447
9788 miles
1000
195
20
391
40
587
60
783
80
978
100
1063450
2627100
4190800
5754450
7317950
Cost
Cost
50000
50
200
1000
26.8 Costs
Autoquads Inspection Ltd hopes to start with 5 crafts for each infrastructure inspection (20 in
total) to start with for the first year and use them to find efficient ways to undertake tasks. This
plan of introducing a few Quad-rotors for the first year will ensure the company establishes
itself and gets used to the way of working in this sector. This period will also ensure that
UAS CHALLENGE 2015
Business Case
116
whatever challenges that are encountered can be solved and recorded down for future
reference. After the first year the company hopes to introduce 20 more Quad-rotors yearly for
the next four years, this will largely depend on the business growth so when the time comes it
could be more or less than planned. The table below shows the expected costs for the first 5
years;
Fixed Costs
Cost ()
Quantity
Total ()
Manufacturing (materials)
1500
20
30000
10000
10000
50,000
50000
Marketing campaign
10000
10000
Administrative costs
30000
30000
Infrastructure
3000000
3000000
Total
3130000
Table 18 Fixed Cost
Running Costs
Monthly Cost ()
Yearly Cost ()
5 year cost
Building Repairs/maintenance
1000
12000
60000
Utility Bills
3000
36000
180000
Controller/Inspectors/Monitors
10000
120000
600000
Maintenance costs
1000
12000
60000
Labour
Training
Miscellaneous (transportation,
7000
2000
1000
84000
24000
12000
420000
120000
60000
Total
25000
300000
1500000
Cost ()
Addition of new
Extra Labour
crafts ()
()
Inflation
Total ()
Information
3430000
Fixed,
infrastructure
3%
463500
Pay, maintenance
Pay, maintenance
3430000
300000
30000
300000
30000
120000
4%
468000
300000
30000
120000
5%
472500
Pay, maintenance
300000
30000
120000
6%
477000
Pay, maintenance
120000
Total
5311000
Table 20 Yearly Costs
Business Case
117
26.8.1
Financial statements
Pro-forma statement
The pro-forma statement table below shows the costs and revenues anticipated for the next 5
years.
Cost/Revenue
Year 1 ()
Year 2 ()
Year 3 ()
Year 4 ()
Year 5 ()
Services revenue
1063450
2627100
4190800
5754450
7317950
120000
240000
480000
960000
1920000
12000
12000
12000
12000
12000
Gross margin
931450
2375100
3698800
4782450
5385950
3130000
270000
510000
990000
1950000
300000
300000
300000
300000
300000
Untaxed income
-2498550
1805100
2888800
3492450
3135950
722040
1155520
1396980
1254380
Net Income
-2498550
1083060
1733280
2095470
1881570
Cash Flow
The cash flow statement table shows the key costs in and out. The key values in the cash flow
statement are the beginning cash balance and the ending cash balance.
Item
Year 1 ()
Year 2 ()
Year 3 ()
Year 4 ()
Year 5 ()
Beginning
Cash
balance
Net income after tax
-2504796.375
-1424444.025
304502.775
2394734.1
-2498550
1083060
1733280
2095470
1881570
Depreciation expense
6246.375
2707.65
4333.2
5238.675
4703.925
-2504796.375
-1424444.025
304502.775
2394734.1
4271600.175
Break even
As shown from the cash flow statement Auto quads Inspection Ltd starts off with nothing (not
including sponsorship and loans) and the ending cash balance is a negative 2.5m, for the
second year the ending cash balance is still negative meaning the company hasnt started
making profit yet but the value is decreasing. By the end of the third year the ending cash
balance is 304000, this is the break-even point. It will be at this point that the company will
start making profit in this sector, so it will take 3 years for the company to break even.
Business Case
118
26.8.2
Profitability
5
4.27
Profit Millions
4
2.39
3
2
1
0.30
-1
-2
-3
-1.42
Years
-2.50
Conclusion
119
Conclusion
As part of the Universitys academic curriculum, engineering projects at Masters Level have both a
documentation aspect (Dissertation or Report) and a physical aspect (product development and
testing); both aspects of the UAS Challenge project were carried out successfully under the
guidance of supervisors and technicians. The UAS challenge is a 1st generation IMechE
competition for Unmanned Aircraft Systems making this project the first of its kind in the University
of Hertfordshire. The UAS was designed and built to have real-world applications and this was
quantified through numerous validation and verification tests as well as quality control processes.
The UAS challenge project was carried out by a team of 12 aerospace engineers who worked
industriously in order to meet the project deadlines and objectives over a course of seven months
to deliver a top-tier product. In order to successfully deliver this project, product development
processes were integrated into the project phases through the creation of the design specification
which was used to keep engineering design process in line with rules from CAA and IMechE.
The management of the project was very professional as the meetings were held with supervisors
to discuss potential project pitfalls and solutions. The project manager also created a project plan
and budget plan to keep the project on schedule and on budget. Project management processes
such as QFD and WBS was used in the requirement analysis carried out on the design
specification in order to determine the right aerial vehicle to use for meeting the requirements.
Frequent requirement analysis were carried out in order to make sure that the product being
development meets the requirements and the management model used is a form of the V model.
An example is the change from a quadcopter to a hexacopter after the results of a structural
analysis showed that the weight limit set by IMechE would be exceeded. Another example is the
switch from Arducopter Autopilot System to Pixhawk Autopilot System after critical analysis
showed that processing capacity, safeguard measures and competency of the Pixhawk Autopilot
System was significantly higher than the Pixhawk Autopilot System.
The technical approach to the project was very professional and conservative as every process is
documented properly for analysis and this is shown in the level of testing carried out on electronic
components and the structural analysis of the UAS materials and components (Finite Element
Analysis and Bending Tests). The selection of materials used for manufacture was done after
meticulously analysing different materials and comparing them in areas such as strength and price,
this resulted in the manufacture of a structure below the weight limit. Catia and Ansys were used to
design the UAV structural components and Mission Planner software was used to program the
Autopilot System and every other programmable component. A control system operating manual
was created to enable non-system group members would be able to use the UAS control systems.
UAS CHALLENGE 2015
Conclusion
120
Safety regulations were followed in the course of the project such as following all laboratory
regulations when using the facilities for manufacturing, assembly and testing and also designing
the UAS according to regulations set by IMechE and CAA. Failsafe have been programmed into
the UAS for safe operation and recovery when failsafe conditions such as loss of GPS, loss of
communication are activated.
The projects objective has been met as the UAV is below the weight limit set by the IMechE and
can also be certified by the CAA. The UAS is also capable of a number of flight modes such as
autonomous flight, semi-manual and manual flight. The project budget was also not exceeded and
the UAS has been built and tested a couple of times. This project would serve as a foundation and
legacy to future generations of aerospace engineers that would partake in the UAS challenge from
University of Hertfordshire in the hope of reaching and surpassing the levels reached in the course
of this project.
REFERENCES
121
REFERENCES
3DR Robotics. (2015, April 13). IRIS+. Retrieved April 17, 2015, from 3drobotics:
http://whois.domaintools.com/3drobotics.com
3DR Robotics. (2015, January 08). Tuning. Retrieved April 7th, 2015, from ardupilot:
http://copter.ardupilot.com/wiki/configuration/tuning/
3DRobotics. (2015). Altitude Hold Mode. Retrieved 03 23, 2015, from
http://copter.ardupilot.com/wiki/altholdmode/
3DRobotics. (2015). Verifying performance with dataflash logs. Retrieved 04 03, 2015, from
http://copter.ardupilot.com/wiki/flying-arducopter/flight-modes/stabilizemode/#Tuning_Parameters
ABC NEWS. (2014, June 11). Retrieved March 30, 2015, from ABC News website:
http://www.abc.net.au/news/2014-06-11/black-saturday-bushfires-largest-class-action-entersfinal-week/5516648
Aibotix. (2015). Aibox international. Retrieved March 30, 2015, from aibotix.com:
https://www.aibotix.com/en/industry.html
Ananda, G. (2015). UIUC Propeller Database. Retrieved 04 04, 2015, from http://mselig.ae.illinois.edu/props/propDB.html
andy, D. (2014). reddit. Retrieved 04 07, 2015, from
http://www.reddit.com/r/Multicopter/comments/2fg4pu/calculating_forward_velocity_for_Quadrotor_design/
APM Plane. (2014). Complete Parameter List. Retrieved December 02, 2014, from
http://plane.ardupilot.com/wiki/arduplane-parameters/
Ardupilot. (2015). Automode. Retrieved April 04th, 2015, from http://copter.ardupilot.com/wiki/flyingarducopter/flight-modes/auto-mode/
ardupilot. (n.d.). Pixhawk Overview. Retrieved February 2, 2015, from
http://copter.ardupilot.com/wiki/common-autopilots/common-pixhawk-overview/
AscTec. (2015). Ascending Techologies. Retrieved March 30, 2015, from asctec.de:
http://www.asctec.de/en/asctec-professional-line/
Austin, R. (2010). Unmanned Aircraft Systems. West Sussex: John Wiley and Sons.
Bailey, D. (2003). Path Loss. In Practical Radio Engineering and Telemetry for Industry (pp. 71-76). Oxford:
Elsevier Science & Technology.
Barragan, D. (2014). mathworks: Optical Character Recognition . Retrieved Ferbruary 2, 2015, from
http://www.mathworks.com/matlabcentral/fileexchange/18169-optical-character-recognitionocr/content/OCR/OCR.m
Bernhard, M. (2009). rc universe. Retrieved 12 24, 2014, from http://www.rcuniverse.com/forum/brushedbrushless-motors-speed-controls-gear-drives-123/9016420-brushless-motor-rpm-formula.html
CAA. (1995). UNMANNED AIRCRAFT AND AIRCRAFT SYSTEMS. Retrieved March 25, 2015, from caa.co.uk:
http://www.caa.co.uk/default.aspx?catid=1995
UAS CHALLENGE 2015
REFERENCES
122
Civil Aviation Authority. (2012, 07 10). Unmanned Aircraft System Operations in UK Airspace Guidance.
Retrieved 12 13, 2014, from
http://www.caa.co.uk/docs/33/CAP%20722%20Sixth%20Edition%20March%202015.pdf
Copter.Ardupilot. (2015). Stabilize Mode. Retrieved April 19th, 2015, from
http://copter.ardupilot.com/wiki/flying-arducopter/flight-modes/stabilize-mode/
Copter.ardupilot.com. (2015). Loiter Mode | Copter. Retrieved march 23, 2015, from
http://copter.ardupilot.com/wiki/flying-arducopter/flight-modes/loiter-mode/#Tuning
Corneliussen, R. (2002). Nylon 66 Molding Compound. Retrieved 03 30, 2015, from
maropolymeronline.com:
http://www.maropolymeronline.com/Properties/nylon_66_properties.asp
Datasheet, N. 6. (2015). Direct Plastic Limited. Retrieved 02 10, 2015, from directplastics.co.uk:
http://www.directplastics.co.uk/nylon-6.6-sheet
Datasheet, N. 6. (2015). Direct Plastic Limited. Retrieved 02 10, 2015, from www.directplastics.co.uk:
http://www.directplastics.co.uk/nylon-6.6-rod.
Datasheet, N. 6. (2015). Direct Plastics Limited. Retrieved 02 10, 2015, from www.directplastics.co.uk:
http://www.directplastics.co.uk/nylon-6-sheet
Ditom. (2014). Qualification Test Plan. Retrieved 04 10, 2015, from http://www.ditom.com/space/wpcontent/uploads/2015/01/Qualification-Test-Plan.pdf: http://www.ditom.com/space/wpcontent/uploads/2015/01/Qualification-Test-Plan.pdf
European Commission. (2014, April 8). Retrieved March 05, 2015, from Europa.eu:
http://ec.europa.eu/transport/modes/air/doc/com(2014)207_en.pdf
Experimental Aircraft Info. (2006). Gyroscopic Principles. Retrieved 03 20, 2015, from
experimentalaircraft.info: http://www.experimentalaircraft.info/articles/aircraft-gyroscopicprinciples.php
google. (2015). maps. Retrieved 02 01, 2015, from https://www.google.co.uk/maps/@51.6637479,0.0803102,13z
Hart, D. K. (2013). Propeller Perfomance . Retrieved 02 01, 2015, from
http://www.studynet1.herts.ac.uk/crs/13/6ENT10100906.nsf/Teaching+Documents?Openview&count=9999&restricttocategory=main
Hove. (2013). PID tuning, how I did it my way. Retrieved 02 17, 2015, from
http://blog.pistuffing.co.uk/pid-tuning-how-i-did-it-my-way/
Khan, M. (2014). Quad-rotor Flight Dynamics. Retrieved 08 01, 2014, from http://www.ijstr.org/finalprint/aug2014/Quad-rotor-Flight-Dynamics.pdf
Mathworks. (2014). MATLAB And Simulink Student Design Challenge Winners. Retrieved April 11th, 2015,
from http://uk.mathworks.com/academia/student-challenge/spring-2014/
Micro Drones. (2015). Drone based aerial inspection. Retrieved March 30, 2015, from microdrones.com:
http://www.microdrones.com/en/applications/areas-of-application/inspection/
mit education. (2012). Retrieved 01 07, 2014, from
http://web.mit.edu/16.unified/www/FALL/thermodynamics/notes/node86.html
Mobius. (2015). Instruction Manual for the Mobius ActionCam. Retrieved Aprial 08, 2015, from
http://www.mytempfiles.info/mobius/MobiusManual.pdf
UAS CHALLENGE 2015
REFERENCES
123
Monhem, R. (2010). The V Model in Service Management. Retrieved March 28, 2015, from
http://rmonhem.blog.com/2010/11/23/the-v-model-in-services-management/
National Grid. (2013). Striving to meet customer needs while reducing costs and maintaining reliability.
Retrieved March 30, 2015, from nationalgridconnecting.com:
http://www.nationalgridconnecting.com/striving-to-meet-customer-needs-while-reducing-costsand-maintaining-reliability/
Network Rail. (2015). Display Report : National rail trends. Retrieved March 30, 2015, from
dataportal.orr.gov.uk: http://dataportal.orr.gov.uk/displayreport/report/html/c35e0c28-324f4168-81b9-be197963f251
NIH. (2011, December 2). What is an AED? Retrieved March 30, 2015, from nhlbi.nih.gov:
http://www.nhlbi.nih.gov/health/health-topics/topics/aed
Norris, D. (2012). In r. stewart (Ed.), Build your own Quad-rotor (pp. 95-128). New york: Mc Graw Hill.
Oscar. (2013, 10 13). Quad-rotor PID Explained and Tuning. Retrieved 01 24, 2015, from
http://blog.oscarliang.net/: http://blog.oscarliang.net/Quad-rotor-pid-explained-tuning/
Physics. (2014). Retrieved 12 01, 2014, from http://www.physicsclassroom.com/class/circles/Lesson1/Speed-and-Velocity
Plane.Ardupilot. (2014). Advanced Failsafe Configuration. Retrieved November 31, 2014, from
http://plane.ardupilot.com/wiki/advanced-failsafe-configuration/
Project, W. D. (2015). Gyroscope. Retrieved 03 23, 2015, from demonstrations.wolfram.com:
http://demonstrations.wolfram.com/Gyroscope/
QinetiQ. (2013). Civil Commercial UAV market. Retrieved March 30, 2015, from uas.qinetiq.com:
http://www.uas.qinetiq.com/Documents/civil-commercial-uav-market.pdf
rc groups. (2008). Retrieved 09 05, 2014, from
http://www.rcgroups.com/forums/showthread.php?t=1646919
robotics. (2014). Retrieved 02 01, 2015, from http://robotics.stackexchange.com/questions/2704/Quadrotor-forward-speed
Rogershobbycenter.com. (n.d.). A Guide to Understanding LiPo Batteries. Retrieved 02 25, 2015, from
http://www.rogershobbycenter.com/lipoguide/
S, J. (2014). physics forums. Retrieved 12 01, 2014, from
https://www.physicsforums.com/threads/propeller-and-thrust.143230/
S, J. (n.d.). Propeller and thrust. Retrieved from Physics Forums:
https://www.physicsforums.com/threads/propeller-and-thrust.143230/
S@M. (2014). samaritakis: How to connect Mobius camera Boscam FPV MinimOSD (noise problems,
solution). Retrieved Aprial 8, 2015, from http://blog.samaritakis.gr/connect-mobius-cameraboscam-fpv-minimosd-problems-solutions/
Samieh, A. (2007). mathworks: Shape Recognition. Retrieved January 26, 2015, from
http://www.mathworks.com/matlabcentral/fileexchange/15491-shape-recognition
Santos, R. (2013). randomnerdtutorials: Arduino Control 2 DC Motors Via Bluetooth (Perfect To Build a
Robot). Retrieved March 23, 2015, from http://randomnerdtutorials.com/arduino-control-2-dcmotors-via-bluetooth/
UAS CHALLENGE 2015
REFERENCES
124
schoolworkhelper.net. (2014). Nylon: Background, Dangers, Disposal. Retrieved 03 23, 2015, from
http://schoolworkhelper.net/nylon-background-dangers-disposal/
sengpielaudio. (2015). Retrieved 07 02, 2014, from http://www.sengpielaudio.com/calculator-ohm.htm
Smith, B. (n.d.). THE SAFE AND EFFECTIVE USE OF LITHIUM POLYMER BATTERIES IN MODEL. Retrieved 03
25, 2015, from http://www.doddingtonkent.org.uk/MMFC/images/front_page_pics/Battery%20Safety%20Booklet%20%20June%202014.pdf
Staples, G. (2014, 12 12). electric rc aircraft guy. Retrieved from
http://www.electricrcaircraftguy.com/2013/09/propeller-static-dynamic-thrustequation.html#.VTZnipWBHIU
techbitar. (2013). instructables: Face detection and tracking with Arduino and OpenCV. Retrieved March 16,
215, from http://www.instructables.com/id/Face-detection-and-tracking-with-Arduino-andOpenC/?ALLSTEPS
Turner, G. (2015). Gyroscopes. Retrieved 03 26, 2015, from gyroscopes.org.uk:
http://www.gyroscopes.org.uk/how.asp
UK CAA Safety and Airspace Regulation Group. (2014, 02 09). UK UAS Operations. Retrieved 02 15, 2015,
from http://jarus-rpas.org/pdf/2_Workshop_140319/2014_Presentation_01_CorbettGerry_CAA_UK.pdf
University of Michigan. (1996, August 26th). PID Tutorial. Retrieved March 16th, 2015, from University of
Michigan: http://www.ee.usyd.edu.au/tutorials_online/matlab/PID/PID.html
unmannedtechshop. (2015). 3DR uBlox GPS with Compass Kit. Retrieved 03 02, 2015, from
https://store.3drobotics.com/products/3dr-gps-ublox-with-compass
unmannedtechshop. (2015). ARDUPILOT MEGA MINIM OSD V1.2. Retrieved 04 15, 2015, from
http://www.unmannedtechshop.co.uk/ardupilot-mega-minim-osd-v1-2/
Wyatt, D., & Tooley, M. (2008). Electrical and magnetic fi elds . In E. S. Books (Ed.), Aircraft Electrical and
Electronic Systems: Principles, Maintenance and Operation (pp. 337-352). Oxford: Elsevier Ltd.
