ESP-Drone: Building An ESP32-Based Quadcopter For Not Much Cash

March 31, 2024 by 11 Comments

What’s the cheapest quadcopter you can build? As [Circuit Digest] demonstrates with their variant of the ESP-Drone project by Espressif, you only need a minimum of parts: an ESP32 MCU, an inertial measurement unit (IMU) such as the MPU6050, and four MOSFETs to drive the brushless DC motors. As the PCB also forms the structural frame and landing struts for the quadcopter, not even a 3D printer is needed. All told, [Circuit Digest] figures the total BOM comes in at around 1,000 Indian Rupees, or about $12 USD.

The fully assembled ESP-Drone flying around. (Credit: Circuit Digest)
The fully assembled ESP-Drone flying around. (Credit: Circuit Digest)

While this [Circuit Digest] project provides basic IMU functionality, the Espressif project also has a few expansion boards detailed on its hardware page, depending on the base model of the mainboard you pick. The [Circuit Digest] project follows the ESPlane-V2-S2 version with no expansion boards, but the ESP32-S2-Drone V1.2 mainboard can be extended with position-hold, pressure and compass modules, as well as custom boards.

As a derivative of the Bitcraze Crazyflie project, the ESP-Drone firmware also supports the rather nifty cfclient software for remote monitoring, logging and control. This may also be in the [Circuit Digest] firmware, but wasn’t listed among the features.

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A Deep Dive Into Quadcopter Controls

January 1, 2024 by 3 Comments

In the old days, building a quadcopter or drone required a lot of hacking together of various components from the motors to the batteries and even the control software. Not so much anymore, with quadcopters of all sizes ready to go literally out-of-the-box. While this has resulted in a number of knock-on effects such as FAA regulations for drone pilots, it’s also let us disconnect a little bit from the more interesting control systems these unique aircraft have. A group at Cornell wanted to take a closer look into the control systems for drones and built this one-dimensional quadcopter to experiment with.

The drone is only capable of flying in one dimension to allow the project to more easily fit into the four-week schedule of the class, so it’s restricted to travel along a vertical rod (which also improves the safety of the lab).  The drone knows its current position using an on-board IMU and can be commanded to move to a different position, but it first has to calculate the movements it needs to make as well as making use of a PID control system to make its movements as smooth as possible. The movements are translated into commands to the individual propellers which get their power from a circuit designed from scratch for this build.

All of the components of the project were built specifically for this drone, including the drone platform itself which was 3D printed to hold the microcontroller, motors, and accommodate the rod that allows it to travel up and down. There were some challenges such as having to move the microcontroller off of the platform and boosting the current-handling capacity of the power supply to the motors. Controlling quadcopters, even in just one dimension, is a complex topic when building everything from the ground up, but this guide goes some more of the details of PID controllers and how they help quadcopters maintain their position.

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Exploring Ground-Effect With A Quadcopter

September 23, 2023 by 2 Comments

The ground-effect (GE) refers to the almost mystical property where the interaction of the airflow around an aircraft’s wing and the ground massively increases efficiency due to the reduction of lift-dependent drag, perhaps best demonstrated by the Soviet Lun-class “ekranoplans” of the 1980s and 90s. Interestingly, this principle also applies to rotary aircraft, which led the [rctestflight] YouTube channel to wonder what would happen if a quadcopter were to be adapted for GE.

As noted on the Wikipedia entry for Ground-effect vehicle (GEV), it’s essential to have some kind of forward motion. With a rotorcraft like a helicopter or quadcopter this motion is already provided by the spinning propeller, which makes it noticeably easier to get the aircraft into the ground-effect. operating mode. Following the notion that the GE becomes noticeable at an altitude that’s dependent on the length of the aircraft’s wings, this got translated into putting the largest propellers available on the custom inverted-prop (to put them lower to the ground) quadcopter, to see what effect this would have on the quadcopter’s performance. As demonstrated by the recorded current drawn (each time with a fully charged battery), bigger is indeed better, and the GE effect is indeed very noticeable for a quadcopter.

Getting a usable GEV out of the basic inverted-prop quadcopter required some more lateral thinking, however, as it was not very easy to control this low to the ground. Here following design cues from skirtless hovercraft designs helped a lot, essentially drawing on the Coandă effect. Although this improved performance, at this point the quadcopter had been fitted with a fifth propeller for propulsion and was skidding about more like a skirtless hovercraft and less of a quadcopter.

Although great for scaring the living daylights out of unsuspecting water-based wildlife, what this unfortunately demonstrates is that GEVs are still hard, no matter which form they take. At the very least it does make for an excellent introduction into various aspects of aerodynamics.

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Hefty 3D Printed Quadcopter Meets Nasty End

September 1, 2023 by 26 Comments

You can readily buy all kinds of quadcopters off the shelf these days, but sometimes it’s more fun to build your own. [Michael Rechtin] did just that, with a hefty design of his own creation.

