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Quad Works

Project Final Review

EG461 Capstone Design Project

May 2, 2015

Oliver Bateman

Nathaniel Burr

Juan Cataño

James Choy

Cory Clark

Tim Graham

Daniel Lopez

Joshua Ricci

Instructors:

Prof. D. Guo

Prof. L. Marquis

Prof. P. Rosner

Overview

• Problem Statement and Approach

• Objectives

• Conceive

• Design

• Implement

• Operate

• Budget

• Lessons Learned

• Future Development

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Problem Statement

• High-altitude structures corrode and deteriorate over time

• Construction and maintenance workers risk injury or death

• Heat loss of large buildings costs money

• Manual inspections are inefficient and time-consuming

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Approach

• QuadCopter Surveillance Platform

Highly stable and maneuverable

Adaptable to various camera types

Live video and telemetry feeds

Requires minimal training

• Other applications

Search and rescue

Law enforcement

Military operations

Relief efforts

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Unpack quadcopter

Turn on controller

Connect battery, wait to initialize

Place in launch area

Complete pre-flight check

Power up, ascend to operating altitude

Move between observation

points

Capture images and transmit

Return to launch area

and land

Disconnect battery

Turn off controller

Collapse and pack

quadcopter

Approach

Objectives

• Design and manufacture a semi-autonomous UAV

• Modify hobbyist’s product to meet commercial applications

• Eliminate tedious tasks and hazardous situations

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Conceive

Initial design goals

• Maximize flight time

• High-resolution camera

• Collapsible frame

• Retractable landing gear

• Capable of carrying larger cameras or sensors

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Technical System Breakdown

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Quad Works

Airframe

D. Lopez

Propulsion

N. Burr

Gimbal & Camera

O. Bateman

Stability & Control

J. Catano

Video & Telemetry

T. Graham

J. Ricci

O. Bateman

J. Ricci

C. Clark

D. Lopez

C. Clark

T. Graham

J. Choy

J. Catano

J. Choy

Project Description

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Quad

Works

Ground Airborne

Flight

Data Pilot (RC) Video Quadcopter Camera

Airframe Power Telemetry Control/

Stability

FPV Gimbal

Structure Control

System Requirements

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Attribute Requirement Units

Climb rate 15 ft/s

Traverse rate 40 ft/s

Signal range 0.25 mi

Max. AGL 400 ft

Max. altitude (density) 6,000 ft

Max. take-off weight 10 lb

Ground station weight 5 lb

Endurance 15 min

Size, main diagonal 36 in

Drop survivability 3 ft

Assembly time 4 min

Operable temperatures 32 – 90 °F

Design

Proposal Preliminary

(PDR) Approved

(CDR) Complete

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Preliminary Design

• Lightweight composite frame

• Collapsible arms

• Live video feed

• Telemetry

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Preliminary Design

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• 3-axis gimbal

• Controllable in pitch and yaw

• Vibration dampers

Preliminary Design

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Telemetry

antenna

Video

antenna

Controls

antenna

Video

display

Joystick

Joystick

Kill switch

Telemetry

display

Video toggle

Loiter mode

Test Bed

• Built a test bed for flight testing and data collection

• Flamewheel f450 frame customized with electronics

GPS and compass

Live video feed (FPV)

On-screen telemetry

Camera gimbal

• Tested stability and control of a common quadcopter

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Approved Design

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Purchased

Manufactured

*Mission camera not shown

Completed Design

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• Fiberglass (G10) body

• Nylon arms and legs

• Collapsible arms

Completed Design

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• Carbon fiber

• Quick-release interface

• Camera holster

• Adjustable CG

Completed Design

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• Lexan top plate

• Composite bottom shell

• Tilt-adjustable screen

• Single battery

On-Board Electronics

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Component Name Rationale

Flight controller Ardupilot 2.7 Open source, inexpensive

Gimbal controller AlexMos 32-bit 3-axis Top-of-the-line, two IMUs

Video camera Luminier 600TVL Good resolution, small and compact

Video switch 3CH Video Switch Inexpensive and good reputation

Telemetry overlay TinnyOSD Ardupilot compatible

On-Board Electronics

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Component Name Rationale

Video transmitter 1.3Ghz 400mW video transmitter Signal penetration and legal frequency

transmission

Video antenna LHCP 1.3Ghz antenna Less prone to interference, good signal

spread

Telemetry transmitter Ardupilot Telemetry Radio Frequency and flight controller

compatible

24V to 12V convertor N/A Low noise, capable of high current

24V to 5V convertor N/A Low noise, capable of high current

Design Evolution

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Feature Design Changes from Initial Concept