125
Appendix. A
ID
Task Name
Duration
Start
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
191 days
15 days
3 days
12 days
0 days
97 days
97 days
12 days
Fri 10/10/14
Fri 10/10/14
Wed 15/10/14
Thu 30/10/14
Fri 10/10/14
Fri 10/10/14
Fri 31/10/14
Thu 30/10/14
Tue 14/10/14
Thu 30/10/14
Thu 30/10/14
Sun 22/02/15
Sun 22/02/15
Sun 16/11/14
7 days
Fri 31/10/14
Sun 09/11/14
7 days
12 days
12 days
0 days
16 days
15 days
15 days
15 days
15 days
15 days
15 days
15 days
15 days
0 days
0 days
8 days
7 days
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
Thu 04/12/14
Fri 05/12/14
Fri 05/12/14
Fri 05/12/14
Sun 16/11/14
Fri 05/12/14
Thu 04/12/14
Thu 04/12/14
Thu 04/12/14
Thu 04/12/14
Thu 04/12/14
Thu 04/12/14
Thu 04/12/14
Thu 04/12/14
Thu 04/12/14
Fri 05/12/14
Tue 16/12/14
Mon 15/12/14
7 days
Fri 05/12/14
Mon 15/12/14
7 days
Fri 05/12/14
Mon 15/12/14
0 days
30 days
Send out order list for components and 30 days
Order parts
delivery
Manufacturing & Assembly
Machine structural frame
47 days
26 days
26 days
23 days
Mon 26/01/15
Mon 26/01/15
Mon 26/01/15
Sun 01/03/15
47 days
47 days
47 days
67 days
23 days
0 days
40 days
Sun 01/03/15
Sun 01/03/15
Sun 31/05/15
Mon 09/03/15
Sun 31/05/15
Tue 31/03/15
Sun 31/05/15
Fri 01/05/15
0 days
0 days
0 days
0 days
26 days
6 days
6 days
11 days
3 days
Mon 09/03/15
Mon 09/03/15
Mon 06/04/15
Fri 01/05/15
Mon 01/06/15
Mon 01/06/15
Mon 08/06/15
Mon 15/06/15
Wed 01/07/15
Mon 09/03/15
Mon 09/03/15
Mon 06/04/15
Fri 01/05/15
Sun 05/07/15
Sun 07/06/15
Sun 14/06/15
Mon 29/06/15
Fri 03/07/15
15 Sep '14
W
T
06 Oct '14
F
S
S
27 Oct '14
M
T
Scope complete
17 Nov '14
T
F
08 Dec '14
29 Dec '14
S
S
M
T
W
19 Jan '15
F
S
09 Feb '15
S
M
02 Mar '15
W
T
23 Mar '15
F
S
S
13 Apr '15
M
T
04 May '15
T
F
Scope
30/10complete
Analysis complete
16/11
04/12
05/12
16/12
Tue 31/03/15
Sat 28/02/15
Sat 28/02/15
Tue 31/03/15
09/03
09/03
Deliver CDR report
06/04
Deliver FRR report
01/05
Task
Summary
External Milestone
Inactive Summary
Finish-only
Split
Project Summary
Inactive Task
Manual Task
Manual Summary
Deadline
Milestone
External Tasks
Inactive Milestone
Duration-only
Start-only
Progress
Page 1
25 May '15
15 Jun '15
S
S
M
T
W
06 Jul '15
F
127
ID
Task
Mode
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Task Name
Duration
Start
FinishSep '14
15
Scope
Determine project scope
Define resources
Scope complete
Sponsorship
Secure project sponsorship
Design Specification/System
Requirements
15 days
3 days
12 days
0 days
97 days
97 days
12 days
7 days
12 days
12 days
Analysis complete
0 days
16 days
Review specifications
15 days
Payload Delivery System
15 days
Propulsion System design
15 days
Systems design
15 days
Concept Structural design
15 days
Preliminary Safety Case consideration
15 days
Preliminary Weights estimation15 days
Obtain approval to proceed 15 days
Preliminary Design complete 0 days
Deliver PDR to IMeche
0 days
Final Design ready for purchase8 days
System compents finalised
7 days
Preliminary Design
Fri 10/10/14
Fri 10/10/14
Wed 15/10/14
Thu 30/10/14
Fri 10/10/14
Fri 10/10/14
Fri 31/10/14
Thu 30/10/14
Tue 14/10/14
Thu 30/10/14
Thu 30/10/14
Sun 22/02/15
Sun 22/02/15
Sun 16/11/14
Fri 31/10/14
Sun 09/11/14
Fri 31/10/14
Fri 31/10/14
Sun 09/11/14
Sun 16/11/14
Sun 16/11/14
Sun 16/11/14
22
Oct '14
29
06
13
20
27
Nov '14
03
0%
10
17
24
Dec '14
01
08
15
Scope complete
Analysis complete
100%
28
29
30
0 days
30 days
55 days
47 days
26 days
26 days
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
16
13
20
May '15
27
04
11
18
25
Jun '15
01
08
15
22
Jul '15
29
06
100%
100%
100%
0%
0%
0%
0%
Tue 31/03/15
Tue 17/03/15
0%
50%
Tue 17/03/15
50%
37 days
23 days
0 days
67 days
71 days
Sun 01/03/15
Mon 09/03/15
Mon 20/04/15
Sun 01/03/15
Mon
09/03/15
Mon 20/04/15
Wed 08/04/15
Mon 20/04/15
Mon 01/06/15
Mon 15/06/15
0 days
0 days
11 days
0 days
15 days
0 days
0 days
11 days
3 days
0 days
Mon 09/03/15
Wed 01/04/15
Mon 18/05/15
Mon 15/06/15
Mon 15/06/15
Wed 01/07/15
Wed 01/07/15
Mon 15/06/15
Tue 30/06/15
Fri 03/07/15
Mon 09/03/15
Wed 01/04/15
Sun 31/05/15
Mon 15/06/15
Fri 03/07/15
Wed 01/07/15
Wed 01/07/15
Mon 29/06/15
Thu 02/07/15
Fri 03/07/15
37 days
Apr '15
30
06
100%
Mon 26/01/15
Mon
26/01/15
Mon
26/01/15
47 days
37 days
23
100%
100%
23 days
Mar '15
02
09
100%
100%
100%
100%
100%
100%
100%
100%
100%
Preliminary Design complete
100%
Deliver PDR to IMeche
100%
7 days
23
100%
34
16
100%
100%
100%
27
Integrate systems
components
Feb '15
02
09
100%
100%
26
100%
19
0%
0%
7 days
31
32
33
12
100%
Scope
0% complete
Jan '15
29
05
100%
26
Order parts
22
0%
0%
Integration testing complete
75%
0%
0%
Deliver CDR report
0%
15/06
Design Presentation
Flight Readiness Review
Task
Summary
External Milestone
Inactive Summary
Finish-only
Split
Project Summary
Inactive Task
Manual Task
Manual Summary
Deadline
Milestone
External Tasks
Inactive Milestone
Duration-only
Start-only
Progress
Page 1
0%
01/07
01/07
0%
03/07
13
129
Alfred
Attendees
Type of meeting
Progress check
Note taker
Johnathan
Timekeeper
Zuber
AGENDA TOPICS
Time allotted | 50 mins | Agenda topic PDS and design convergence | Presenter Alfred
Discussion Presenting the product design specification and the design convergence to Johanna to update the
supervisors on decision and conclusion has been made by the group.
Conclusion: we still need to validate some criterias with numbers and not just use assumptions
Time allotted | 10 mins | Agenda topic |Ordering products | Presenter Alfred
Discussion We asked if it was possible to order products from eBay seen as it would be a lot cheaper ordering
product of their manufacture website itself. A list of product was also shown to Johanna specifying what products
we want
Conclusion Johanna proposed that she would as Howard ash if he could purchase some of the products we want
seen as the aerospace department dont allow purchases from eBay
Time allotted | 10 mins | Agenda topic The need for sponsors | Presenter Alfred
Discussion We was considering if there was a need for sponsors because seen as we are getting a budget of 1000
from the university, there wouldnt really be a need because we believe the can easily be made with a budget of
1000
Conclusion we probably wont need a sponsorship but the option is still open if need but we need to act soon if we
want a sponsor rather than later
Time allotted | 30 mins | Agenda topic multi rotor concept | Presenter Alfred
Discussion For our final concept of a multi rotor, we need to decide if we are going for a 3, 4, 6 or 8 rotor system as
our finalized concept
Conclusion to come up with another design convergence which has a list of criteria for multi rotor which will
compare different types of multi rotors and hence the win concept will be our final design.
Action items
Person responsible
Deadline
Alfred
10/11/2014 12:00 PM
Zee
10/11/2014 12:00 PM
For one motor failing research the stability for 3 to 8 rotor system
and maneuverability of multi rotor systems
Kasun
10/11/2014 12:00 PM
Hassan
10/11/2014 12:00 PM
Research into the costs and strength of material for multi rotors
Ozy
10/11/2014 12:00 PM
Mohin
10/11/2014 12:00 PM
Amit
10/11/2014 12:00 PM
Look into root sizing and complexity and spacing for a series of
multi rotor system
Zuber
10/11/2014 12:00 PM
Mo
10/11/2014 12:00 PM
Tarek
10/11/2014 12:00 PM
Look into systems required for a multi rotor system and present a Jonathan and micky
list to the group
10/11/2014 12:00 PM
Alfred
10/11/2014 12:00 PM
Johanna
10/11/2014 12:00 PM
Page 2
132
AGENDA
Finalizing Design Concept
October 28, 2014
12:00PM 2:30 PM
Meeting called by Alfred Dzadey
Attendees:
Alfred, Mohin, Zuber, Tarek, Jonathan, Micky, Reyad, Kasun, Osman, Mozammel, Hassan,
Amit
Note taker:
Jonathan
Please bring:
Location:
Objective:
Discussion of multi rotor concept, finalizing roles of groups and ideas of having sponsors
Introduction
Taking register of attendees and general updates
Schedule
Presenter
Alfred
Alfred
Alfred
Additional Instructions:
DONT BE LATE PLEASE!!!
Alfred
134
Jonathon Ebhota
5
4
3
2
1
0
Jonathan has from the very beginning, been very enthusiastic about the project, even though he had been
moved around quite a few times from one role to another. Though his enthusiasm had led to great results,
it took some work getting there as the systems group had not properly managed their time. Having said
this, he has guided the group through many hurdles, some of which may have been daunting, and helped
speed up certain processes. Jonathon has on multiple occasions tried to stick to the plan to allow for ample
amount of time for testing, and while there have been delays, the planning for of all the systems
integration has allowed for little room for error. Even though there is room for improvement in managing
the team, Jonathon took great pride in both, his team and work, and this has led to a great contribution on
his part.
Tarek Kherbouche
5
4
3
2
1
0
Enthusiasm
Team value
Planning
Delivery
Contribution
Tareks strong point, coming into this project, was his experience in electronics and has provided his
knowledge in getting some of the systems up and running quickly. His importance to the team was noted
fairly quickly as he could simply put his head down and make good headway. Nevertheless, there were
times where he was slowed down by delays in purchasing which meant he had to wait. While he had
planned for contingency, he never expected certain things to take as long as it did delaying thing further.
UAS CHALLENGE 2015
135
His knowledge was still valued to the team and his never wavering enthusiasm and support allowed him to
work well with all members of the group very well and help make a large contribution overall.
Malwenna Malwenna
5
4
3
2
1
0
Enthusiasm
Team value
Planning
Delivery
Contribution
While Malwenna has not shown as much enthusiasm in the beginning, although this could be attributed to
him being an introvert, it did grow as the group started to become much more comfortable with each
other. Malwenna had constantly researched for a large part of semester one, making sure the rest of the
systems team was going the simplest and most effective route to a successful project. While Malwenna was
a great team player and a great asset to the team, by taking up more workload to help out, he ended up
pausing his own role for a short while, but on the other hand, had he not, the rest of the systems would
have been delayed anyhow making this a no win situation. Nevertheless, he has delivered his role
effectively and made a great contribution to the team.
Team value
Planning
Delivery
Contribution
While Mohammed showed some good levels of enthusiasm, his lack of planning led to rushing and some
late nights to get the task done on time. He initially started to help the propulsion engineer to make sure
that the motors that were chosen were right for the task. While this led to a more objective choice for the
motors, his actual role as a stability engineer had to take a back seat. However, he has since focused on his
role as the stability engineer alongside Malwenna and has made great progress in simulation and testing in
the short time he had. Overall, he started on the right path before getting side-tracked but has come to and
has made some great contribution to the team.
136
Hassan Turabi
5
4
3
2
1
0
Enthusiasm
Team value
Planning
Delivery
Contribution
Hassan has continuously worked very hard on his role as the propulsion engineer and has continuously
delivered, driven by his enthusiasm. Hassan has spent a large amount of time making sure that the parts he
chose were the right ones. From an extensive number of calculations through to testing; he has worked
very hard throughout the entire project. However, all this came at the cost of time management, although
he has pulled off all the stops and has completed his work on time to great results.
Amit Ramji
5
4
3
2
1
0
Enthusiasm
Team value
Planning
Delivery
Contribution
Amit has consistently pushed for more throughout the entire project, not only from himself but from
others as well. He brought in great level of experience and insight to almost all issues for the Quad-rotor.
His enthusiasm has never wavered and motivated some of the other team members to compete on who
can produce the most quality work. He regularly put his team in front and tried to help out where he could,
and though it may occasionally come as unneeded, and sometimes overbearing, he never let it bother him
and continued forward. His delivery to the project was invaluable and his overall contribution was
exceptional.
137
Zuber Khan
5
4
3
2
1
0
Zuber has been consistently enthusiastic about the project, and while this enthusiasm has led to good
results, the ability to get the structural side of the group to work within deadlines has been good. Having
said this, he has guided the group through certain objectives which had helped speed things up the process,
else would have been hampered by unnecessary delays. Zuber has on multiple occasions stuck to plan and
delivered products on time as promised. While there is still room for improvements in managing the team,
he has executed and delivered his role as a structural team leader very well and has made large
contributions as a whole.
Micky Ngouani
5
4
3
2
1
0
Enthusiasm
Team value
Planning
Delivery
Contribution
Micky had a lot of personally issues during the duration of the project by has tried to manage this with his
academic work. He has some been unable to attend meeting for various reason but when work is asked of
him he delivers good quality work. Weakness I would say is need from contribution from him but his
strength are he works had when he commits to doing so.
138
Mohammed Mohinuddin
5
4
3
2
1
0
Enthusiasm
Team value
Planning
Delivery
Contribution
While Mohin showed some good levels of enthusiasm, his lack of planning led to rushing and some late
nights to get the task done on time. He generally isnt a morning person and means that he usually is only
available during the day and late evening. During semester B he has become more involved with the group
and has made some great contribution to the team. His work was mostly of good standard and but
struggled to meet deadlines at times due to various reasons. Mohin is team player and is by far his best
attribute.
Osman Sibanda
5
4
3
2
1
0
Enthusiasm
Team value
Planning
Delivery
Contribution
Osman has contributed greatly with his all-round support to everyone. He is always willing to help out in
any task and go the extra mile. He completes task in reasonable and expected time and has a good amount
of contribution to the team. He is definitely a team player and has shown some levels of enthusiasm during
the period of the project.
139
Mozammel
5
4
3
2
1
0
Enthusiasm
Team value
Planning
Delivery
Contribution
Mozammel has not shown as much enthusiasm in the beginning, although this could be attributed to him
being an introvert. He grew in confidence and began to take responsibility for his role and contribution to
the team. His time management wasnt great due to personal problems outside academic work but
nevertheless he has produced reasonably standard work. He had put in the extra hours to complete tasks
when asked to and hence has had great contribution to the team progression so far.
140
Scale -- Please use the rating code below to appraise the project managers work
The Absolute Best Project Manager that we have knowledge of and experience with anywhere. Very
Exceptional and Far Superior to others. Value added to the project / Achieved on almost always /
Above Average -- Noticeably competent / capable / proficient / adept / knowledgeable / skilled / High
Quality / Achieved on a consistent basis /
Average: (satisfactory / acceptable / suitable / reasonable / no major problems / potential is there /
dependable / meets the stands of the job
Marginal (Fair: improvement is necessary / deficient in certain area, but potential may be there)
Below Average (Needs significant or substantial improvement / really lacking / unsatisfactory)
Not observed or applicable
4 Professionalism
4 Achieved project goals
OVERALL PROJECT PERFORMANCE OR END PRODUCT (use 1 to 5 scale again on project basis)
4 Adherence to Budget
3 Adherence to Schedule
Overall Rating 5 in terms of public / private time, resources, and money required to work with them
Circle One:
Definitely looking forward to working with this Project Manager again on another project.
Willing to work with this Project Manager again on another project without any changes
Willing to work with this Project Manager again on another project with some changes
Prefer not to work with this Project Manager again or Project Manager needs significant
improvements
Please note any specific comments here or on a separate sheet (weak points needing improvement, strong
points, instances of going the extra mile.)
+
+
+
Needs to be kept within the deadlines, you are far too lenient.
Good communication skills, and persuasiveness
Always going the extra mile
Always stands up for teams in front of supervisors and very supportive
UAV Design
141
In order to eliminate excess mass, design considerations such as those discussed in Appendix G.1
have been used. The main focus was to achieve a high strength to weight ratio with a fairly high
stiffness; hence the use of thin plates in a sandwich design justifies the decision rationale. Using
an initial arm bending calculation and iterative process, the best tube diameter was converged to
be 16mm x 11.5mm with a wall thickness of 2.25. The Outside diameter of the tube now needs a
support to sandwich the plates, a high strength Nylon 66 material is selected for the compression
blocks (FB-001, FB-002, EB-001 Appendix B.7). Decreasing the plate spacing to 25mm proves a
challenge for incorporating systems and mechanical pivots, however this reduced the overall
weight significantly.
Furthermore the Nylon 6 plates (BP-001 & 002 Appendix B.7) incorporates cut-outs and holes to
reduce weight further and allow for a reduced cross section during flight. The gust pressure loading
of such cross section has been calculated in 8.4 and added to the maximum flight forces however
assuming an opposed direction in order to satisfy worst-case flight conditions. The isolated plate
deflection is modelled in Appendix G.11 as an infinite plate assembly. Compared with the analytical
technique, the error between results is minimal as is discussed in section 8.7.
Main Body Plate sizes (BP-001 & 002) have been sized to be the minimal thickness to allow for
stress distribution and maintain a stiffened root structure. Reducing the thickness of these plate
further without changing materials would mean the plates would be subject to localised bending
and shear deflections (similar to ladder/truss design with weak rail supports). Additionally the
planar dimensions consider the contact positions of the Arm support brackets and every attempt
has been made to reduce the overall root size of the main body plates.
Further cut-outs and weight reduction on most components is still possible however due to time
and resource constraints, further material optimisation is not considered. Further mass can be
removed from the Undercarriage components (UV-001 & UH-001), along with increased cut-outs
on the Main Body plates (BP-001 & 002) and tapering of out-board structures. A further study into
the use of Short Fibre Reinforces Composite (SFRC) blocks can also be carried out, however this
would be mass produced injection moulded components as detail and finer machining is time
consuming and costly.
The design of the Quad-rotor has been carried out while considering manufacturability and
precision of machinability. The overall geometry of the Quad-Rotor is controlled by positions of the
Main Body plates (BP-001 & 002), where the CNC process is accurate of 0.2mm. If the Fixed or
Movable blocks (FB and MB series) are not accurate to nominal values, the through bolts being
used in compression will take up the tolerance as Nyloc Nuts are also being used to ensure no
assembly is loosened during flight. The 16mm diameter hole in the blocks for the Arms is also
considered at the manufacturing stage during component design; if the manufactured component
is loose fit, the gap can be closed by the O-rings and hand finishing of mating half-block surfaces
(sandwich of FB-001 x 2 to FA-001 - Appendix B.7). Compression and bolt preload of the fasteners
holding this local sandwich together will allow the Arm to be secure during assembly and in flight.
UAV Design
Figure 102 - Motor Mount Design (Left) & Undercarriage T-Joint (Right)
Figure 103 - Undercarriage Pivot Design (Left) & Main Body Sandwich Design (Right)
142
UAV Design
143
The value of structural components such as raw Nylon (PA6 & PA66) blocks / sheets have been
demonstrated in Appendix. D where the usage costs have been calculated. The usage cost of
materials is equivalent to a buy-back scheme used in industry where off-cuts and machining swarf
is sold back to the supplier for recycling. Ensinger Ltd (Watford Plastics division) is one of the
largest suppliers globally and has agreed to provide the raw materials at a cost equivalent to
supply costs in exchange for advertisement. Buy-back schemes are usually used for long term and
large volume purchases, however advertisement has been offered in place of a large contractual
order. Costing of plastics is non-standard and a retail price is differing between suppliers, many
suppliers can afford to offer the same materials at a fraction of the cost depending on their
commercial footprint.