The build is an exploration of all kinds of interesting techniques. The frame itself uses generative design techniques to reduce weight while maintaining strength, while the motors themselves make heavy use of 3D-printed components. The design is modular and much of it slots together, too, and it uses a homebrewed flight controller running dRehmflight. It draws 2.5 kW from its lithium polymer batteries and weighs over 5 kg.

The DIY ethos led to some hurdles, but taught [Michael] plenty along the way. Tuning the PID control loop posed some challenges, as did one of the hand-wound motors being 5% down on thrust.  Eventually, though, the quad flew well enough to crash into a rectangular gate, before hitting the ground. Any quad pilot will tell you that these things happen. Drilling into the quad with a battery still inside then led to a fire, which did plenty of further damage.

[Michael’s] quad doesn’t appear to be specifically optimized to any one task, and it’s easy to see many ways in which it could be lightened or otherwise upgraded. However, as a freeform engineering thinking exercise, it’s interesting to watch as he tackles various problems and iteratively improves the design. Video after the break.

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Hackaday Podcast 130: Upside Down 3D-Printer, Biplane Quadcopter, Gutting A Calculator Watch, And GitHub CoPilot

August 6, 2021 by No comments

Hackaday editors Elliot Williams and Mike Szczys get charged up on the best hacks the week had to offer. The 3D printer design gods were good to us, delivering an upside-down FDM printer and a hack that can automatically swap out heated beds for continuous printing. We look at a drone design that builds vertical wings into the frame of a quadcopter — now when it tips on its side it’s a fixed-wing aircraft! We chew the artificially-intelligent fat about GitHub CoPilot’s ability (or inability?) to generate working code, and talk about the firm future awaiting solid state batteries.

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download (60 MB or so.)

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VTOL Tailsitter Flies With Quadcopter Control Software

August 2, 2021 by 11 Comments

Quadcopters are great for maneuverability and slow, stable flight, but it comes at the cost of efficiency. [Peter Ryseck]’s Mini QBIT quadrotor biplane brings in some of the efficiency of fixed-wing flight, without all the complexity usually associated with VTOL aircraft.

The Mini QBIT is just a 3″ mini quadcopter with a pair of wings mounted below the motors, turning it into a “tailsitter” VTOL aircraft. The wings and nosecone attach to the 3D printed frame using magnets, which allows them to pop off in a crash. There is no need for control surfaces on the wings since all the required control is done by the motors. The QBIT is based on a research project [Peter] was involved in at the University of Maryland. The 2017 paper states that the test aircraft used 68% less power in forward flight than hovering.

(Editor’s Note: [Peter] contacted us directly, and he’s got a newer paper about the aircraft.)

Getting the flight controller to do smooth transitions from hover to forward flight can be quite tricky, but the QBIT does this using a normal quadcopter flight controller running Betaflight. The quadcopter hovers in self-leveling mode (angle mode) and switches to acro mode for forward flight. However, as the drone pitches over for forward flight, the roll axis becomes the yaw axis and the yaw axis becomes the reversed roll axis. To compensate for this, the controller set up to swap these two channels at the flip of a switch. For FPV flying, the QBIT uses two cameras for the two different modes, each with its own on-screen display (OSD). The flight controller is configured to use the same mode switch to change the camera feed and OSD.

[Peter] is selling the parts and STL files for V2 on his website, but you can download the V1 files for free. However, the control setup is really the defining feature of this project, and can be implemented by anyone on their own builds.

For another simple VTOL project, check out [Nicholas Rehm]’s F-35 which runs on his dRehmFlight flight control software. Continue reading “VTOL Tailsitter Flies With Quadcopter Control Software” →

Micro Quadcopter Designed In OpenSCAD

April 2, 2021 by 20 Comments

Quadcopters are fantastical things, and now come in a huge variety of flavours, from lithe featherweight racers to industrial-grade filming rigs worth tens of thousands of dollars. The Beatle-1 from [masterdezign] comes in at the smaller scale, and its body was created entirely in code.

To create the Beatle-1, [masterdezign] used OpenSCAD, a 3D modelling program that uses code rather than visual tools for producing geometry. Thus, with a series of Boolean operations, extrusions and rotations, a basic lightweight quadcopter frame is created in a handful of lines of text. Then, it’s just a simple job of 3D printing the parts, wiring up four Olimex F1607 motors and hooking up a flight controller and the little drone is ready for takeoff.

The Beatle-1 serves as not only a fun flying toy but also a great example of applying OpenSCAD modelling techniques to real-world applications. Parts are available on Thingiverse for those wishing to roll their own. 3D printed drone frames are popular, and we’ve seen a few around these parts before. Video after the break.

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