Boom arm locking method

Fixed shaft and collars insure tight fit

Thumb screws for collapsibility

Gimbal-to-airframe attachment

Binding post instead of adhesives

Withstands higher loads

Ground station design

Utilizes fiberglass and Lexan

Matches quadcopter aesthetically

Implement

• Manufacturing process

• Subsystem integration

• First prototype

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Manufacturing – Composites

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Manufacturing – Nylon

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Ground Station

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Composite Shell

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Electronics Integration

Integration

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Structural Integration First Complete Prototype

Operate

• Testing and results

• Failure analysis

• Verification

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Ground Testing

*At 50% throttle 31

Test Performed Requirement Result

Max. thrust (per motor) 3.3 lb 4.5 lb

Battery endurance* 15 min 20 min

Control signal range 0.25 mi 0.27 mi

Telemetry OSD N/A Achieved

Flight controller N/A Achieved

Signal loss protocol Safe return Achieved

Live video feed Continuous Achieved

Assembly time Airborne in 4 min 1:18

Gimbal control Pitch and yaw Not met

Max. take-off weight 10 lb 7.2 lb

Ground station weight 5 lb 4.5 lb

Assembly Time

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Flight Testing

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Test Performed Requirement Result

Maiden flight N/A Achieved

Endurance 15 min 15 min 45 s

Maximum altitude 400 ft AG Achieved

Climb rate 15 ft/s 30 ft/s

Traverse rate 40 ft/s 49 ft/s

Operable wind Light & variable Achieved

Spatial lock r5 ft, ↑10 ft Achieved

Signal loss protocol Land safely Achieved

Mission Test – First Attempt

• Location: DWC courtyard

• Pilot: Cory Clark

• Wind: Greater than “light and variable”

• Visibility: 10+ mi

• Outcome: Failed

• Results:

Operable in greater than “light and variable” winds

Retractable landing gear functioning

Ground station functioning

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DWH

ERC 2

1

Home

Crash Site

Actual

Planned

Crash Footage

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Failure Analysis

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• Signal loss caused failsafe to activate

Bad connection in controller

Signal loss protocol malfunctioned

• Solution

Re-soldered connection

Reconfigured flight controller to land when signal is lost

Design Changes

• Fixed Landing Gear

• Thickened gimbal arms

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Mission Test – Second Attempt

• Location: DWC courtyard

• Pilot: Juan

• Wind: Greater than “light and variable”

• Visibility: 10+ mi

• Outcome: SUCCESS

• Results:

Stable video recording

Stable quadcopter

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DWH

ERC

1

Home

Actual

Planned

Mission Test – Second Attempt

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Verification of Requirements

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Attribute Requirement Actual Units

Climb rate 15 30 ft/s

Traverse rate 40 49 ft/s

Signal range 0.25 0.27 mi

Max. AGL 400 400+ ft

Max. altitude (density) 6,000 TBD ft

Max. take-off weight 10 7.2 lb

Ground station weight 5 4.5 lb

Endurance 15 15:45 mm:ss

Size, main diagonal 36 32.5 in

Drop survivability 3 1 ft

Assembly time 4 3:27 mm:ss

Operable temperatures 32 – 90 TBD °F

Budget

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Subsystem Allotted Spent Remaining

Airframe Structure $ 240.00 $ 215.57 $ 24.43

Propulsion $ 520.00 $ 406.78 $ 113.22

Communication & Electronics $ 1,710.00 $ 1,083.74 $ 626.26

Gimbal & Camera $ 290.00 $ 494.80 $ (204.80)

Manager’s Reserve $ 440.00 $ 296.04 $ 143.96

SYSTEM TOTAL $ 3,200.00 $ 2,496.93 $ 703.07

Lessons Learned

• Have a backup plan

• Have spares

• Assume nothing works the first time

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Future Development

• Improve the gimbal stability

• Change video frequency

• Improve video signal quality

• Reduce EMI

• Reinforce the landing gear

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Summary

• Problem Statement and Approach

• Objectives

• Conceive

• Design

• Implement

• Operate

• Budget

• Lessons Learned

• Future Development

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Thank You

Dean Bertozzi

Professor Rosner

Professor Guo

Professor Carlstrom

SAE First Gen Supermile

Professor Kostar

Professor Sadreay

Professor Marquis

RC Buyers Warehouse

DWC Facilities

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