UAV Design
144
In order to avoid having multiple versions of the same components with little changes in geometry,
a single group member had carried out all modelling. This ensures there is one main CAD model
with no chance of duplication of parts and introducing variants. An industry equivalent to this
restriction would be a check-in/check-out database such as Siemens Teamcentre or CATIA
Enovia, however this could not be possible during the timescales involved in the project for
integration.
The entire model has undergone a 4-step manufacturing readiness level; where level 1 is
conceptual design, level 2 being detail design of components, level 3 being further product level
design and manufacturing readiness and level 4 being systems 3D modelling and cable routing.
Part Numbering Scheme
XY - 00Z
MB = Movable Bracket
LB = Landing Bracket
TJ = T-Joint
UV = Undercarriage Vertical
Revision Control:
Revisions of parts are a possibility to introduce under configuration control when the Fit, Form or
Function of the part does not change. Due to the constant update of design parts and releasing in
a 4 level time-line, revision numbers are not required. Additionally the fact that a single entity is in
control of the entire CAD model and configuration control, the potential to introduce part and
assembly revisions is unnecessary.
Part and Drawing Release for Manufacture:
Real engineering projects involving a multitude of parts would require a release process, however
as the same team member models the Design and carried out the Stress analysis of the structural
components, the need for internal release is non-essential. Only one working copy of the entire
Quad-Rotor design exists, hence part release and freezing of the design is carried out at internal
stage reviews (Levels 1 - 4). Release for manufacture and configuration control again is simplified
as a single member is in control of the design and drawing release that also inputs into selecting
materials and purchasing. For this reason, drawing release uses the same part-numbering scheme
as above and all drawings are deemed as Work-In-Progress until the drawing is assigned a
number. An industry equivalent would involve a workflow process where each part and assembly
along with material cards and instructions are released at separate departments, however due to
project integration constraints, tools such as Teamcentre have not been used.
UAV Design
145
171
A detailed mass breakdown was carried out of the whole UAV to ensure that it is within specifications. The itemised breakdown of components
and their quantities are shown below.
Material
Part No.
Length/
Structural
Density Area
Volume Mass
Total
Picture
(Appendix.
(Appendix
Thickness
Qty
Part Name
(g/cm3)
cm2
(cm3)
(g)
Mass (g)
(Appendix B.7)
B.7)
(cm)
E)
Tubular Arms
MA-001,
FA-001
PVC
1.4
0.97
29
28.18
39.46
157.84
Fixed-arm
Nylon clamps
LB-001
Nylon
1.14
5.2
3.56
4.06
16
65.00
Moveable arm
half block
clamp
FB-002
Nylon
1.14
4.52
3.14
3.58
7.16
Moveable arm
full block
clamp
MB-001
Nylon
1.14
8.92
5.52
6.29
12.59
Moveable arm
pivot
AP-001
Nylon
1.14
6.25
13.11
14.95
29.90
172
Motor clamp
full block (end)
EB-001
Nylon
1.14
10.2
7.77
8.86
35.45
Motor block
plate
MP-001
Aluminium
2.7
20
0.1
1.81
4.90
39.24
Plates
BP-001, BP002
Nylon
1.14
351.
58
0.2
70.25
80.09
160.19
Undercarriage
pivot
assembly
LP-001, LB003
Nylon
1.14
7.37
21.67
24.70
49.41
Undercarriage
tube
UV-001
PVC
1.4
0.97
20
19.43
27.21
54.42
Horizontal
undercarriage
tube
UH-001
PVC
1.4
0.97
35
34.01
47.62
95.24
173
Undercarriage
T Joint
TJ-001, TJ002
Nylon
1.14
Payload box
PB-000
Nylon
1.14
M3 x 35
Button Head
M3 x 35 x 0.5
Stainless
Steel
7.2
M3 Nyloc Nut
Nyloc M3 x 0.5
Stainless
Steel
7.2
M5 x 30
Button Head
M5 x 30 x 0.8
Stainless
Steel
7.2
M5 Nyloc Nut
Nyloc M5 x 0.8
Stainless
Steel
7.2
13.1
2
16.06
18.31
101.924
35
30
36.63
116.19
0.28
1.7
34
57.8
0.09
0.4
34
13.6
0.4123
4.4
8.8
0.176
1.4
2.8
174
25mm M3 Hex
standoff (F/F)
Hexagonal
Standoff
Brass
8.45
25
M3 Nylon
Spacer
Nylon
1.14
M5 Nylon
Spacer
Nylon
M6 Nylon
Spacer
M3 x 10
Button Head,
pitch 0.5mm
O-Rings
16mm
internal,
M3 Nylon
Spacer
3.2mm
Internal, Outer
6mm, length
25mm
M5 Nylon
Spacer
5.3mm
Internal, Outer
10mm, length
10mm
M6 Nylon
Spacer
6.4mm
Internal, Outer
12.5mm,
length 10mm
3.7
14.8
25
0.7
1.4
1.14
10
0.7
1.4
Nylon
1.14
10
M3 x 10 Button
Stainless
Steel
7.2
10
0.6
24
14.4
O-Rings
Rubber
30
0.55
175
18mm
External, c/s
1mm
Quick Release
0.50
Quick Release
Aluminium
2.7
4.5
Pin
3
Springs
Springs
Steel
7.2
Total
(Structural)
Table 23 Itemised Mass Breakdown of all Structural UAV Components
2.26
6.11
12.21
10
20
1012.5
(g)
176
80
40
50
50
194
52.5
Width
(mm)
49
40
18
30
45
35
Thickness
(mm)
15
9
10
10
47
0
80
61
30
35
17
18
46
35.5
140
28
22.5
105
13
12
70
Height (mm)
Mass
(g)
40
14.4
4
50
1848
187.4
40
75.2
50
150
73.2
13.4
1000
Qty
1
1
1
1
2
4
4
4
1
1
1
1
1
Total
Mass (g)
40
17.1
4
50
1848
749.6
160
300.8
50
150
73.2
13.4
1000
100
10
30d
10
7
5
21.5
4.8
1
1
21.5
4.8
20
15
10
1.5
1.5
25
1.8
1.8
59
38
50
50
85
85
120
118
55
1
1
1
18
120
102
15
35
118
50
30
15
55
5013.7(g
Total (Electronics / Misc)
)
From the summation of all the masses for the electronic and miscellaneous components in
Table 24, a total mass of 5013.7 grams was calculated. Total Mass of the UAV 6026.2 grams.
Table 24 - Electronics and Misc Component Masses
177
PVC Tube
10mm Nylon 6.6
Block
16mm Nylon 6.6
Block
30mm Nylon 6.6
Block
25mm Solid
Circular Bar
2mm Nylon 6
Black Plate
1mm Nylon 6
Black Plate
Rigid Angle
Sections
Used for
(Appendix B.7 for
Structural Parts
and Section 10 for
Systems)
MA-001, FA-001,
UV-001, UH-001.
Usage cost
for Parts
( inc Vat and
Delivery)
Usage cost
for Parts
Excluding
Delivery
( inc Vat)
50.34
37.92
31.67
FB-001, FB-002,
MB-001, EB-001
LB-001, LB-002
PB-009, PB-010
4.40
2.25
1.25
TJ-001, TJ-002
4.40
1.01
0.51
LB-003, LP-001
6.60
1.33
0.67
AP-001
4.40
2.29
1.145
BP-001, BP-002,
PB-005
8.80
7.44
3.72
PB-004
4.40
3.04
1.52
PB-001, PB-002,
PB-003, PB-006,
PB-007, PB-008
39.54
18.56
12.31
Aluminium 1mm
Plate
Pixhawk
GPS & Telemetry
Kit
OSD
MP-001
9.08
7.26
7.26
Pixhawk
GPS & Telemetry
Kit
OSD
159.98
159.98
159.98
89.77
89.77
89.77
44.95
44.95
43.45
Batteries
Batteries
188.76
188.76
182.74*
Motors
Motors
91.80
91.80
91.80
Propeller Blades
Blades
12.00
12.00
12.00
ESCs
Lights & LED
panel Board
Servo
ESCs
Lights & LED panel
Board
Servo
141.75
141.75
135.80
14.13
14.13
14.13
13.69
3.42
3.42
Camera
M3 x 35mm x
0.5mm Pitch Bolt
M3 Nyloc Nuts
M5 x 30mm x
0.8mm Pitch
Bolts
Camera
52.43
52.43
47.01
Fasteners
3.95
2.37
2.37
Fasteners
1.78
1.21
1.21
Fasteners
2.79
0.56
0.56
Fasteners
1.19
0.24
0.24
M5 Nyloc Nuts
M3 Nylon Spacer
3.2mm internal,
outside 6mm,
length 25mm
M5 Nylon Spacer
5.3mm internal,
outside 10mm,
length 10mm
M6 Nylon Spacer
6.4mm internal,
outside 12.5mm,
length 10mm
M3 Brass
Hexagonal F/F Standoff
M3 x 10mm x
0.5mm Pitch
Cable Ties
2.5x100mm
O-Rings 16mm
Internal, 18mm
External, c/s 1mm
Nylon Hinges 20
x 20mm for
Payload Box
Heat Shrink
Tubing Set
Braided Sleeve
Cable Protection
Strobe controller
Black Rubber
Washers
M3 x 40mm x
0.5mm Pitch Bolt
XT60 Connectors
and Velcro
Motor Extension
Cable
ESC for servo
Additional
Systems Battery
Springs
LEDs x20,
Require 4
Total
Spacer
4.09
0.68
0.68
Spacer
3.39
0.57
0.57
Spacer
3.59
1.20
1.20
Spacer
3.09
2.06
1.07
Fasteners
1.39
1.11
1.11
Cable Ties
0.99
0.99
0.99
O-Rings
4.24
3.60
3.60
Hinge
2.90
0.97
0.97
Tubing
5.28
2.53
0.65
Cable Protection
19.35
1.55
1.55
Strobe controller
Black Rubber
Washers
4.49
4.49
4.49
4.39
4.39
4.39
Fasteners
1.79
0.72
0.72
Connectors and
Fasteners
14.29
14.29
8.87
Wires
15.80
9.88
9.88
8.40
8.40
8.40
8.50
8.50
8.50
1.60
11.98
2.40
2.40
1062.48
954.80
906.18
Batteries
Lights
178
Material Properties
179
1 - Al Alloy
(MIL-HDBK-5H)
Material ID
4 - Nylon 6
[TECAMID-6-MOBlack]
(Ensinger, 2015a)
3 - Nylon 66
2 - Brass
[TECAMID-66-MO- (Diehl, 2015)
Black]
(Ensinger, 2015b)
Brass M3x25
F/F Spacers.
BP-001,
BP-002,
PB-004 &
PB-005
FA-001,
MA-001,
UV-001 & UH001
Property
Value
Density
Youngs Modulus
Poissons Ratio
Bulk Modulus
Shear Modulus
Tensile Yield Strength
Compressive Yield Strength
Ultimate Tensile Strength
Density
Youngs Modulus
Poissons Ratio
Bulk Modulus
Shear Modulus
Tensile Yield Strength
Ultimate Tensile Strength
Density
Modulus of Elasticity (Flexural)
Poissons Ratio
Bulk Modulus
Shear Modulus
Tensile Yield Strength
Ultimate Tensile Strength
Density
Modulus of Elasticity (Flexural)
Poissons Ratio
Bulk Modulus
Shear Modulus
Tensile Yield Strength
Ultimate Tensile Strength
= 2770 kg/m3
= 7.1E10 Pa = 71 GPa
= 0.33
K= 6.9608E10 Pa = 69.6 GPa
G= 2.6692E10 Pa = 26.6 GPa
TYS= 280 MPa
CTS= 280 MPa
UTS= 310 MPa
= 8450 kg/m3
= 1.15E11 Pa = 115 GPa
= 0.331
K= 1.1341E11 Pa = 113.4 GPa
G= 4.3201E10 Pa = 432 GPa
TYS= 160 MPa
UTS= 270 MPa
= 1150 kg/m3
= 3100 MPa
= 0.4
K= 4.1667E9 Pa = 4.1667 GPa
G= 8.9286E10 Pa = 89.28 GPa
TYS= 83 MPa
UTS= 84 MPa
= 1140 kg/m3
= 3100 MPa
= 0.4
K= 4.1667E9 Pa = 4.1667 GPa
G= 8.9286E10 Pa = 89.28 GPa
TYS= 82 MPa
UTS= 84 MPa
Density
Modulus of Elasticity (Flexural)
Poissons Ratio
Bulk Modulus
Shear Modulus
Tensile Yield Strength
Ultimate Tensile Strength
= 1800 kg/m3
= 3100 MPa
= 0.41
K= 5.7407E9 Pa = 5.7407 GPa
G= 1.0993E9 Pa = 1.0993 GPa
TYS= 55 MPa
UTS= 56 MPa
Material Properties
180
7 PVC Rigid
Angle
(Direct_Plastics,
2015)
6 - Austinitic Stainless
Steel - (Class 70, 304
grade - cold drawn)
(BSSA, 2015)
M3 & M5
Fasteners and
Nyloc Nuts.
PB-001,
PB-002,
PB-003,
PB-006,
PB-007 &
PB-008
Density
= 8030 kg/m3
Modulus of Elasticity
Poissons Ratio
Bulk Modulus
Shear Modulus
Tensile Proof Strength (0.2% R1, P0.2)
Ultimate Tensile Strength
Density
Modulus of Elasticity (Flexural)
Poissons Ratio
Bulk Modulus
Shear Modulus
Tensile Yield Strength
Ultimate Tensile Strength
= 193 GPa
= 0.29
K= 134 GPa
G= 86 GPa
= 450 Mpa
UTS= 700 Mpa
= 1800 kg/m3
= 3100 MPa
= 0.41
K= 5.7407E9 Pa = 5.7407 GPa
G= 1.0993E9 Pa = 1.0993 GPa
TYS= 55 MPa
UTS= 56 MPa
181
Appendix. F
F.1.
A steady flight case scenario during which the UAV would be under maximum flight loads. This
would include: the motors producing the maximum amount of thrust, the UAV flying at maximum
velocity and maximum gust being applied in the opposite direction of flight. The steady flight case
analysis covers various conditions which the UAV will be put under such as, take-off, manoeuvres
during flight and hover.
Section by Zuber Khan
F.2.
Maximum flight speed would be achieved when the UAV is at a maximum tilt angle of 54 degrees
(Section 7.1) to the vertical. Using this along with the total surface area of the main body plates,
the Drag force could be calculated.
54
Total Projected
Area
()
= 28420.532
35129.71
Equation 18 - Projected Area
For steady flight the motors produce enough thrust to balance the weight. Therefore the mass was
7
is by 4. 4 = 1.75. However this would not be the thrust when in flight due to the UAV being at
an angle of 54 degrees. Therefore a component was taken as shown below.
()
1.75Kg
54
T
To calculate the drag force, the following equation is used:
1
= 2
2
Equation 20 - Drag Equation (R. H. Barnard, 2010)
Where: D = Drag Force, p = Density, V = Velocity, S = Area, Cd = Coefficient of Drag
The maximum gust the UAV has to fly in is 25knots and the maximum allowable flight speed of the
UAV is restricted to 60knots. Therefore the maximum wind on the UAV would be 85Knots.
A Cd value for the plate was worked out using, (1.28 x sin(angle)) (NASA, 2014).
1
1.28 sin(54) = 1.0355
= 2 1.226 (85 0.5144)2 28420.53 106 1.0355
= 34.491
= 3.516 is the drag force equivalent distributed on the main plate. To this a
global load safety factor of 1.5 was added for the purpose of working out the Maximum stresses
and deflections. 1.5 3.516 = 5.274
Stress Analysis
182
A gain in fatigue life can in most situations be achieved without an increase in cost, simply by
attention to design detail. The following should be taken into account when considering the QuadRotor structure:
Avoiding sharp edges, corners and sudden changes in cross-section can reduce stress
concentrations. Fillet and intersection radii should be as large as possible as such used in
the Lug Bracket (LB-003) and Pivots (AP-001 & LP-001).
Avoiding joggles in the load line or catering for joggles by additional stiffening to bridge the
joggles. Considering the combined loading effect of cut outs and holes in close proximity as
those used in the Main Body Plates and Motor Mount Plates (BP-001, BP-002 and MP001). A detail hand calculation using Petersons Stress Concentration Factors (Pilkey and
Pilkey, 2008) has not been carried out as this complex geometry and cut-outs are
previously considered in the Finite Element Model with mesh refinement, inflation and
pinch controls.
The majority of fatigue cracks will start at stress concentrations such as holes, notches, etc.
Any design features or processes that can be applied to reduce the severity of such stress
concentrations should be used.
Ensuring design of joints are such as not to give rise to built-in stresses on assembly, or
load some portions of the joint unduly. The use of M3 and M5 from the same supplier to
avoid mixing fasteners of dissimilar material/strength and those that require differing
tolerances of fit. Fasteners with tighter tolerances will load the local structure during
repeated flexure more than a loose tolerance fastener due to the miniscule freedom of
movement of the joint.
In fatigue critical areas, interference fit fasteners shall be used whenever possible in
preference to clearance fit. A close tolerance for clearance/transition fit fasteners will
improve the fatigue performance of the joint, as this will minimize the risk of individual holes
being over-loaded. For the current Quad-Rotor design, fasteners are loaded axially hence
UAS CHALLENGE 2015
Stress Analysis
183
introducing a bolt pre-load and reducing the miniscule movement if any existed.
Pre-tensioning of the bolt can reduce alternating stresses in the bolt and improve its fatigue
performance. The correct seating of the fastener head and nut along with use of the correct
installation torque is therefore essential to avoid local bending.
Fatigue damage can often arise from induced vibration from the motors as compared with
fatigue damage arising from directly applied structural stresses. Often this vibration is not
sustained for long periods of time, a modal analysis case has been considered for the
Fixed-arm assembly as shown in Appendix 8.17 and compared to analytical methods as
shown in Appendix 8.16. Such calculated modal frequencies should be avoided or swiftly
passed through the first 3 natural frequencies when powering up the motors to idle and can
be programmed into the ESCs as soft, medium, hard starts.
Avoiding the use of long cantilevered members, as these will experience high inertia forces
in vibration. The modal analysis of the Arm has been the main concentration for the
purpose of frequency response analysis, as the cantilever of the Arms are more
susceptible to vibration than any other components.
Rigidly mounted equipment may be vibrated by the structure to which it is attached, hence
the use of O-Rings at the motor mounts and dampening foam being used on all sensitive
components such as Pixhawk due to its susceptibility to compass excitation during
vibration.
Stress Analysis
184
Rough
The rough connection is similar to the frictionless type however models perfectly rough frictional
contact where there is no sliding. Alternative connection types are also possible where friction
factors can be modelled, however increases solution time significantly and for the purpose of this
analysis is deemed unnecessary. Rough connections apply to regions of faces or edges of plates,
brackets and O-ring locations (Appendix B.7). By default, no automatic closing of gaps is
performed and corresponds to an infinite friction coefficient between the contacting bodies (Ansys,
November 2013a).
The rough connection had been replaced by No Separation connections in motor plate regions
(MP-001 to EB-001 & FB-001) for the entire quad analysis and landing cases (Appendix G.14).
Using this method, the solution time is reduced and allows for accurate stress solutions at the root
of the quad-rotor as non-linearity is previously demonstrated in the arm stress analysis (Appendix
G.7 and G.8)
No Separation Rigid Body
The No Separation contact setting is similar to the bonded case and only applies to regions of
faces or edges. Separation of the geometries in this contact connection is not permitted (Ansys,
November 2013a). The No Separation connection is used in the motor plate regions (MP-001 to
EB-001 & FB-001) for the entire quad analysis and landing cases (Appendix G.14). Once again,
solution time is reduced and allows for accurate stress solutions at the root of the quad-rotor as
non-linearity and friction contact has previously been demonstrated in the arm stress analysis
(Appendix G.7 and G.8).
Bolted Rigid Body
For modelling bolted connections in Ansys Workbench an MPC184 Revolute Joint Element is used
instead of Rigid Body Elements (RBE2 or RBE3) used in Ansys Mechanical APDL or NASTRAN.
The MPC184 revolute joint is a two-node element that has only one primary degree of freedom,
the relative rotation about the revolute (hinge) axis. The Revolute joint is similar to modelling a
Beam Line Element at the bolt location alongside using RBEs to average the bearing pressure
loading at hole contact surfaces. This element imposes kinematic constraints such that the nodes
forming the element have the same displacements. Additionally, only a relative rotation is allowed
about the revolute axis, while the rotations about the other two directions are fixed (Ansys,
November 2013a, Ansys, November 2013c).
Spring
For the landing consideration a compression spring has been modelled between components (LB002 and LP-001 (Appendix B.7)). The compression stiffness was set to 300 N/mm and the
damping was set to 0 N.s/mm for an initial deflection analysis. The solution is yet to converge due
the increased DOF solution from the Ansys modeller.
Stress Analysis
185
Augmented Lagrange solver method has been used for the majority of contact models involving
Bonded and No separation contact, as it is a penalty-based method. In comparison to the Pure
Penalty method, this method usually leads to The Augmented Lagrange method requiring
additional iterations, especially if the deformed mesh becomes too distorted (Ansys, November
2013g). In some analysis cases, Program Controlled or the Pure Penalty method is used for
decreasing the solution time and iterations. Such cases include the landing case where solution
time is significant due to the Degrees of Freedom of the Undercarriage components.
G.6. Mesh
Element Types Used
SOLID187
The SOLID187 element used as per Table 26 is a high order 3 dimensional, 10-node element. The
SOLID187 has a quadratic displacement behaviour and is well suited to modelling irregular
meshes (Ansys, November 2013c).
The element allows for having 3 DOF
at each node: translations x, y, and z
directions. The element has large
deflection and strain capabilities;
alongside plasticity, hyperelasticity,
stress stiffening and creep capabilities.
Stress Analysis
186
Mesh Refinement
The process of mesh refinement is a post mesh generation step in which elements on the selected
parts are split and refined. The process of mesh refinement has only been used for small subassemblies where the local features are to be studied, for example in the arm stress cases and
motor mount plates. Local mesh refinement has been used on main body plates for entire quadrotor flight analysis cases at the hole and cut-out locations and has been removed at the arms and
motor plate regions to decrease computing time. Mesh refinement being removed from such
regions is no longer important as the parts have been justified in another upstream analysis case.
Contact Pinch Controls and Inflation
Pinch controls have been used at contact positions where removal of small features (such as short
edges and narrow regions) at the mesh level. Pinch control helps to generate better quality
elements around such contact positions as the nodes are aligned and shared between mating
components. The Pinch control provides an alternative to Virtual Topology modeling used at
geometry level. Both Virtual Topology and Pinch Controls work together to simplify meshing
constraints due to small features such as edge chamfers and corner radii and grooves. To further
ensure the mesh and analysis was efficient, such small features had been removed in a separate
simplified CAD model, which also removed fasteners and small non-structural components.
Inflation is used in certain locations where high stress concentrations exist and involves additional
layers or elements surrounding the feature under question. An example of where inflation has
been used is at the Motor plate fastener positions (Table 26).
Stress Analysis
187
Material ID
(Appendix. E)
1
Property
Value
Element
Type
Type of
Mesh
Size (Aspect
Ratio)
Refinement
Inflation
FB-001
FB-002
MB-001
EB-001
LB-001
LB-002
PB-009
PB-010
FA-001
MA-001
UV-001
UH-001
Pinch
Controls
Element
Type
Type of
Mesh
Size (Aspect
Ratio)
Refinement
Inflation
Pinch
Controls
Element
Type
Types of
Mesh
Size (Aspect
Ratio)
Refinement
Inflation
Pinch
Controls
TET10 SOLID187
1.15 (Min)
9.5 (Max)
2.5 (Ave)
Level 2 @ 40 Hole
and Slot Faces
3 Layers at Bolt
Interface Positions Growth Rate 1.2
Default at Bolt
Locations
Solid Tet 10 node
TET10 SOLID187
1.3 (Min)
26 (Max)
2.8 (Ave)
None
None
None
Plane Quad 4 Node
PLANE182 /
QUAD182, [PATRAN
Conversion:
WEDGE15, HEX20]
1.28 (Min)
26.4 (Max)
2.82 (Ave)
None
None
None
Image
Stress Analysis
LB-003
LP-001
AP-001
Element
Type
Types of
Mesh
Size (Aspect
Ratio)
Refinement
Inflation
Pinch
Controls
Element
Type
Types of
Mesh
Size (Aspect
Ratio)
Refinement
Inflation
Pinch
Controls
TJ-001
TJ-002
Element
Type
Types of
Mesh
Size (Aspect
Ratio)
Refinement
Inflation
Pinch
Controls
BP-001,
BP-002,
PB-004 &
PB-005
Element
Type
Types of
Mesh
Size (Aspect
Ratio)
Refinement
Inflation
Pinch
Controls
188
Stress Analysis
PB-001,
PB-002,
PB-003,
PB-006,
PB-007 &
PB-008
Element
Type
Types of
Mesh
Size (Aspect
Ratio)
Refinement
Inflation
Pinch
Controls
Table 26 Mesh Attributes for Components
189
Stress Analysis
190
F2
F1
D
1
D
2
Transferring loads from F1 to F2 required a moment transfer using:
=
Equation 21 Moment Calculation
Fixed-arm
Full Arm length of 0.23m
1 = (1.75 9.81) 0.23 = 3.9485
Equation 22 - Moment for Fixed Arm
The moment can then be transferred to the first Nylon clamp where D1 =0.06m. Which can then be
used to find out the force that will be applied on the Nylon clamps.
3.9485 = 2 0.06
2 = 65.81
Maximum Fixed Arm Stress
Maximum force was applied to represent maximum thrust produced by the motor. The thrust was
then multiplied by the global load safety factor of 1.5.
0.17m
D1=0.016
Reaction
m
Moment
0.23m
Force
D2=0.0115
m
21
=
=
4
4
64 (1 2 )
Equation 23 - Stress in a Cylindrical Pipe (Warren C. Young)
Compression
Tension
When the motors are on full thrust the arm will be under
maximum compression on the top surface and under
maximum tension on the bottom surface as shown in Figure
109.
Stress Analysis
191
=
= 14416251.37 2
(0.0164 0.01154 )
64
= 14.42 () & 14.42 ()
Stress analysis at Fixed-arm FEA Method
Mesh: Values as per section G.6
Figure 110 Mesh for Fixed-arm Assembly Values as per Appendix G.6
Results:
Figure 111 - Deflection of Fixed-arm Assembly (Flight Loads) with 7.6mm Deflection
Stress Analysis
192
Figure 112 - Stress of Fixed-arm Assembly (Flight Loads) with Stress 15.8MPa (Contact)
and 20MPa (Peak)
Figure 113 Stress (Close-up) of Fixed-arm Assembly (Flight Loads) with Stress 15.8MPa
(Contact) and 20MPa (Peak)
FEM Verification: Tube Stress Comparison
One can observe the results from the above analytical stress calculation being 14.42MPa and the
stress level as seen in the far field stress contour of the tube in Figure 109 (15.8MPa) being very
close. Substantiation of the numerical modelling and contact constraints can be deemed as
accurate as a very small difference is observed between the methods.
Stress Analysis
193
2
=
= 15264266.16 2
(0.0164 0.01154 )
64
= 15.26 () & 15.26 ()
25 0.18
The yield strength of the material used for the arms is 55MPa (Appendix. E). One can observe that
the arms have a minimum of 3.6 reserve factor remaining, in addition to the added factor of 1.5 for
the global safety. From this analysis, it can be justified that the arms at this size and with the
properties defined in Appendix. E are suitable for the UAV.
FEA Method for Movable-arm
Mesh: Values as per section G.6
Figure 114 Mesh for Arm Assembly (With additional Tab) Mesh Values as per G.6
Stress Analysis
194
Results:
Figure 116 - Stress Concentration at Arm (without addition) Contact (a) & Close-up (b)
Modified FB-002 Bracket with Tab Addition
Benefits Increased fatigue resistance and larger Non-Linear contact area, which is important for
repetitive loading and general contact stress reduction. Point contact is now a Line contact (for
Non-Linear Flexure) and Line contact is now a Surface Contact (for Linear Flexure).
Stress Analysis
195
Figure 117 - Deflection of Modified Movable Motor Arm of 7.88mm for flight loads with SF
Figure 118 - Stress of Modified Movable Motor Arm of 20.8MPa for flight loads with SF
Figure 119 - Modified Movable Motor Arm with Stress of 20.8MPa for flight loads with SF (a)
& Close-up (b)
Stress Analysis
196
PA
W
PT
A2
A4
0.707
1 = ((
)(
))
2
2
25
0.707 5
1 = (( ) (
)) 4.5 = 48.292
2
2
Equation 25 - Area A1 on Lug (Niu, 1988)
45'
A1
A3
PT
) AreaA2
Thickness = ( ) . =
= (
Width-Diameter
(
)
2
Stress Analysis
197
() = = 4.5 5 = 22.52
Equation 30 - Bearing Area on Lug (Niu, 1988)
= 2.095
Using 2.095 and the tension efficiency graph a Ktu & Kty value of 0.923 was
determined.
Therefore the allowable traverse load = Ktu x Abr x Ftu = 1765.15
1765.15
Therefore the reserve factor for the lug is: . = 72.84 = 24.23
From this one can conclude that the lug is more than sufficient for the purpose of this UAV.
Lug Analysis Using FEA Methods with Flange addition
Section by Amit Ramji
Mesh: Values as per section G.6
Results:
Previous Lug Bracket without Flange
To improve the stress distribution within the Lug bracket (LB-003) for the Undercarriage, additional
flanges have been incorporated to distribute the load evenly to the fastened plate face. It proves
beneficial to repeated heavy landings and side impact cases.
Figure 123 - Lug Bracket Without Flange (Left) & with additional Flange (Right)
Stress Analysis
198
Figure 124 Lateral Unit Load Deflection (Left) & Stress (Right) of Lug Bracket Without
Flange
Modified Lug Bracket with Flange Addition
Benefits Increased fatigue resistance and multiple load paths which is important with repetitive
heavy landing and sideward crash cases.
Figure 125 Lateral Unit Load Deflection (Left) & Stress (Right) of Lug Bracket With Flange
Stress Analysis
199
Figure 126 - Mesh for MP-001 (Appendix B.7) with values as per Appendix G.6
Results:
Figure 127 Motor Plate Deflection (0.038 mm) and Stress (41.7 MPa) for flight case with SF
at start-up
Figure 128 - Error Elements in Model - Due to Separation at FB-001 and EB-001
Stress Analysis
200
Y = b
280mm
X = a
315mm
(, ) = sin
sin
=1 =1
2
2
= 11 sin sin
+ 12 sin sin
+ 21 sin
sin
+
= 4
2
2
2
[( 2 ) + ( 2 )]
33.8445
=
= 383.72 2
6
88200 10
Stress Analysis
201
w11 =
w13 =
w31 =
33 =
1
2.61905
1
2.61905
1
4 2.61905
4
1
2.61905
622.063
12
12
)
+
(
)]
[(
0.3152
0.282
207.35
12
32
= 4.67689 103
= 5.21215 105
= 7.59333 105
= 6.41566 106
)+(
)]
[(
0.3152
0.282
207.35
32
12
)+(
)]
[(
2
0.315
0.282
69.12
32
32
)
+
(
)]
[(
0.3152
0.282
The coefficients were then input into the Navier solution equation to calculate the deflection at the
centre.
0.1575
0.14
0.1575
(, ) = 4.67689 103 sin (
) sin (
) + 5.21215 105 sin (
)
0.315
0.28
0.315
3 0.14
3 0.1575
sin (
) + 7.59333 105 sin (
)
0.28
0.315
0.14
3 0.1575
3 0.14
sin (
) + 6.41566 106 sin (
) sin (
)
0.28
0.315
0.28
w(x, y) = 4.67689 103 5.21215 105 7.59333 105 + 6.41566 106
w(x, y) = 4.555 103 m = 4.555mm
Section by Zuber Khan
FEA Simplified Rectangular Approximation
Using Catia the same plate was modelled with the same constraints and loads to see the
deflection it would cause.
Figure 130 - Simple Plate Deflection Carried out on CATIA structural analysis
Stress Analysis
202
From the FEA model it can be observed that the deflection has been calculated to be 4.54mm.
The mesh used was set to a size of 2mm with absolute sag of 1.5mm. Therefore any further plate
bending analysis carried out on CATIA, should be set to the same mesh size and constraints as it
has been substantiated to provide accurate answers.
Method
Deflection
Analytical (Rectangular Plate)
4.555mm
FEA CATIA (Rectangular Plate)
4.54mm
Table 27 Comparison of Simplified Plate Deflection for Model Substantiation
FEA As Built (Single Plate) Ansys Results
Mesh: Values as per section G.6
Figure 131 - Mesh of Main Body Plate - Values as per Appendix G.6
Results:
Figure 132 Single Main Body Plate Analysis with 17.8MPa Stress at contact holes for
flight case with pressure load
Stress Analysis
203
Representation: In order to carry out a quick analysis of the main body assembly, point masses
for the payload, systems and batteries had been added to the structure with the masses defined in
Appendix. C.
Figure 134 - Mesh of Main body assembly with Values as per Appendix G.6
Results:
Figure 135 Contact model Flight Case for Main body assembly Deflection (left) and
Equivalent Stress (right)
Stress Analysis
204
Figure 136 - Contact model Flight Case for Main body assembly - Equivalent Stress with
predicted locations
( 4 4 ) =
(0.0164 0.01154 ) = 2.35845 109 4
=
64
64
UAS CHALLENGE 2015
Stress Analysis
205
Radius of Gyration, =
Slenderness Ratio,
20.18
4.926103
= 4.926 103
2 3100106
55106
73.082 23.586 Therefore the buckling formula can be used for this scenario.
The critical load which would cause the leg to buckle is shown below.
=
= 556.78
This demonstrates that approximately 56.76Kg landing on one leg would cause the leg to buckle, if
the leg was pointing vertically down.
To get a more accurate buckling load, the component of that was taken.
556.78N
A
45
cos 45 =
= 393.7 = 40.13
556.78
D=178mm
F
F
Figure 138 - Undercarriage Leg Under Pure Bending
Stress caused on the undercarriage leg due to pure bending has been calculated below. The
assumptions made for the calculation was that the pivot was treated as fixed which considered a
jam or lateral crashing load. Another assumption made was that the t-joint at the bottom of the leg
was also treated as rigid. The force applied on the leg was the full weight of the craft, which was
multiplied by 1.5 (Global load safety factor).
Stress Analysis
206
21
=
=
4
4
64 (1 2 )
0.016
7 1.5 9.81 0.178 2
0.14668
=
=
= 62193016.6 = 62.2
2.35845 109
(0.0164 0.01154 )
64
62.2MPa is the maximum stress the leg would undergo under pure bending if the UAV were to
land on one leg. This would cause the leg to yield however the load applied is excessive and it is
applied only to one leg, which would not occur repeatedly. Additionally this analysis does not
consider the entire body deflection that would dramatically reduce the stress levels. In this
calculation, the pivot is assumed to be fixed with infinite stiffness, however in reality this cannot be
true, as the main assembly would also deflect.
Working backwards using Equation 23 the max force could be found out which would cause the
undercarriage leg to yield.
55 106 =
0.178 0.008
= 91.0918 = 9.29
2.35845 109
9.29Kg is the force required in pure bending to cause the leg to yield. This is a significantly low
load, however in reality the UAV would land on both legs repeatedly therefore this force could be
doubled. The undercarriage design proposes to incorporate springs to help reduce the impact
force on the structure and provide some give by allowing for a designed deflection.
Analytical Undercarriage leg Torsion
Stress Analysis
207
Buckling
Load
Bending
Figure 140 - StressLoad
Element A (Warren C. Young)
Using the stress element A as shown in Figure 140, the equations of combined load can be used.
A plan view of element A has been shown below.
Stress Analysis
208
The formulas used to work out the combined stress and their principle angles have been shown
below.
21
=
=
4
2 4 )
64 (1
Equation 23 - Stress in a Cylindrical Pipe (Warren C. Young)
11.5
0.016
71.50.178
2
= (0.0164
= 6.34
0.01154 )
64
71.50.1759.818
= 30.572
4716.878884
-34.495
27.095
Stress Analysis
209
The maximum shear caused by the combined loadings has been calculated below using Equation
45.
1
2
= ( ) + 4 2
2
Equation 45 - Shear Due to Combined Loadings
1
Figure 143 - Undercarriage Mesh for Contact Model with values as per G.6
FEA Results Bending Lateral Crash Landing
Figure 144 Lateral Landing on Single Undercarriage Leg with 53.6mm Deflection
Stress Analysis
210
Figure 145 - Lateral Landing on Single Undercarriage Leg with 60MPa Bending Stress
Figure 145 and Figure 146 show the results of the bending analysis to be 60MPa. The analytical
bending calculation from above also results in a similar bending stress of 62.2MPa. The
justifications on yielding in the above section still hold true for this analysis.
As above, the entire
structure will deform and
reduce
stress
hence
60MPa is not a realistic
situation.
This
infinite
stiffness constraint can be
solved by finer mesh and
adding
a
spring
(Deformable support) with
the stiffness of Nylon at
the Lug bracket holt-holes.
Lateral
Single
Stress Analysis
211
Figure 147 - Tip Landing on Single Undercarriage Leg with 60MPa Bending Stress
FEA Results Combined Torsion and Bending Tip Contact
Figure 148 -Tip Landing on Single Undercarriage Leg with 66mm Combined bending and
torsion deflection
As with the Lateral bending and Tip landing cases above, the entire structure will deform and
reduce stress, hence 71MPa is not a realistic situation. This infinite stiffness constraint can be
solved by finer mesh and adding a spring (Deformable support) with the stiffness of Nylon at the
Lug bracket holt-holes. Additionally the T-Joint in this analysis is considered as a rigid body,
however there will be some deflection at the T-Joint, which will reduce the stress upstream. The
reason for regarding the T-Joint as rigid in the analysis is to reduce computing time as such a nonlinear solution is very lengthy to set-up and run
Stress Analysis
212
Figure 149 - Tip Landing on Single Undercarriage Leg with 71MPa Combined bending and
torsion stress
FEM Verification Summary or Undercarriage Results
Case
Description
Deflection (mm) or
(deg)
Buckling Analytical Axial loading of UV-001
N/A
Bending Analytical
N/A
Bending of UV-001
Bending FEA
53.6 mm
Torsion Analytical
Torsion of UV-001
35.85 deg
Combined
Combined Bending and N/A
Analytical
Torsion of UV-001
Combined FEA
66.76mm
Table 28 Summary of Undercarriage Results
Stress Analysis
213
Figure 150 Entire Quad-Rotor Flight Deflection of 7.9mm at Motor Arm Tips
Figure 151 - Entire Quad-Rotor Flight Deflection of 7.9mm at Motor Arm Tips (Close-up)
Figure 152 - Entire Quad-Rotor Flight Stress of 28.8 MPa at Motor mount plates
Stress Analysis
Figure 153 - Entire Quad-Rotor Flight Stress with Plate Stress peak at 14.42Mpa
214
Stress Analysis
215
Figure 154 Downward Load - 1kg Payload and 10N Additional Load onto PB-005 Plate
Figure 155 - Side Load - 1kg Payload and 10N Additional Load onto Hinge Plate at 45deg to
horizontal
Stress Analysis
216
Figure 156 - Side Load - 1kg Payload and 10N Additional Load onto short edge 45deg to
horizontal
Figure 157 - Side Load as per Figure 156 - Showing Pre-mature Release due to global
deflection
Stress Analysis
217
Figure 158 Downward Load as per Figure 154 - new design showing 0.73mm Deflection
Figure 159 - Side Load as per Figure 155 new rigid design and Deflection of 1.56mm
Stress Analysis
218
219
MTOW 2 1.2
) = 2.8kg of thrust/motor
Number of motors
4. Identified performance criteria to complete the mission in 2minutes The mission consists of a
range of 2km, taking into account 2 minutes the velocity that the Hex-rotor requires to travel at is
16.67m/s (32knots) taking into account 12.8m/s (25knot) gust and 10.2m/s (20knot) wind the Hexrotor would require to travel at relative speed of 29.7m/s (57knots)
5. Propeller, Motor, ESC and Battery selection- It was very quickly identified that a low rpm/V brushless
electric motor was required so that it can use a large propeller with high pitch so that it can produce
the lift and thrust required but also not too larger of a propeller so the velocity isnt sacrificed. The
selection of these important components required the use of a sophisticated website called
ecalc.com and theoretical calculations, which identified 20 different combination of producing the
thrust required, velocity required and battery life that can last greater than 2 minutes. By performing
these calculations it helped to narrow down from countless number of propeller, motor, ECS and
battery combinations that would achieve the specification required. Specification of these
components can be found in Apendix E
6. Calculations using xcalc.com
As it can be seen from Appendix C the Turnigy G32-770kv motor has a maximum of 1000Watts. The
1000W is based on no load condition were a propeller is not attached to the motor, but these
conditions change when a propeller is added to the motors, the effect is that the added load reduces
the motors capability to 791.9W. The motor itself also has an efficiency factor of 0.882 which is
specified by the manufacturer that further reduces the motors capability to 698.2W
Performance Calculations
The flight profile for the Hex-rotor has been calculated using the flight path specified in Appendix C and the
performance calculations has been based on using the Turnigy G32-770 motor, APC-E 11x7 composite
propellers, 60A ESC and 16000mAh lipo batteries options include using 5S but cost constraints may result in
using multiple 3S or 4S. Results of the flight profile, velocity, time, distance covered and battery status are
presented below table 1.1.1
Location
Velocity (m/s)
Time (s)
[Runway]
100
[Runway]-[30.5m Altitude]
6.77
3.85
98.7
26.2
[30.5m Altitude]-[1]
15.932
16
92.5
(282-26)=255.8
0.875
92.2
[1]-[2]
15.932
50.78
66.5
(842-7-26)=809
[30.5m Altitude]-[descend to
1m]
6.77
3.85
65.3
26.2
Hover
N/A
64.5
N/A
From 1m to 30.5m
6.77
3.85
63.3
26.2
[30.5m]-[3]
15.932
24.6
51.8
(418-26.2)=391.8
0.875
51.5
[3]-[Target]
15.932
18.9
42.7
(334-7-26)=301
[30m Altitude]-[descend to
1m]
6.77
3.85
41.3
26.2
Hover
N/A
40.5
N/A
From 1m to 30.5m
6.77
3.85
39.1
26.2
[30.5m]-[Runway]
15.932
6.13
36.2
(124-26.2)=97.8
Hover
N/A
35
N/A
Total
N/A
152.41
(2.54
minutes)
N/A
2000
Sample Calculation
Max velocity calculation
Total Thrust = Max thrust per motor*number of motors*9.81
2
49
2 2
108
21.226 2
= 26.22m/s
220
0.267268.62
60
= 1.193Ah
14.8
16
100 = 92.5%
H.2. DATA
Figure: 1.1 shows lift (N) of 11*8 propeller at different RPM
Lift (N)
Lift Vs RPM
Graph
RPM
Range
RPM
7*6
221
Power Vs RPM
Graph
Power (W)
RPM
Power required
line for
propeller 7*6
Propeller Manufacturer
APC
1.11
Graunper
1.18
Aeronaut
1.31
222
9*7
9*7.5
9*8
9*9
9*10
10*3
10*4
10*4.7
10*5
10*6
10*7
10*8
10*9
10*10
11*3
11*3.8
11*5
11*6
11*7
11*8
11*9
18,750
20,000
18,100
20,000
17,800
20,000
17,500
20,000
17,000
20,000
16,550
20,000
18,550
20,000
17,000
20,000
16,570
20,000
16,400
20,000
15,600
20,000
15,000
20,000
14,600
20,000
14,100
20,000
13,750
20,000
15,700
20,000
14,800
20,000
13,900
20,000
13,200
20,000
12,700
20,000
12,300
20,000
12,000
1042
1476
1094
1582
1115
1130
930
1898
1165
2109
1195
965
770
1286
832
1511
859
1608
886
1929
915
2250
949
2572
1000
2893
1013
3215
1044
1412
683
1788
724
2353
790
2824
811
3295
843
3765
875
4236
915
35.02
43.04
35.24
44.55
35.28
46.01
35.22
48.80
35.26
51.43
35.22
40.73
35.05
47.04
35.20
50.99
35.00
52.59
35.36
57.62
35.05
62.22
35.00
66.52
35.45
70.56
35.07
74.37
35.15
56.87
35.04
64.00
35.05
73.41
35.46
80.42
35.03
86.87
35.02
92.86
35.12
98.50
35.46
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
223
11*10
12*6
12*8
13*4
13*6
13*8
13*10
14*13
15*6
17*10
20,000
11,700
20,000
11,350
20,000
10,600
20,000
10,900
20,000
9,900
20,000
9,200
20,000
8,700
20,000
7,150
20,000
7,700
20,000
5,450
4707
942
4000
731
5333
764
3672
594
5509
668
7345
715
9182
755
16056
733
9765
557
26852
543
103.82
35.53
109.06
35.12
125.93
35.37
117.83
35.00
144
35.36
166.70
35.26
186.31
35.25
275.33
35.19
238.14
35.29
476.45
35.37
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Table: 1.3 shows a section of table 1.2 with propeller dimensions 9*6
Rpm
9*6
20,000
1265
39.84
18,750
1042
35.02
Table: 1.4 shows a section of table 1.2 with propeller dimensions 17*10
Rpm
17*10
20,000
26852
476.45
5,450
543
35.37
224
225
Manufacturer Power KV
Max
/Model
(W) (rpm/V) Current
(I)
Working
Current
(I)
Power
Supply
Cell
Range
(s)
Propeller
Dimension
Range (in)
Weight
(g)
Cost
()
Max
RPM
BRC HOBBIES
PRODUCTS
EMax
GT2820/07
600
850
54
48
3-4
9*4.7 12*6
140
20.95
10064
A2826-5T
645
840
45
37.6
12*6 13*6.7
175
27.70
9945
Emax
BL2820-07
740
919
59
33.5
3-4
10*5 13*6
145
17.95
10880
Emax
GT2826-06
962
710
52
42
4-5
10*5-14-7
175
23.95
12987
Emax
GT3526-04
875
870
69
55
3-4
12*6-13*6.5
265
32.95
10300
Boost 0.50
800
600
55
45
3-5
12-13
295
62.95
8880
Boost 0.60
900
490
60
50
4-6
13-14
345
69.95
8702
Boost 0.80
950
340
60
52
5-7
14-15
395
79.95
7044
Boost 0.90
1000
300
65
55
6-9
16-17
455
79.95
7992
12-15
303
34.43
8140
159
13.30
13024
HOBBY KING
PRODUCTS
Turnigy G46
925
550
55
46
4-5
Turnigy
D3548/4
910
1100
50
45
3-4
Turnigy
D3542/4
690
1450
48
42
2-3
10-12
130
13.60
12876
Turnigy
2834-800
660
800
45
40
2-4
10-12
195
22.38
9472
226
Turnigy
3508-640
550
640
30
25
2-5
10-13
98
20.05
9472
Turnigy
3639
800
1100
45
38
2-3
11-13
136
17.39
9768
Turnigy SK3
3542
670
1000
45
40
3-4
11-12
141
18.63
11840
Turnigy
L3020B
800
600
54
48
3-4
10-12
146
14.59
5328
Turnigy
4250
900
540
60
55
3-5
9-12
236
13.80
7992
NTM 35-30
560
1400
37
32
9-13
88.3
12.23
12432
NTM 35-36
722
800
43
34
3-4
9-15
130
16.84
9472
NTM 35-42
600
1250
56
42
3-4
10-11
142
18.64
14800
NTM 35-48
640
1100
70
62
3-4
11-13
173
14.61
13024
Scorpion SII3026
1000
710
60
55
4-5
12-15
205
83.74
10508
Scorpion SII3014 V2
600
1040
40
35
3-4
11-14
129
67
12313
Scorpion SII3014
550
830
30
25
4-5
10-15
129
61.63
12284
Scorpion SII3020
780
890
45
40
4-5
10-14
166
73.69
13172
Quanum MT
4010
548.3
580
24.7
20
4-6
9-12
127
23.818 10300
Quanum MT
3510
568.3
630
25.6
18
3-6
9-11
100
16.52
11188
Quanum MT
3510 V2
672.7
700
30.3
24
3-6
10-12
100
16.52
12432
4-MAX
Professional
Series
3542-1000
605
1000
60
55
2-4
12-14
142
33.49
11840
Professional
Series
590
1250
60
55
2-4
11-14
142
33.49
14800
227
3542-1250
Professional
Series
3548-790
850
790
50
45
3-4
11-12
171
35.99
9353
Professional
Series
3548-900
840
900
50
45
3-4
11-13
171
35.99
10656
Professional
Series
3548-1100
850
1100
50
45
3-4
11-12
171
35.99
13024
Professional
Series
4250-650
1150
650
60
55
3-4
12-14
230
48.95
13616
E-FLITE
Power 32
800
770
60
45
4-5
11-14
200
50.27
11396
Power 15
575
950
42
34
3-4
10-13
152
43.57
11248
Power 60
1000
470
80
65
5-6
15-17
230
73.73
8347
Power 46
925
670
55
40
5-6
12-14
290
60.32
11899
Power 25
600
870
44
32
3-4
11-14
190
46.92
10300
Power 25BL
850
1250
58
50
3-4
8-10
183
46.92
14800
Table: 1.6 shows a section of table 1.5 for motor model EMax GT2820/07
Manufacturer Power
KV
Max
/Model
(W) (rpm/V) Current
(I)
EMax
GT2820/07
600
850
54
Working
Current
(I)
Power
Supply
Cell
Range
(s)
Propeller
Dimension
Range (in)
Weight
(g)
Cost
()
Max
RPM
48
3-4
9*4.7 12*6
140
20.95
10064
228
Table: 1.6 shows a section of table 1.5 for motor model EMax GT2820/07
Manufacturer Power
KV
Max
/Model
(W) (rpm/V) Current
(I)
EMax
GT2820/07
600
850
Working
Current
(I)
Power
Supply
Cell
Range
(s)
Propeller
Dimension
Range (in)
Weight
(g)
Cost
()
Max
RPM
48
3-4
9*4.7 12*6
140
20.95
10064
54
Table 1.2.1 shows updated version of table 1.2 taking into account motor capabilities
Rpm
10*8
20,000
2572
66.52
14,600
1000
35.45
20,000
2893
70.56
14,100
1013
35.07
20,000
3215
74.37
13,750
1044
35.15
20,000
1788
64.00
14,800
724
35.05
20,000
2353
73.41
13,900
790
35.46
20,000
2824
80.42
13,200
811
35.03
20,000
3295
86.87
12,700
843
35.02
20,000
3765
92.86
12,300
875
35.12
20,000
4236
98.50
12,000
915
35.46
20,000
4707
103.82
11,700
942
35.53
20,000
4000
109.06
10*9
10*10
11*3.8
11*5
11*6
11*7
11*8
11*9
11*10
12*6
UAS CHALLENGE 2015
12*8
13*4
13*6
13*8
13*10
14*13
15*6
17*10
11,350
731
35.12
20,000
5333
125.93
10,600
764
35.37
20,000
3672
117.83
10,900
594
35.00
20,000
5509
144
9,900
668
35.36
20,000
7345
166.70
9,200
715
35.26
20,000
9182
186.31
8,700
755
35.25
20,000
16056
275.33
7,150
733
35.19
20,000
9765
238.14
7,700
557
35.29
20,000
26852
476.45
5,450
543
35.37
Table: 2.0 shows maximum rpm required at different propeller pitch setting to achieve 29.46m/s
(degrees)
29.46
32
20,371
29.46
32
19,352
29.46
32
15,481
29.46
32
12,901
29.46
32
11,058
29.46
32
9,676
29.46
32
8601
10
29.46
32
7740
13
29.46
32
5954
Propeller Pitch
(in)
(m/s)
3.8
229
Table 1.2.2 shows updated version of table 1.2.1 taking into account motor capabilities
Manufacturer
Turnigy nano-tech
Turnigy nano-tech
Multistar
Turnigy nano-tech
Zippy
Turnigy nano-tech
Turnigy power
Turnigy nano-tech
UAS CHALLENGE 2015
230
Zippy
Turnigy nano-tech
Turnigy nano-tech
Turnigy nano-the
Turnigy power
Zippy
Turnigy nano-tech
Zippy
Turnigy power
Turnigy power
Turnigy nano-tech
Zippy
Zippy
Turnigy nano-tech
Turnigy nano-tech
Turnigy power
Turnigy power
Zippy
Zippy
Turnigy nano-tech
Turnigy power
Turnigy nano-tech
Turnigy nano-tech
Turnigy nano-tech
Turnigy nano-tech
Zippy
Turnigy power
Turnigy nano-tech
Zippy
Zippy
Turnigy nano-tech
Zippy
Turnigy power
Zippy
4
4
4
4
4
4
5
5
5
5
5
5
5
5
6
6
6
6
6
6
6
6
6
7
7
7
7
8
8
8
8
8
8
9
4000
4500
5000
6000
7200
8000
4000
5000
5000
5000
5000
5000
8000
8000
4000
4500
5000
5000
5000
5000
5800
6000
8000
4500
5000
5000
5000
4400
4500
5000
5000
5800
5800
5000
20/30
25/50
65/130
25/50
40/80
30/40
25/50
45/55
25/30
30/40
35/70
20/30
30/40
25/50
25/50
30/40
35/45
20/30
30/40
25/50
25/35
25/50
25/50
65/130
65/130
25/35
60/120
65/130
35/45
25/35
65/130
25/35
25/35
25/35
399
467
576
623
840
845
525
732
677
695
659
640
1054
924
623
745
812
754
784
769
914
908
1105
895
978
818
1025
1012
911
937
1106
1025
1216
1021
19.98
31.00
53.71
46.08
48.36
42.83
31.99
46.57
33.12
39.53
47.73
29.19
53.65
63.87
38.36
51.84
44.52
35.60
41.30
51.66
55.58
57.48
78.56
66.99
66.99
46.79
50.46
90.03
67.19
53.59
110.03
60.68
66.99
69.12
Table: 1.8 shows a section of table 1.7 which investigates different power supplies
Manufacturer
Turnigy nano-tech
Turnigy nano-tech
Turnigy nano-tech
Turnigy nano-tech
Zippy
Zippy
Zippy
231
232
Table 1.9 showing increasing number of lithium cells for a calculated power consumption, current draw will
decrease
Rpm to sustain
lift of 35N
Power
(W)
3s 4s 5s 6s 7s 8s 9s
10*8
14,600
1000
9,676
90 67 54 45 38 33 30
Table 2.1 shows the rpm required to sustain lift and rpm required to achieve forward velocity of 29.46m/s
coupled with current draw using different lithium ion cells
10*8
14,600 1000
9,676
90
67
54
45
38
33
30
10*9
14,100 1013
8,601
91
68
55
46
39
34
30
10*10
13,750 1044
7,740
94
70
56
47
40
35
31
11*6
13,200
811
12,901
73
54
43
36
31
27
24
11*8
14,088 1316
9,676
118 88
71
59
50
44
39
11*9
12,522 1039
8,601
93
70
56
46
40
35
31
11*10
11,700
942
7,740
84
63
50
42
36
31
28
12*6
11,350
731
12,901
65
49
39
32
28
24
21
12*8
14,088 1864
9,676
71
62
55
13*6
9,900
668
12,901
60
25
22
20
13*8
14,088 2567
14088
86
77
13*10
11,270 1643
11270
148 111 89
74
63
55
49
14*13
8,670
1307
5,954
117 88
70
58
50
44
39
15*6
7,700
557
12,901
50
30
25
21
18
16
17*10
11270
4804
11270
45
37
36 30
233
Table 2.2 shows the rpm required to sustain forward velocity of 29.46m/s exceeds the rpm to sustain 35N of
lift
Rpm to sustain
lift of 35N
Power
(W)
3s 4s 5s 6s 7s 8s 9s
13*6
9,900
668
12,901
60 45 36 30 25 22 20
Table 2.3 shows that by increasing the rpm power consumption increases along with current draw
Rpm to sustain
lift of 35N
Power
(W)
13*6
12,901
1478
12,901
3s
4s 5s 6s 7s 8s 9s
133 99 79 67 57 49 44
Propeller Rpm
Dimensions to
(in)
sustain
lift of
35N
10*8
14,600
10*9
14,100
10*10
13,750
11*6
13,200
11*8
14,088
11*9
12,522
11*10
11,700
12*6
12,901
12*8
14,088
13*6
12901
13*8
14,088
13*10
11,270
14*13
8,670
15*6
12901
17*10
11270
Power
(W)
1000
1013
1044
811
1316
1039
942
1073
1864
1478
2567
1643
1307
2621
4804
Rpm to
sustain
forward
velocity
(29.46m/s)
9,676
8,601
7,740
12,901
9,676
8,601
7,740
12,901
9,676
12,901
14088
11270
5,954
12,901
11270
90
91
94
73
118
93
84
97
167
133
231
148
117
236
432
67
68
70
54
88
70
63
72
125
99
173
111
88
177
324
54
55
56
43
71
56
50
58
100
79
138
89
70
141
259
45
46
47
36
59
46
42
48
83
66
115
74
58
118
216
38
39
40
31
50
40
36
41
71
57
99
63
50
101
185
33
34
35
27
44
35
31
36
62
49
86
55
44
88
162
30
30
31
24
39
31
28
32
55
44
77
49
39
79
144
234
Propeller Rpm
Dimensions to
(in)
sustain
lift of
35N
10*8
14,600
10*9
14,100
10*10
13,750
11*6
13,200
11*9
12,522
11*10
11,700
12*6
12,901
Power
(W)
1000
1013
1044
811
1039
942
1073
Rpm to
sustain
forward
velocity
(29.46m/s)
9,676
8,601
7,740
12,901
8,601
7,740
12,901
90
91
94
73
93
84
97
67
68
70
54
70
63
72
54
55
56
43
56
50
58
45
46
47
36
46
42
48
38
39
40
31
40
36
41
33
34
35
27
35
31
36
30
30
31
24
31
28
32
Table 2.5 showing the rc wiring rating and maximum current permissible
AWG Maximum current permissible
8
200
10
140
12
90
14
60
16
35
18
16
24
Table 1.7.1 shows updated version of table 1.7 in power supply data
Manufacturer
No.Cells
(s)
Capacity
(mAH)
Coulomb
(C)
Weight
(g)
Cost
()
Turnigy nano-tech
Zippy
Turnigy power
Turnigy power
Turnigy nano-tech
Zippy
Zippy
Turnigy nano-tech
Turnigy nano-tech
Turnigy power
5
5
5
5
5
5
5
5
6
6
4000
5000
5000
5000
5000
5000
8000
8000
4000
4500
25/50
45/55
25/30
30/40
35/70
20/30
30/40
25/50
25/50
30/40
525
732
677
695
659
640
1054
924
623
745
31.99
46.57
33.12
39.53
47.73
29.19
53.65
63.87
38.36
51.84
Total Total
Weight Cost
(g)
()
2100 128
2196 140
2031
99
2085 119
1977 143
1920
87
2108 107
1848 128
2492 153
2980 207
235
Turnigy power
Zippy
Zippy
Turnigy nano-tech
Turnigy power
Turnigy nano-tech
Turnigy nano-tech
Turnigy nano-tech
Turnigy nano-tech
Zippy
Turnigy power
Turnigy nano-tech
Zippy
Zippy
Turnigy nano-tech
Zippy
Turnigy power
Zippy
6
6
6
6
6
6
6
7
7
7
7
8
8
8
8
8
8
9
5000
5000
5000
5000
5800
6000
8000
4500
5000
5000
5000
4400
4500
5000
5000
5800
5800
5000
35/45
20/30
30/40
25/50
25/35
25/50
25/50
65/130
65/130
25/35
60/120
65/130
35/45
25/35
65/130
25/35
25/35
25/35
812
754
784
769
989
908
1105
895
978
818
1025
1012
911
937
1106
1025
1216
1021
44.52
35.60
41.30
51.66
55.58
57.48
78.56
66.99
66.99
46.79
50.46
90.03
67.19
53.59
110.03
60.68
66.99
69.12
2436
2262
2352
2307
2967
2724
2210
2685
2934
2454
3075
3036
2733
2811
3318
3075
3648
3063
133
107
124
155
167
172
157
268
201
140
151
360
269
161
330
182
201
207
Table 2.6 shows section of table 1.7.1 which identifies lowest weight and lowest costing power supplies
H.7.
Manufacturer
No.Cells
(s)
Capacity
(mAH)
Coulomb
(C)
Weight
(g)
Cost
()
Zippy
Turnigy nano-tech
5
5
5000
8000
20/30
25/50
640
924
29.19
63.87
Total Total
Weight Cost
(g)
()
1920
87
1848 128
Motor data
Table 2.7 showing updated version of table 1.5
Manufacturer Power KV
Max
/Model
(W) (rpm/V) Current
(I)
EMax
GT2826-06
Boost 0.50
Boost 0.60
Boost 0.80
Boost 0.90
Turnigy G46
Turnigy
3508-640
Turnigy
4250
Scorpion SII-
Working
Current
(I)
BRC HOBBIES
PRODUCTS
42
Power
Supply
Cell
Range
(s)
Propeller
Dimension
Range (in)
Weight
(g)
Cost
()
Max
RPM
4-5
10*5-14-7
175
23.95
12987
3-5
4-6
5-7
6-9
12-13
13-14
14-15
16-17
295
345
395
455
62.95
69.95
79.95
79.95
8880
8702
7044
7992
4-5
2-5
12-15
10-13
303
98
34.43
20.05
8140
9472
962
710
52
800
900
950
1000
600
490
340
300
55
60
60
65
925
550
550
640
55
30
45
50
52
55
HOBBY KING
PRODUCTS
46
25
900
540
60
55
3-5
9-12
236
13.80
7992
1000
710
60
55
4-5
12-15
205
83.74
10508
236
3026
Scorpion SII- 550
3014
Scorpion SII- 780
3020
Quanum MT 548.3
4010
Quanum MT 568.3
3510
Quanum MT 672.7
3510 V2
Power 32
Power 60
Power 46
800
1000
925
830
30
25
4-5
10-15
129
61.63
12284
890
45
40
4-5
10-14
166
73.69
13172
580
24.7
20
4-6
9-12
127
23.818 10300
630
25.6
18
3-6
9-11
100
16.52
11188
700
30.3
24
3-6
10-12
100
16.52
12432
770
470
670
60
80
55
E-FLITE
45
65
40
4-5
5-6
5-6
11-14
15-17
12-14
200
230
290
50.27
73.73
60.32
11396
8347
11899
Table 2.8 shows rc brushless motors that can use 5s lithium-ion power supply
Manufacturer Power KV
Max
/Model
(W) (rpm/V) Current
(I)
EMax
GT2826-06
Quanum MT
3510 V2
Power 46
962
672.7
925
710
700
670
Working
Current
(I)
Power
Supply
Cell
Range
(s)
Propeller
Dimension
Range (in)
Weight
(g)
Cost
()
Max
RPM
Based
on 5s
52
BRC HOBBIES
PRODUCTS
42
4-5
10*5-14-7
175
23.95
12987
30.3
HOBBY KING
PRODUCTS
24
3-6
10-12
100
16.52
10360
55
E-FLITE
40
5-6
12-14
290
60.32
9916
Table 2.9 shows maximum thrust, maximum velocity, current draw, power consumption and maximum flight
time based on 83% thrust setting and 11168rpm
Maximum angle
(degrees)
43
Maximum
Velocity
(m/s)
20.9
Power
(W)
Current Draw
(I)
Flight Time
(Minutes)
800
43
5.6
237
Manufacturer/Model Constant Current (I) Burst Current (I) Weight (g) Cost ()
Platinum Pro
60
90
68
47.95
Robotbirds Pro
60
80
63
33.95
60
70
50
33.49
4 max 60A
60
70
62
44.95
SimonK
60
80
63
17.49
Hobbywing
60
80
60
39.97
Table 3.0 show a section of appendix L that has two escs that is lowest in weight and lowest in cost
Manufacturer/Model Constant Current (I) Burst Current (I) Weight (g) Cost ()
Robotbirds Pro
60
80
63
33.95
Hobbywing
60
80
60
39.97
Component
Propeller
15.8
100
Power supply
128
1848
Motor
95.8
700
ESC
135.8
252
375.4
2900
Total
At the start of the project certain limitation as stated below were set. By looking at table 3.1it can be seen
that these initial limitation has been met and even exceeded resulting in extra cost saving of 174.6 and total
weight saving of 800g.
Initial cost limitation of 550 after taking into account structural other electrical components
Initial propulsion and power supply weight limitation of 3.7kg was set after taking into account structural,
payload and electrical components weights
238
The test rig in figure 1.7 works by applying throttle from the radio controller to the receiver, this then engages
the esc, which then controls the rc motor rotational speed and ultimately the rotation of the propeller. The rc
motor is attached to an aluminium tube and the aluminium tube at the bottom end is wired onto the lift scale.
When the throttle setting is increased the lift also increased which pulled the lift scale and displayed the
result on the digital read out in grams. When the motor and propeller is rotated there is also a torque
component that occurs in the same direction as the rotation, this is measures by the torque scale. The
torque values were particularly important to the stability section when it came to using the Quad-rotor
simulation model. For this testing an ammeter is used for measuring the current draw and power required
illustrated in figure 1.8. These two values were essential as the rc brushless motor and the esc both have a
specific power and current draw values that cannot be exceeded, if these values are exceeded has the
potential to damage the motor and the esc. Current draw was particularly important because this is the
deciding factor for flight time, the higher the current draw the lower the flight time will be for a given power
supply capacity. Another important factor that was tested involved using an infrared temperature sensor, this
is illustrated in figure 1.9. RPM (revolutions per minute) was investigated using an optical rpm reader
239
illustrated in figure 2.0, rpm values were particularly important in calculating the maximum velocity of the
Quad-rotor.
Figure 1.8 shows ammeter used for testing
Table 5.3 is used to log the data obtained for propeller with dimensions 11*8
16.6
33.2
2.35
Lift (N)
0.29
Torque (Q)
0.70
49.8
2.71
66.4
83
99.6
RPM
Temperature (0C)
37
43
45
52
68
72
From this data the total flight time can be obtained using equation 3.2. In this case we have 4 motors and
reach one can draw up to 49.63A, therefore 198.52A in total. Under these values the Quad-rotor can have a
flight time of up to 4.83 minutes. The Quad-rotor can hover for much longer time than 4.83minutes as the
current draw reduces to around 11.26A, this give a total hover time of up to 21minutes. Take the
temperature of the motor as particularly important because over heating could lead to motor failure during
the competition day. Temperature results was conducted after running the motors at each motor setting to
1minute which allowed for them to heat up to a certain degree presented in table 5.3. Similar analysis as the
one in table 5.3 was conducted for the remaining six propellers and presented below.
()
()
60 =
Equation 3.2
16 ()
60 = 4.83
49.63 () 4
Table 5.3.1 is used to log the data obtained for propeller with dimensions 10*8
16.6
33.2
49.8
66.4
83
99.6
2.42
7.21
14.7
22.1
36.4
48.2
Lift (N)
0.24
Torque (N.m)
RPM
0
Temperature ( C)
0.57
3.71
7.1
17.1
20.2
795
37
40
44
54
65
70
Table 5.3.2 is used to log the data obtained for propeller with dimensions 10*9
16.6
33.2
49.8
66.4
83
99.6
2.43
7.24
14.9
22.5
37.1
48.9
Lift (N)
0.22
Torque (N.m)
3.45
6.9
17.0
19.7
RPM
841
Temperature (0C)
37
41
0.54
47
55
67
71
240
241
Table 5.3.3 is used to log the data obtained for propeller with dimensions 11*6
16.6
33.2
49.8
66.4
83
99.6
2.47
8.2
15.4
24.1
38.2
49.4
Lift (N)
0.25
Torque (N.m)
0.64
5.41
RPM
940
Temperature (0C)
37
43
48
57
68
74
Table 5.3.4 is used to log the data obtained for propeller with dimensions 11*10
16.6
33.2
49.8
66.4
83
99.6
3.4
12.0
22.1
34.1
47.2
52.1
Lift (N)
0.27 0.75
Torque (N.m)
RPM
Temperature (0C)
37 46
49
5.87
54
8.98
67
21.47 23.1
72
78
Table 5.3.5 is used to log the data obtained for propeller with dimensions 12*6
16.6
33.2
49.8
66.4
83
99.6
2.2
7.1
12.42 31.74
40.3
45.7
Lift (N)
7.1
12.9
18.2
21.7
29.2
31.2
Torque (N.m)
0.31
0.68
0.94
1.09
1.20
1.31
RPM
Temperature (0C)
38
30
42
47
55
67
Now that the propeller that will be used on the Quad-rotor has been identified as 12*6, its time to analyse the
performance further. The second test rig was built with the intention to calculating the maximum velocity the
Quad-rotor can achieve under different wind speeds and also the current draw increase due to increased
headwind velocity.
242
Figures 2.1 & 2.2 illustrate the full test rig set up in the wind tunnel.
Figure 2.1 shows test rig inside wind tunnel Figure 2.2 shows test rig structure in wind tunnel
For this test
rig to
operate a
prototype
Quad-rotor
was built as
shown in
figure 2.3
Figure 2.3 shows the prototype Quad-rotor built for testing purposes.
KK 2 Board
Figure 2.3 shows the prototype Quad-rotor was built for the purpose of initial propulsion system integration
and performance testing. System integration involved all the components, ecss, motors, and power system
working together harmoniously, this also helped to eliminate any problems before it was wired onto the main
Quad-rotor. Some of the problems encountered involved esc throttle recalibration and esc programming, all
of which would have been difficult to accomplish once the system gets wired onto the main Quad-rotor and
the esc wires will be installed inside the arms of the copter. The prototype also allowed for the positive,
negative and signal wires to be accurately cut to side ready for installation. From the performance side of
things the KK 2 board was an important and a necessary piece of hardware to positioning the Quad-rotor in
correct pitch angle via digital read out.
243
calculated to cover 0.185m. Figure 2.5 to 271 shows how the events video recording was captured. This test
was conducted under different wind speeds from 0m/s to 25.6m/s which was the limit of the wind tunnel.
Table 5.3.6 identifies the velocity that the Quad-rotor can travel at under different headwind velocities.
Figure 2.4 shows pre-set distance of 0.185m
Table 5.3.6 shows wind tunnel velocity and corresponding Quad-rotor velocity
20.2
10.28
10.4
12.86
8.4
15
5.7
20
1.2
25
Went Backwards
49.8
66.4
83
99.6
0 2.23
12.8
32.4
42.2
47
Temperature (0C)
UAS CHALLENGE 2015
37
38
7.5
30
41
43
51
64
244
From table 5.4 and table 5.3.5 the same propeller can be compared to each other, as stated earlier one of
the propeller is tested in ideal conditions with 0m/s head wind and the other in the wind tunnel with 25.6m/s
head wind. The results indicated that the maximum current draw increases from 45.7A to 47A but the overall
temperature of the motors decreased as a result of headwind cooling down the motors. The rpm of the
propellers in this case could not be obtained because the door to the wind tunnel at 25.6m/s was very hard
to open due to suction cause by the wind turbine.
2
60
Equation 1.8
Rc motor torque can be calculated using equation 1.9 (rc groups, 2008)
( ) =
5252
Equation 1.9
Where
HP = horsepower of motor 1.289HP, as 1HP = 746W and the motor that is used has 962W
Revs Per Minute = 10508 rpm, this was calculated earlier
1.289
5252
10508
( ) =
2
60
Where
V0 = Forward velocity = 20.2m/s obtained from wind tunnel test
D = Propeller diameter = 0.3048m
n=
60
= 186rev/s
20.2
1860.3048
= 0.356
Equation 2.0
245
Now by using figure below propeller efficiency Vs advanced j ratio provided by UIUC propeller efficiency can
be obtained. Which in this case is 42%.
Figure 3.1 (Ananda, 2015) shows graph of propeller efficiency Vs advanced J ratio for propeller dimension
12*6
To calculate propeller power engine power is required as it can be seen from equation 2.2 (Hart, 2013)
Propeller power = Engine power * Propeller efficiency
Equation 2.2
594
20.2
= 29.5
Theoretical thrust was calculated using equation 1.3 as 34N per motor at thrust setting of 83% and the
results were shown in table 2.9, appendix G.
Experimental data using the test rig shows that thrust obtained at 83% thrust setting is equal to 29.5N.
As the propeller thrust has changed from 34N as stated in table 5.3.5 to 29.5N so will the maximum angle,
maximum velocity, power current draw and flight time. The new changes has been calculated and stated in
table 3.2
Maximum angle
(degrees)
Maximum Velocity
(m/s)
Power
(W)
Current Draw
(I)
Flight Time
(Minutes)
29.5
32
20.2
800
43
5.6
246
capabilities of this copter. The Quad-rotor can be defined under two frames one which moves with its body
called the body frame and the other which is defined with respects to the ground, the layouts of these can be
seen in figure 1.5
Figure 1.5 (Khan, 2014) showing body frame and inertial frame
Each
of
and produce thrust independently for example if the Quad-rotor is required to hover at any height the thrust
must equal to its MTOW which in this case is 68.67N and reach motor will work independently to produce
one fourth of this value. If the Quad-rotor is to perform any type of manoeuvre such as pitch to move forward
then again each motor would work independently to produce the thrust required but in this case each motors
thrust value will vary. Manoeuvres such as, pitch, roll and climb. Equation 2.3 (Khan, 2014) shows total
thrust required during certain pitch angle and roll angle.
=
Equation 2.3
()()
Where
T = Thrust (N)
mg = MTOW (N)
cos() = pitch angle
() = roll angle
If the Quad-rotor climbs and performs any of the same manoeuvres then equation 2.4 (Khan, 2014) is
considered to calculate the total thrust required.
4( )+
Equation 2.4
()()
Where
= Density kg/m3
A = Total propeller area m
g = 9.81m/s
247
Magnitude of component vectors within the x-y and z axis are calculated using equations 2.5, 2.6 and 2.7
(Khan, 2014).
= 2 cos()2 (1
1
cos()2
Equation 2.5
= () sin()
Equation 2.6
= cos() cos()
Equation 2.7
Table 3.2 (Khan, 2014) shows the pitch and roll angle that the Quad-rotor can operate within
Pitch () Roll ()
Manoeuvre
Hover
+ or -
Pitch Forward
0-90
+ or -
Pitch Backward
-90-0
+ or -
Roll Left
0-90
+ or -
Roll Right
-90-0
+ or -
0-90
0-90
+ or -
-90-0
-90-0
+ or -
The manoeuvre that is required ultimately depends on the angle setting as it can be seen form table 3.2. For
example if the Quad-rotor was required to hover then both pitch and roll is required to be zero as it can be
seen in table 3.2. Another example can be considered when the Quad-rotor moves forward therefore pitch is
required, this results in a pitch forward manoeuvre with angles between 0 and 90, which requires zero roll
angle.
68.6
68.8
Table 3.4 (Khan, 2014) shows thrust that is required by each propeller to perform a certain manoeuvre
Propeller Hover
Pitch Forward/Pitch
Backward
Roll left/Roll
right
( ) +
( ) +
2
4
248
+( ) +
+( ) +
2
4
Table 3.4 is used to calculate thrust required by individual propellers example for hover can be seen in table
3.5
For hover the very first column will be used and it can be seen that each individual propeller is divided by 4
as its a Quad-rotor. All the values within the x and y axis is identified as zero because no pitching or roll is
required.
17.15
17.15
17.15
17.15
17.15
17.15
17.15
17.15
68.6
68.6
Another example can be identified in table 3.6 and 3.7 which shows forward flight with an angle setting of
0
32 .
Table
3.6
shows
thrust
68.67
80.9
From table 3.6 it can be seen that there is a variation of thrust required by different propellers, which is quite
different from hover, table 3.7 also confirms this.
Table 3.7 shows thrust required by individual propeller for forward flight .
9.09
14.54
17.15
9.09
14.54
17.15
9.09
14.54
17.15
15.61
24.97
29.45
Thrust (N)
42.9
68.6
80.9
249
Propeller: 4 = +( ) +
Where
Z = Total thrust in the z-axis which in this case is 68.6N
T = Total thrust which in this case is 80.8N
Now that the total thrust column has been calculated z-axis column can be calculated.
It is known that total z-axis thrust is 68.6N and total thrust is 80.9N, therefore
68.6
80.9
= 0.530
. =
. =
60 .
Equation 2.8
Equation 2.9
Taking the example used for forward flight each propellers thrust, velocity and corresponding voltage is
shown in table 3.8
Table 3.8 shows thrust, velocity and voltage for each propeller
250
Propeller No Propeller Thrust (N) Velocity using equation 2.8 (m/s) Voltage using equation 2.9 (V) Voltage required per
motor (V)
1
17.15
13.85
1.22
18.5
17.15
13.85
1.22
18.5
17.15
13.85
1.22
18.5
29.45
18.15
1.60
20.9
From table 3.8 it can be seen that for the Quad-rotor to attain an angle of 32 degrees the voltage required
from the batteries is 18.5V for three motors and 20.9V for one motor which can be achieved by the lithiumion batteries chosen for this project.
Equation 3.0
Where:
T = Thrust
= Density kg/3
= 2
Table 4.0 shows different density setting at certain altitude coupled with Quad-rotor thrust required with and
without payload
Table 4.0
Density at
30.48m
Density at
121.92m
kg/3
kg/3
1.192
1.179
68.67
58.86
Using table 4.0 and equation 3.0 take-off velocity can be calculate:
Take-Off Velocity with payload to 30.48m = 9.9m/s
Take-Off Velocity without payload to 30.48m = 9.1m/s
Take-Off Velocity with payload to 121.92m = 10m/s
Take-Off Velocity without payload to 121.92 = 9.2m/s
Time to reach cruise altitude
Time to cruise altitude of between 100ft and 400ft can now be calculated using equation 3.1 (Physics,
2014)
() = +
1
2
( 2) 2
Equation 3.1
0.292
251
Where:
d = Distance m
= Initial velocity m/s
= Initial time s
=
()
= Acceleration m/ 2
()
t = time taken s
Table 4.1
Distance
(m)
Distance
(m)
Initial
velocity
(m/s)
Initial
time (s)
Force
(N)
Mass
with
payload
(kg)
Mass without
payload (kg)
Acceleration
with payload
(m/ 2 )
Accelerati
on
without
payload
Time
taken (s)
(m/ 2 )
30.48
121.92
86.33
12.33
()2
( 2 )
Stall for a Quad-rotor that weights 7kg will stall if the maximum tilt angle of 32 is exceeded
14.38
252
1. Flight performance calculations will be based on a worst case scenario were the Quad-rotor has a
mass 7kg and in full gust conditions throughout the flight path.
2. Having constructed a test rig and performed analysis on the propeller/brushless motor combination it
was obtained that a current draw per motor is identified as 47Amps and power required as
829Watts.
Figure 1.6 (google, 2015) shows example flight course provided by IMECH
Location Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[Runway]
100
First leg: Quad-rotor will take-off to its cruise altitude of 100ft ready to transit to its maximum pitch angle of
0
26.87 . 100ft is used as the cruise altitude so that when it approaches the drop box it can perform a quicker
drop of time. Also a Quad-rotor cannot tilt immediately from the runway position as the propeller will make
contact with the asphalt, therefore it would require a certain height before a manoeuver is performed.
As the time is known to vertically climb to height of 30.46m and also the current draw of 37.26A per motor is
obtained from test rig based on 75% throttle setting, the battery percentage can therefore be calculated
using equation 3.2
()
()
60 =
Equation 3.2
()
60 = 2.2 0.0167()
37.26() 4
Battery Capacity remaining can be calculated
() =
2.2 0.0167
(37.26 4)
60
() = 0.091
Therefore
16 0.091 = 15.91
253
Battery Status %
15.91
16
100 = 99.4%
Table 4.3 shows time taken and battery state from runway to cruise altitude
Location
Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[Runway] to [30.46m]
2.2
99.4%
0
0
Second Leg: Now that the Quad-rotor is at a safe altitude maximum tilt angle of 26.87 can be applied. Also
using google earth the distance from runway to point [1] is calculated as 282m. Earlier it was calculated that
the Quad-rotor can achieve maximum velocity of 20.2m/s. Taking into account wind condition of 25knots
(12.86m/s) then the Quad-rotor can travel at a maximum velocity of 7.51m/s. Current draw of 47A per motor
was obtained again from the sophisticated test rig
Using the data above calculations for time and battery status can be calculated
()
( )
282
() =
7.51/
() =
() = 37.55
()
60 =
()
()
60 = 37.55 0.0167()
47() 4
Battery Capacity remaining can be calculated
() =
37.55 0.0167
(47 4)
60
() = 1.96
Therefore
15.91 1.96 = 13.95
Battery Status %
13.95
16
100 = 87.2%
Table 4.4 shows time taken and battery state from cruise altitude to point [1]
Location
[30.5m]-[1]
Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
7.51
37.55
87.2
282
Third Leg: After a quick turn at point [1] the Quad-rotor will travel another 842m which again was measured
from google earth. Again the velocity will be taken as 7.51m/s and current draw of 47A per motor.
() =
842
7.51/
() = 112.12
()
()
60 =
254
60 = 112.12 0.0167()
112.120.0167
60
(47 4)
() = 5.87
Therefore
13.95 5.87 = 8.08
Battery Status %
8.08
16
100 = 50.5%
Table 4.5 shows time taken and battery state from [1] to point [2]
Location Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[1]-[2]
7.51
112.12
50.5
842
Fourth Leg: Again at point [2] the Quad-rotor will perform a sharp turn to align itself with point [3] which 418m
away from point [2]. With velocity of 7.51m/s and current draw of 47A per motor
() =
418
7.51/
() = 55.7
()
()
()
47()4
60 =
60 = 55.7 0.0167()
55.70.0167
60
(47 4)
() = 2.91
Therefore
8.08 2.91 = 5.17
Battery Status %
5.17
16
100 = 32.3%
Table 4.6 shows time taken and battery state from [2] to point [3]
Location Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[2]-[3]
7.51
55.7
32.3
Fifth Leg: Again for this section same performance criteria can be assumed
() =
334
7.51/
() = 44.47
()
()
60 =
418
255
60 = 44.47 0.0167()
44.470.0167
60
(47 4)
() = 2.33
Therefore
5.17 2.33 = 2.84
Battery Status %
2.84
16
100 = 17.8%
Table 4.7 shows time taken and battery state from [3] to [Target]
Location
Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[3]-[Target]
7.51
44.47
17.8
334
Hover and Navigation Leg: A this point the Quad-rotor will be hovering over the top of the target but also
navigating so that is can precisely on top of the 2x2 red square. It is estimated that it would take 20 seconds
for this to occur with current draw of 17.3A per motor
() = 20
()
()
()
17.3()4
60 =
60 = 20 0.0167()
200.0167
60
(17.3 4)
() = 0.39Ah
Therefore
2.84 0.39 = 2.45
Battery Status %
2.45
16
100 = 15.3%
Location Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[Target]
20
15.3
Final Leg: Final leg of the mission is to return from the target drop off point back to the runway
() =
124
7.51/
() = 16.51
()
()
()
47()4
60 =
60 = 16.51 0.0167()
256
16.510.0167
60
(47 4)
() = 0.86Ah
Therefore
2.45 0.86 = 1.59
Battery Status %
1.59
16
100 = 9.93%
Table 4.8 shows time taken and battery state from [Target] to [Runway]
Location
Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[Target]-[Runway]
7.51
16.51
9.93
124
60 =
60 = 2.2 0.0167()
2.20.0167
60
(37.26 4)
() = 0.091
Therefore
8 0.091 = 7.91
Battery Status %
7.91
8
100 = 98.8%
Table 4.9 shows time taken and battery state from [Runway] to [30.46m]
Location
[Runway] to [30.46m]
Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
0
2.2
98.8%
Final Leg: The Quad-rotor will be at a height of 30.46m and will head towards the target.
() =
124
7.51/
() = 16.51
257
60 =
60 = 16.51 0.0167()
16.510.0167
60
(47 4)
() = 0.86Ah
Therefore
7.91 0.86 = 7.1
Battery Status %
7.1
8
100 = 88.12%
Table 5.0 shows time taken and battery state from [Runway] to [Target]
Location
Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[Runway]-[Target]
7.51
16.51
88.12
124
Again we will have the Hover and Navigation Leg: A this point the Quad-rotor will be hovering over the top of
the target but also navigating so that is can precisely on top of the 2x2 red square. It is estimated that it
would take 20 seconds for this to occur with current draw of 17.3A per motor
() = 20
()
()
()
17.3()4
60 =
60 = 20 0.0167()
200.0167
60
(17.3 4)
() = 0.39Ah
Therefore
7.1 0.39 = 6.71
Battery Status %
6.71
8
100 = 83.8%
Location Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[Target]
20
83.8
Lastly we have final leg again: Final leg of the mission is to return from the target drop off point back to the
runway
258
Table 5.2 shows time taken and battery state from [Target] to [Runway]
Location
Velocity (m/s) Time (s) Battery Status (%) Distance Covered (m)
[Target]-[Runway]
7.51
16.51
() =
73.1
124
124
7.51/
() = 16.51
()
()
()
47()4
60 =
60 = 16.51 0.0167()
16.51 0.0167
(47 4)
60
() = 0.86Ah
Therefore
6.71 0.86 = 5.85
Battery Status %
5.86
8
100 = 73.12%
259
there are others such as the Arduino Uno were it enables the two servos and the camera to be integrated
together.
To ensure that all the hardware works with each other certain softwares programs are required to ensure
that the firmware is implemented correctly. Codes are available on request.
How the whole system will function
Method 2
The second idea involves calculating the error between google maps and the pixhawk. Firstly a location is
chosen in google maps as seen in figure 2.8 and figure 2.9
Figure 2.8 (google, 2015) shows an easily identifiable location for easy GPS extraction
260
Figure 2.9 (google, 2015) show street view of the location in figure 2.8
By identifying a specific point on google earth the coordinates can then be identified pretty accurately, e.g.
0
the location above has coordinates of 51 3847.13N; 0 0429.80W. The next process was to take pixhawk
0
to that exact same location which showed coordinates of 51 3847.28N and 0 0429.88N which is about 3.5
meters in difference. This process is repeated over several days at different locations so that a data base is
built up and the error between the two coordinates can be calculated and inputted back into pixhawk so that
it would have the same coordinate points as google earth.
Competition day scenario
On the competition day when the target location in given, at that point it would be logged into google maps
and the location identified via surrounding structures e.g. runway. From there the coordinates will be
identified and inputted into pixhawk after taking into account the error which has been calculated. From
0
figure 3.0 google maps identifies the target coordinates as 53 55128.83N; 0 5827.94W
Figure 3.0 (google, 2015) shows the target drop point zone
261
Appendix. I
Section by Johnathan
When Pixhawk is connected to the GCS, the buzzer would play a musical note to alert the
programmer that it has been connected to a power source.
After the first connection, a dedicated port is chosen by the laptop for the serial connection
and this port would show as COM5 on the GCS whenever Pixhawk is connected.
To connect Pixhawk to a GCS through a telemetry kit, the port to be used is COM3. An
easier method is to choose the option of AUTO whenever connecting Pixhawk to the GCS,
it would automatically find the correct port for whatever connection is chosen.
After the correct port is chosen and Pixhawk can then be fully connected. The following
screen would show if Pixhawk is connected properly.
262
The Initial Setup menu is the environment where the firmware and all hardware are
configured whether they are mandatory or optional.
At the above shown environment in mission planner, the longitude, the latitude and altitude
of the waypoints for a flight plan. The waypoint radius, loiter radius and default altitude are
set at this environment.
263
Other commands for secondary mission purposes such as servo commands or camera
commands for image processing or payload deployment. Flight modes such as loiter is also
set in this environment.
The commands would work at the waypoint altitude before them and as such it is not
necessary to set waypoints for the secondary commands.
Figure 166: Area for writing flight plans into Pixhawk's Memory
Another method to enter in commands is to load waypoint files that have been saved in the
form of text files.
The speed of the Quad-rotor flight to waypoints can be also programmed at this
environment with a DO_CHANGE_SPEED command or at the configuration setting area
where PID values are set.
Click on Extended tuning; in the environment, all PID numbers can be set as well.
Waypoint Speed, radius, ascending and descending speed.
264
A list of parameters would appear and most of them would have been set to default or
disable in order to prevent systems from malfunctioning.
For changed parameters to have effect they have to be written to Pixhawk memory, to do
that, after changing the parameter click write and to be sure it has saved, a progress bar
would appear and then disappear when the parameter is being written.
265
There are a lot of parameters that can be changed and as such in this manual; only a
necessary few would be shown such as GPS failsafes, change of speed and acceleration,
flight modes.
Instead of scrolling to find parameters, click on the find button and type in the parameter
you are looking for and it would show only that parameter and the others would disappear.
The fail safe parameters in figure 9 are all set to disabled as a default value as they can
vary depending on the type of UAS
266
These parameters would hold even after a reboot but they would be set to their default
values if Pixhawk is reset (firmware deleted or overwritten on the board).
The monitoring system parameters are shown at their defaults value in figure 11.
The monitoring system parameters include the arming check for the Quad-rotor, GPS
failsafe, throttle failsafe enable.
To be flight ready, the monitoring system should be set as shown in figure 12.
267
268
Before any flight, pre-arm check must be carried out on the components of the control
system.
Do not arm the motors when the batteries are low, if the propellers arent screwed on
properly and if the pre-arm check is failed.
Systems
269
Appendix. J
J.1.
Test
1
Systems
Section by Malwenna
Malwenna
to
PID Expectations
Changes required
This would be done to primarily observe
the effect of altitude hold P gain on the
system and purpose of AltHold mode
being maintaining the altitude to hover,
Altitude Hold gain P will be never zero.
P -0.7500
I- 1.500
D- 0.000
1.1
Altitude
Hold
P The copter will start Increment in Altitude Hold P is needed
slightly increased
responding to the for a better desired climb or desired
throttle
command decent rate to maintain the altitude
PID at standard 3DR and will be able to
Quad-rotor levels
maintain altitude at
40% -60% throttle
P -0.7500
I- 1.500
D- 0.000
1.2
Altitude
Hold
increased more
D- 0.000
1.3
Altitude
Hold
increased
to
higher number
P Controlling
the Altitude Hold P gain should always be
a throttle will result in kept below this value since it can cause
abrupt stops and mechanical failure.
starts of motors
PID at standard 3DR
Quad-rotor levels
P -0.7500
I- 1.500
D- 0.000
Changing
The Has to be observed As advised in the Ardupilot tuning
Throttle Rate P, D since
the guide, The Throttle Rate gains would
expectation is not not require tuning and therefor will be
Systems
270
gains
clear
P -0.7500
I- 1.500
D- 0.000
3
Increase D gain
3.1
Decrease
throttle Quad should be For powerful Quad-rotors like ours,
Accel PI gains
more stable with decreasing these values will better the
less
oscillations performance.
To
maximize
the
while
correcting performance, further changing will be
altitude
required. However, while changing
gains, P: I ratio of 1:2 will be
maintained.
3.2
Decrease
throttle Should
be
very
Accel PI gains by stable
while
50%
maintaining altitude
and will have a good
response to throttle
command.
Systems
271
J.2.
Auto Tuning
Ensure the quad is properly tuned at AltHold mode prior Auto Tuning.
Procedure
1. Change one flight mode switch to AltHold.
2. Change Ch7 Opt or Ch8 Opt at Extended parameters to Auto tune.
3. Keep the Auto tune set switch in Low position.
4. Take the cat in a large open area away from the crowd to be tested.
5. Ensure there is no trim been set up in Radio controller.
6. Arm motors and take off to a desired altitude (not too high) and switch to AltHold mode to
hover.
7. Put Auto tune set switch to high position to engage auto tuning.
8. Input roll, pitch and yaw if quad starts drifting away.
9. Use switch to abandon Auto tuning if it seems too destabilized.
10. At the end of the tuning, PID gains will be changed back to original and can be monitored
through mission planner.
11. Switch Auto tune set switch to low position and back to high position to test the new PIDs.
12. Land and disarm the motors while at high position to save the new PIDs.
13. Land and disarm motors at low position to return to original PIDs
J.3.
Risk Assessment
Likelihood definition
1
Systems
272
Severity definition
1
There will be a nominal impact associated with small budgets and lateness impacts and
There will be significant effects on the project exceeding the budget by at least 10% with at
There will be a significant impact on the outcome of the project exceeding the budget by at
The project is likely to fail exceeding the budget by at least 50% with at least a 50%
Likelihood
lateness impact.
10
15
20
25
12
16
20
12
15
10
Severity
Systems
273
I.D
Risk
Likeli
Seve
Ris
hood
rity
Control/Mitigation
Lev
el
1
Bird Strikes
Cannot be managed.
components
Propeller Injuries
Battery detachment
Battery combustion
10
11
12
Suppliers
delivery
delaying
of
the
components/
time plan
material
13
10
Systems
274
14
Stage
testing
earlier
and
include
Manufacturing
lab
and
Book in advance
procurement
Finalizing
equipment unavailable
16
University
process delays
required
materials
and
17
UAS overheats
18
Book
sessions
in
advance,
design
Stability
and
control
15
algorithms fail
20
Project delays
15
Good
planning
and
including
contingency time
21
Structural failure
22
Autonomy fails
Systems
275
J.4.
Diposal methods
Component
Circuit Boards
Open burning
Environmental Hazards
Acid baths
Hazardous gas
emissions
Burning of chips
Air emissions of
brominated dioxins,
heavy metals and
hydrocarbons can be
poisonous
Wires
Hydrocarbon residues,
free into water, air and
soil.
Systems
276
J.5.
OSD Specification
This section is used to justify the purchase of the autopilot equipment explained below.
Scope
The UAS Equipment is the on screen display board (OSD) to view the telemetry data.
Purpose
The On Screen Display is the video output of telemetry data of the UAS and will be
connected to the autopilot control board. The OSD transmits the telemetry ground data to the
ground control station. The module chosen for purchase is the MINIM OSD V1.1.
System Description
Overview
Configuration ease
Cost
Power consumption
Size
Error indication and warning system (Lost GPS Fix, stall, over speed, battery voltage
and percentage, RSSI)
Systems
277
Suppliers
The following are links where the Minim OSD Rev 1.1 can be bought.
http://www.hobbyking.co.uk/hobbyking/store/__36844__Minim_OSD_v1_1.html
http://store.3drobotics.com/products/apm-minimosd-rev-1-1
http://www.buildyourowndrone.co.uk/ardupilot-mega-minim-osd-rev-1-1.html
http://www.unmannedtechshop.co.uk/sample-marc-retro-style-summer-mid-dress/
Prices
Buidyourowndrone - 45.98
Hobby King - 13.63
Unmanned tech shop - 44.95
Systems
278
J.6.
GPS Specification
This section is used to justify the purchase of the autopilot equipment explained below.
Scope
The UAS Equipment is the external GPS with compass. The GPS with Compass chosen for
purchase is the 3DR uBlox GPS with Compass Kit,
Purpose
The GPS+compass unit will be the primary means navigation and tracking of the UAS and
will be connected to the autopilot control board.
System Description
Overview
Figure 175: 3DR uBlox GPS with Compass Kit (unmannedtechshop, 2015)
Part Name/Number
The UAS Equipment is the external GPS with Compass. The GPS with Compass chosen for
purchase is the 3DR uBlox GPS with Compass Kit.
Criteria for Selection
A number of GPS + Compass modules were evaluated under the following checklist:
GPS accuracy
Configuration ease
Cost
Systems
279
Power consumption
Battery life
Battery rechargerbility
Protectiveness
5 Hz update rate
Protective case
Conclusion
After comparing with other GPS modules and also considering the recommendation to use
3DR uBlox GPS with Compass Kit on Pixhawk by Pixhawk manufacturer, the MEng control
system group have decided that this is the GPS module that should be bought. However,
given the unavailability, , GPS Crius CN-06 v2 was purchased instead.
Suppliers
The following are links where the uBlox GPS with Compass Kit can be bought.
http://www.buildyourowndrone.co.uk/3dr-ublox-gps-with-compass-lea-6h.html
http://www.hobbyking.co.uk/hobbyking/store/__42833__UBLOX_LEA_6H_GPS_Mod
ule_w_Built_in_Antenna_2_5m_Accuracy_V1_01.html
http://store.3drobotics.com/products/3dr-gps-ublox-with-compass
Prices
Buidyourowndrone - 54.16
Also includes following
3D Robotics - 57.24
Also includes following
Systems
280
Altitude control
281
Section by Reyad
Malwenna
Altitude control
282
J.1.
PID Values
Effect on Quad-rotor
Desired effect
Mitigation
P=0
I =0
D=0
P=1
I =0
D=0
No expectations
P = 0.4
I =0
D=0
P = 0.5
I =0
D = 0.1
P=2
I =0
D=0
P = 0.5
I =0
D=0
P = 0.5
I =0
Altitude control
283
D = 0.5
P = 0.5
I =0
D=1
P = 0.5
I =0
D=2
P = 0.5
I =0
D=4
P=1
I =0
D=2
P=1
I =0
D=4
P=2
I =0
D=4
P=4
I =0
D=4
P=3
I =0
D=4
at
time
Improved damping
Small overshoot
Altitude control
284
J.2.
PID Values
P=1
I =0
D=0
P=1
I =0
D=1
P=2
I =0
D=2
P=2
I =0
D=2
P=2
I =1
D=2
P=2
I =2
D=2
P=4
I =2
D=4
P=6
I =2
D=6
Effect on Quad-rotor
Very unstable, but cannot stabilise and
falls out of the sky in less than 20
seconds
Stabilises fairly quickly and continues to
fly
Desired effect
Gradually pitching
becoming unstable
down
Mitigation
before D value will be increased to see if It can
stabilise
Double values to see if there are any changes
Altitude control
285
Test
Changes to PID
values
P minimised
I set to zero
D set to zero
Expectations
Changes required
Very
little
sensitivity,
gradually moving in the axis
with little recovery from
stabilise mode
P
slightly
increased
I at zero
D at zero
P
moderately
increased
I at zero
D at zero
Much better
sensitivity
P value greatly
increased
I at zero
D at zero
P
value
in/decreased
I at zero
D at zero
P set as before
I at zero
D
slightly
increased
P value from
previous
I at zero
D
slightly
increased
P value from
previous
I at zero
D
slightly
in/decreased
P increased
I at zero
D set as before
P
value
increased
I at zero
D as before
P as before
I slight increased
D as before
10
P as before
I
slightly
increased
D as before
P as before
2.1
2.2
2.3
11
levels
of
Improved responsiveness
or possibly oscillations
Altitude control
286
12
13
14
15
16
I slight increased
D as before
P as before
I
slightly
decreased
D as before
P as before
I as before
D as before
weight added to
one motor
P as before
I as before
D as before
High airflow fan
used
for
controlled
wind
conditions
P as before
I as before
D as before
P as before
I as before
D as before
Flown outside
Altitude control
287
Altitude control
288
289
Appendix. L
Section by Tarek
Verification
Requirement
t number
2.3
Inspection
Analysi
Demo
Test
Comments
s
The UAV shall be capable of being controlled manually via radio
2.4
2.5
2.6
2.7
UAV shall take off from the designated take-off and landing area
289 | P a g e
290
2.9
and Judges:
3.2
3.3
291
3.4
3.5
(60.4Kts_(TAS)).
w/w.
3.6
4.1
4.2
allocated timeslot.
4.6
292
6.1
border.
All radio equipment and data links must comply with EEC
6.2
6.3
UAS shall receive (RX) and transmit (TX) data between the
zones.
7.1
7.4
7.5
293
7.6
8.1
8.2
8.3
At least 25% of the upper, lower and each side surfaces of the
UAV shall be bright coloured to facilitate visibility (see also 2.2)
in the air and in the event of a crash.
the safety pilot from the ground station at any time deemed
necessary.
to return to home.
9.2
demonstration.
built.
293 | P a g e
294
Test
Procedure
Date
Result
Telemeter
Establishing
Plug in the telemetry kit receiver into the laptop using ground
09/03/2015
kit
connection
with Tx and
Rx
Transmission
09/03/2015
rate
attitude response)
09/03/2015
Place the receiver indoor and the transmitter outdoor and see the
10/03/2015
Transmission
range
16/03/2015
295
Transmission
Transmit the video through pixhawk and receive the live video
transmissio
rate
11/05/2015
transmission)
Transmission
range
test.
Video display
Connect the camera to the Minim OSD and verify if the display
11/05/2015
11/05/2015
Video display
processing
12/05/2015
processing
19/01/2015
file.
Pixhawk will able to take picture when triggered, which will then
14/05/2015
Testing
The servo test will try to operate four servo channels connected
pixhawk
14/04/2015
sensors
02/03/2015
296
LED test will show the different conditions of the pixhawk (when
02/03/2015
16/04/2015
Navigation
Signal
system
strength
23/03/2015
Plan a journey using the ground control, and test the navigation
19/03/2015
The setting of the way point for the Quadrotor is straight forward either by the use of
coordinates or point selection on the map.
Propulsion
performance
Test the voltage usage at full power and the current drain from
19/03/2015
the batteries
Test the current drain from the engines at different wind speeds
27/03/2015
Safety test
25/03/2015
20/05/2015
18/05/2015
represent landing
Test the final model in the wind tunnel to see the structural rigidly
31/03/2015
297
16/04/2015
during flight
16/04/2015
PID
Controllability
controller
of the Quad-
test
rotor
08/04/2015
A test rig is built for the sole purpose of testing the UAS in order
16/04/2015
The last method is an auto tune method where the UAS is flown
25/05/2015
with a radio controller and the autopilot then auto-tunes the PID
parameters to its final values.
Payload
Testing the
deployment
servo
test
20/03/2015
298
13/04/2015
Deploy the payload at the set destination or target (as the Quad-
24/03/2015
rotor would not be built yet an initial test will be carried out as
18/05/2015
Checking the
Remote
operations of
controller
the merged
systems
sent by:
01/04/2015
01/04/2015
station
Test the return home function after signal is lost, during period
03/06/2015
17/04/2015
Testing the
01/06/2015
ground
298 | P a g e
299
control
18/03/2015
operation
02/06/2015
299 | P a g e
300
K.3. Schematics
Transmitter and Receiver with Video Graphics Processing Unit (VGPU) the MinimOSD
300 | P a g e
301
301 | P a g e
302
Section by Micky
Malwenna
V2
302 | P a g e
303
Polarization: vertical
Gain: 9dbi
Maximum power: 15 W
Length: 275 mm
VSWR: <1.5
RADIOS DESCRIPTION
SPECIFICATION
Processing
100 mW maximum output power
(FHSS)
(adjustable)
RP-SMA connector
UART interface
bit error
Features
2 Interchangeable air and ground
radio modules
Micro-USB port
303 | P a g e
304
Power
Supply voltage: 3.7-6 VDC (from USB
or DF13)
Dimensions
26.7cm x 55.5 cm x 13.3 cm (without
Receive current: 25 mA
antenna)
304 | P a g e
305
FEATURES/SPECS:
LED indication for both network status
and power
Small footprint (5cm x 4.5cm)
Breadboard compatible for easy
POTENTIAL APPLICATIONS:
prototyping
UAVs and Balloons - live data reporting
4.5VDC-16VDC power supply input
- GPS, pressure, altitude, streaming
3.3V or 5V UART Interface (voltagevideo
shifting is done on board)
High serial data rate (up to 115200
set waypoints, camera commands, etc.
baud)
Cars- remote start, car alarm
GPRS communication rate (86.5 kbps
notification, GPS tracking
downlink) - cellular to server
communication
Security systems - cars, boards, sheds,
CSD (up to 14.4 kbps) - cellular to
etc.
cellular communication
Home automation - thermostat control,
Software configurable baud rate
lighting
Works with any SIM card
Quad band cellular connectivity
Robots - data transfer, remote
Internal switch to detect SIM card
commands
presence
Processors and computers- data
Dial and receive phone calls
(however, no microphone or speaker
transfer, wireless ssh, telnet
interface setup)
Wireless Industrial Systems - reset
Send and receive text messages
computers, activate pumps
Send and receive Multimedia
Messages
Wireless Asset tracking - GPS track
Send and receive data to any Internet
your car, your spouse, your cat
connected computer
Send and receive data over TCP or
TCP/UDP DATA TRANSFER METHODS:
UDP sockets
iPod server/client socket app
Super long range (anywhere there is
HyperTerminal
cell reception)
High altitude (at least 10,000 feet, up
Custom socket server/client - Perl,
to 30,000 depending on Cell tower)
Python,
Phonebook entries and storage
Software libraries for AVR
Real time clock, synced to cellular
tower time
User set alarms
305 | P a g e
306
L.1.
Payload box
306 | P a g e
Servo calculation
307
1 = Fnorm + Fhinge
307 | P a g e
Manufacturing
308
Appendix. N Manufacturing
Section by Mozammel
Malwenna
Figure 186: Dry assemble of landing gear lug, pivot and the vertical landing strut
Figure 189: Support corners machined in CNC Figure 190: Triangle payload support
glued with hinges
308 | P a g e
Manufacturing
309
309 | P a g e
Manufacturing
310
Figure 198.1-2 Laser Cutting of Nylon 6 sheet for main body plate
Figure 199: Cutting Nylon 6.6 cast block in vertical band saw machine
310 | P a g e
Appendix. O
Test Rig
311
311 | P a g e
Appendix. O
Test Rig
312
312 | P a g e
14
13
Side view
4
Top view
26
47.5
101.4
271.4
2nd Pin
36.5
22
11
Stand Pin
Note: All dimensions in mm
unless mentioned otherwise
DRAWN BY
Mohinuddin
CHECKED BY
26
14
27
Mohin
DATE
24/01/2015
Detail A
Scale: 1:3
SIZE
XXX
DESIGNED BY
78
864.5
76.59
B
Detail B
Scale: 1:3
DRAWING NUMBER
A4
SCALE
ONE
1:1 WEIGHT(kg)
XXX
REV
X
SHEET
1/1
Appendix. O
Test Rig
314
314 | P a g e
B
13
14
Top View
4
26
47.5
Mid/Outter Pin
Stand Pin
36.5
11
121.4
14
DRAWN BY
Mohinuddin
27
DATE
15/03/2015
SIZE
XXX
Mohin
Detail B
Scale: 1:3
DESIGNED BY
2nd Pin
CHECKED BY
26
106.4
Front View
78
22
3
Detail A
Scale: 1:3
41.1
698.3
DRAWING NUMBER
A4
SCALE
ONE
1:1 WEIGHT(kg)
XXX
REV
X
SHEET
1/1
Appendix. O
Test Rig
316
316 | P a g e
3
.
5
436.5
A
1000
60
10 TYP
R5
25.4
4T
YP
20
47
135
DRAWN BY
130
Front View
D
42
1 5 Mohinuddin
CHECKED BY
DESIGNED BY
Mohin
DATE
15/03/2015
SIZE
XXX
Detail B
Scale: 1:4
Note: All dimensions in mm
unless stated otherwise.Debur
and polish all sharp edges.
Front View
Exploded View
B
10
25
60
Front View
P
Y
T
47.3
127
Detail A
Scale: 1:4
34.6
A4
SCALE
DRAWING NUMBER
ONE
1:1 WEIGHT(kg)2.51
REV
Appendix. O
Test Rig
318
318 | P a g e
.
5
2
2
.
3
9
P
TY 5
.
67
YP
T
9
4. 493.2
30
30
25.4
1139
493.2
3
3
246.62
Front View
Isometric view
Scale: 1:14
4T
YP
20
47
135
DRAWN BY
130
Front view
D
42
1 5 Mohinuddin
CHECKED BY
DESIGNED BY
Mohin
SIZE
XXX
DATE
15/03/2015
A4
SCALE
DRAWING NUMBER
ONE
1:1 WEIGHT(kg)1.8
REV
Appendix. O
Test Rig
320
320 | P a g e
YP
4.9 T
30
4
30
.5
TYP
67
7.
51
53
8.
538.8
12
538.8
49
269.4
Exploded View
Note: All dimensions in mm unless
stated otherwise.Debur and polish
Detail A
Scale: 1:4 all sharp edges.
Front View
4T
YP
20
47
135
DRAWN BY
130
Front View
D
42
1 5 Mohinuddin
CHECKED BY
DESIGNED BY
Mohin
SIZE
XXX
DATE
15/03/2015
A4
SCALE
DRAWING NUMBER
ONE
1:1 WEIGHT(kg)1.96
REV
Appendix. O
Test Rig
322
322 | P a g e
45
TY
40
R5
0
L Bracket
Side View
4T
47
20
YP
135
130
Front View
42
DRAWN BY
Mohinuddin
Mohin
G
DESIGNED BY
15
80
25.4
40
87.3
R5
20
13
40
31.1
10
25.4
300
137.3
L Bracket
Top View
40
25.4
137.3
40
40
10
60
60
20
107.5
30
960
30
1.2
4.
.5
215
30
L Bracket
Isometric View
67
67
30
.5
960
SIZE
DATE
15/03/2015
A3
WEIGHT(kg) 2.7
1
REV
Appendix. O
Test Rig
324
324 | P a g e
Material
Item
Box
Auminium
Brackets
Auminium
Sheet (1.2mm)
Pins
Mid Frame
Stainless Steel
Round bar
Material
Auminium
Item
Square Tube
Material
Auminium
Item
Square Tube
Material
Auminium
Item
Square Tube
Auminium
Square Tube
(5m lengths) 1
TOTAL REQUIRED LENGTH (mm)
19758
TOTAL NO. OF REQUIRED 5m LENGTH BOXES 3.9516
Qty
Cost () Ex VAT
(80mmx80mm) x 48
16.32
(1mx1m) 1
21.1
7.33
Qty
3946 (5m lengths) 1
Cost () Ex VAT
Qty
4310.4 (5m lengths) 1
Cost () Ex VAT
Qty
6019.2 (5m lengths) 1
Cost () Ex VAT
16.32
Outter Frame
16.32
Stand
Extra Material
http://www.metals4u.co.uk/stainlesssteel/round/8-mm-diameter303/detail.asp?prd_id=1686
http://www.ascmetals.com/downloads/wholebrochure.pdf
http://www.rapidtables.com/calc/wire/swg-to-mm.htm
16.32
16.32
4
5
110.03
132.08
11.00666667
11.50
Appendix. O
Test Rig
326
Thermal Shock
Thermal shock testing shall be performed to ensure the hardware can survive rapid changes
in ambient temperature without any degradation to its coatings, surfaces or electrical
performance.
326 | P a g e
Appendix. O
Test Rig
327
Random/Sine Vibration
Random vibration testing shall be performed to ensure the hardware can survive the
vibrations associated with the launch and ascent of the Quad-rotor without any degradation to
its coatings, surfaces, or electrical performance.
Refining design of the gimbal test rig for more than 5 times
The CAD model shown below was the very first concept of the gimbal test rig presented at
the PDR. Conversely design iterations had led to changes in to a more robust design
discussed in the previous chapters.
The figure on the top right shows an angled bracket that was planned to be used in the
updated octagonal gimbal test rig. However lack of facilities present at the universitys
fabrication workshop, they had to be subcontracted. But to save finances and quicken the
manufacturing stage of the test rig, a tri angular bracket as shown below on the bottom right
figure was designed to replace the angled bracket from above. The use of these brackets had
tremendously helped in speeding up the fabricating process of the final design as shown on
the bottom left figure.
327 | P a g e
Appendix. O
Test Rig
328 | P a g e
328
D
4
135
20
47
YP
4T
Isometric view
Scale: 1:1
12
24
15
42
130
Front view
Scale: 1:1
DRAWN BY
Mohinuddin
CHECKED BY
DESIGNED BY
Mohin
D
SIZE
XXX
DATE
31/03/2015
A4
SCALE
Joint Bracket
DRAWING NUMBER
REV
ONE
1:1 WEIGHT(kg) 0.043
X
SHEET
1/1
Appendix. O
Test Rig
330 | P a g e
330
60
4
10 TYP
47.3
34.6
10
25
60
4 TYP
25.4
Front view
Scale: 1:1
DRAWN BY
Mohinuddin
CHECKED BY
Mohin
D
DATE
31/03/2015
SIZE
XXX
DESIGNED BY
Isometric view
Scale: 1:1
A4
SCALE
T BRACKET
DRAWING NUMBER
REV
ONE
1:1 WEIGHT(kg) 0.023
X
SHEET
1/1
332
332 | P a g e
333
Probabilit
y
Trivial
Minor
Moderate
Major
Extreme
Rare
Low
Low
Low
Medium
Medium
Unlikely
Low
Low
Medium
Medium
Medium
Moderate
Low
Medium
Medium
Medium
High
Likely
Medium
Medium
Medium
High
High
Very likely
Medium
Medium
High
High
High
10
12
15
12
16
20
10
15
20
25
Impact
Probability
Where;
Impact rating
1 There is little or no impact at all
2 - Nominal risk
3 - Significant effect on project
4 - Significant impact on outcome
5 Project may fail and affects organisation function
Probability rating
1
0-10%
2
11-40%
3
41-60%
4
61-90%
5
91-100%
#
333 | P a g e
334
Potential
Failure
Mode/Risk
Effect
business
Impac
t
rating
on Possible
Cause
Likelihood
of
occurrenc
e
Risk
Ratin
g
Remedial
Action(s)
Use
a
checklist to be
used
prior
every
flight,
use
setup
guides
and
manuals
provided
by
equipment
manufacturers
.
Plan
ahead
and include a
contingency in
time plan
Research on
compatibility
and use same
suppliers
Manufacturing
Incorrect
assembly of Product
will
UAS
not be launch
components
Lack
of
executing
4
incorrect
procedure
Suppliers
delaying the
Delay
in Delays
delivery
of
manufacturing shipping
components/
material
Systems
compatibility
issues
in
Product
will Lack
of
2
not operate
validation
Testing
Legislation
changes
Affect
and
delay project CAA review
delivery
Exceeding
allowable
noise
pollution
Product
not Specification
allowed to be s not well 3
flown
defined
Insufficient
Delay
in
Poor project
time
for launch
and
2
management
testing
poor quality
Product
will
Stability and
Inaccurate
not
meet
control
stability
design
algorithms fail
analysis
specification
15
-dedicate
a
team to follow
up
and
anticipate
changes
-Get involved
with
the
governing
bodies
in
order
to
influence
changes
-specifications
should be well
defined
-proper testing
should
be
carried out
Stage testing
earlier
and
include
a
contingency in
time plan
Use Matlab to
validate
obtained PID
values
through
334 | P a g e
335
testing
Flight Operations
UAS
overheats
Electrical
Product
will performance
not sustain in test
not 2
market
conducted
appropriately
Technology
advancement
Business will
Market
not
sustain
competition
longer
Bird Strikes
Loss
economy
One
failure
motor
Product
not
operation
of Unexpected
encounter
will Power
in supply
failure
Take-off and
Testing not
Product will be
Landing
conducted
1
damaged
failure
appropriately
Adverse
weather
conditions
Autonomy
fails
Radio
frequency
interference
Reduction
gross sale
in
Product may
be
irresponsive
and potential
chance
of
collision
Product
launch
embarrassme
nt and will not
operate
as
desired
N/A
-Error
in
system code
- Power loss
2
in
the
products
software
Presence of
other radio 3
source
Designed
be able
manually
control
to
to
Keep
wire/cable
away
from
transmitters
and antennas,
Use
of
335 | P a g e
336
Propeller
Injuries
Bad reputation
Poor quality
1
control
Battery
detachment
Loss
economy
Business
specification
was not met
Battery
combustion
Reduction in
gross
sales
due to safety
issues
Inappropriat
e procedure
1
followed
during wiring
Hackers
Committed
crimes,
possible
accidents
Intentional
suspect/
Pre-planned
by criminal
10
of
UAS theft
Hacking
purposes,
hacking
the
selling
system
or
1
product parts
vandalism
and criminal
activity
Mechanical
Failure
Some system
might
not
function
or
vehicle
may
not start
Old parts in
the vehicle
or
not 3
maintained
properly
shielding for
your
wiring
runs,
Keep
antennas as
far apart as
possible,
Monitor
RC
Channel
interference in
between
flights.
Operate away
from
congested
areas,
50m
away from all
personals and
structures.
Use a Velcro
Strap to hold
the batteries.
Monitor their
temperature
and regulate
their charging
and
discharging.
Automatic
return home
override
in
case of any
control
interruptions
- The vehicle
must
have
CCTVs
mounted
in
and
around
outside
-Allow
immediate
control
of
vehicle by CT
staff
-alert CT staff
of
anything
suspicious or
out of ordinary
-certify regular
maintenance
for all vehicle
parts
and
system
-adequate
336 | P a g e
337
System
Failure
Staff
Changes
product may
be
irresponsive
and potential
chance
of
collision
-Error
in
system code
- Power loss
5
in
the
product
computer
Project delay
Retirement,
illnesses,
demotion,
strategic
focus
Poor public
of awareness
5
for product
operation
10
Public
Loss
damaging the
business
UAS
and
professional
training
provided
to
maintenance
crew
- Substantial
product
system
testing.
- Emergency
Stop
button
must
be
present in the
product.
Remotely
monitor
product
Failsafe
system
embedded in
the product
identify
skill
shortages and
act
accordingly
-sub-contract
suitable
skilled
workers from
different
organisation
Regular
product usage
presentation
and
advertisement
s
Disposal
Decompositio
n of materials
High
manufacturing
cost
Wrong
choice
of 3
materials
Carbon
print
High
operational
costs
Business
expansion
foot
-thorough
analysis
before
material
selection
-strategic
business plan
for
product
distribution.
337 | P a g e