Author: Danie Conradie

424 Articles

Solar Planes Are Hard

October 12, 2024 by 12 Comments

A regular comment we see on electric aircraft is to “just add solar panels to the wings.” [James] from Project Air has been working on just such a solar plane, and as he shows in the video after the break, it is not a trivial challenge.

A solar RC plane has several difficult engineering challenges masquerading as one. First, you need a solid, efficient airframe with enough surface area for solar panels. Then, you need a reliable, lightweight, and efficient solar charging system and, finally, a well-tuned autopilot to compensate for a human pilot’s limited endurance and attention span.

In part one of this project, a fault in the electrical system caused a catastrophe so James started by benching all the electricals. He discovered the MPPT controller had a battery cutoff feature that he was unaware of, which likely caused the crash. His solution was to connect the solar panels to the input of a 16.7 V voltage regulator—just under the fully charged voltage of a 4S LiPo battery— and wire the ESC, control electronics, and battery in parallel to the output. This should keep the battery charged as long as the motor doesn’t consume too much power.

After rebuilding the airframe and flight testing without the solar system, [James] found the foam wing spars were not up to the task, so he added aluminum L-sections for stiffness. The solar panels and charging system were next, followed by more bench tests. On the test flight, it turned out the aircraft was now underpowered and struggled to gain altitude thanks to the added weight of the solar system. With sluggish control responses,[James] eventually lost sight of it behind some trees, which led to a flat spin and unplanned landing.

Fortunately, the aircraft didn’t sustain any damage, but [James] plans to redesign it anyway to reduce the weight and make it work with the existing power system.

We’ve seen several solar planes from [rctestflight] and meticulously engineered versions from [Bearospace Industrues]. If long flight times is primarily what you are after, you can always ditch the panels and  use a big battery for 10+ hour flights.

Continue reading “Solar Planes Are Hard” →

Tiny Drones Do Distributed Mapping

October 11, 2024 by 12 Comments

Sending teams of tiny drones to explore areas and structures is a staple in sci-fi and research, but the weight and size of sensors and the required processing power have long been a limiting factor. In the video below, a research team from [ETH Zurich] breaks through these limits, demonstrating indoor mapping with a swarm of tiny drones without dependence on any external systems.

The drone is the modular Crazyflie platform, which uses stackable PCBs (decks) to expand capabilities. The team added a Flow deck for altitude control and motion tracking, and a Loco positioning deck with a UWB module determining relative distances between drones. On top of this, the team added two custom decks. The first mounts four VL53L5CX 8×8 pixel TOF sensors for omnidirectional LIDAR scanning. The final deck does handles all the required processing with a GAP9 System-on-Chip, which features 10 RISC-V cores running on just 200 mW of power.

Of course the special sauce of this project lies in the software. The team developed a lightweight collaborative Simultaneous Localization And Mapping (SLAM) algorithm which can be distributed across all the drones in the swarm. It combines LIDAR scan data and the estimated position of the drone during the scan, and then overlays the data for the scans for each location across different drones, compensating for errors in the odometry data. The team also implemented inter-drone collision avoidance, packet collision avoidance and optimizing drones’ paths. The code is supposed to be available on GitHub, but the link was broken at the time of writing.

The Crazyflie platform has been around for more than a decade now, and we’ve seen it used in several research projects, especially related to autonomous navigation. Continue reading “Tiny Drones Do Distributed Mapping” →

3D Printed Bearings With Filament Rollers

October 9, 2024 by 24 Comments

Commodity bearings are a a boon for makers who to want something to rotate smoothly, but what if you don’t have one in a pinch? [Cliff] of might have the answer for you, in the form of 3D printed bearings with filament rollers.

With the exception of the raw filament rollers, the inner and outer race, roller cage and cap are all printed. It would also be possible to design some of the components right into a rotating assembly. [Cliff] makes it clear this experiment isn’t about replacing metal bearings — far from it. Instead, it’s an inquiry into how self-sufficient one can be with a FDM 3D printer. That didn’t stop him from torture testing the design to its limits as wheel bearings on an off-road go-cart. The first version wasn’t well supported against axial loads, and ripped apart during some more enthusiastic maneuvers.

[Cliff] improved it with a updated inner race and some 3D printed washers, which held up to 30 minutes of riding with only minimal signs of wear. He also made a slightly more practical 10 mm OD version that fits over an M3 bolt, and all the design files are downloadable for free. Cutting the many pieces of filament to length quickly turned into a chore, so a simple cutting jig is also included.

Let us know in the comments below where you think these would be practical. We’ve covered some other 3D printed bearing that use printed races, as well as a slew bearing that’s completely printed. Continue reading “3D Printed Bearings With Filament Rollers” →

3D Printed Hydrofoil Goes From Model Scale To Human Scale With Flight Controller

October 6, 2024 by 5 Comments

Hydrofoils have been around for several decades, but watching a craft slice through the water with almost no wake never get old. In the videos after the break, [rctestflight] showcases his ambitious project: transforming a standup paddleboard into a rideable hydrofoil with active stabilization.

Unlike conventional electric hydrofoil boards that depend on rider skill for balance, [rctestflight] aims to create a self-stabilizing system. He began by designing a small-scale model, complete with servo-controlled ailerons and elevators, dual motors for differential thrust, and a dRehmFlight flight controller. A pair of sonar sensors help the flight controller maintain constant height above the water. The wings are completely 3D printed, with integrated hinges for flight control surfaces slots for wiring and control components. It’s better suited for 3D printing than RC aircraft since it’s significantly less sensitive to weight, allowing for more structural reinforcement. The small scale tests were very successful and allowed [rctestflight] to determine that he didn’t need the vertical stabilizer and rudder.

The full-sized version features a scaled up wing, larger servos and motors attached to an 11-foot standup paddleboard — minus its rear end — mounted on commercially available e-foil booms. A foam battery box stores a hefty LiFePO4 battery, while the electronics from the smaller version are repurposed here. Despite only catching glimpses of this larger setup in action at the end of the video, it promises an excitingly smooth lake ride we would certainly like to experience.

We’ve seen several 3D printed hydrofoils around here, but this promised to be the largest successful attempt. Don’t fail us [Daniel].

Continue reading “3D Printed Hydrofoil Goes From Model Scale To Human Scale With Flight Controller” →

Automated Pixel Art With Marbles

October 6, 2024 by 11 Comments

Marble machines are a fun and challenging reason to do engineering for the sake of engineering. [Engineezy] adds some color to the theme, building a machine to create 16×16 marble images automatically. (Video embedded below.)

The core problem was devising ways to sort, lift, place, and dump marbles in their correct positions without losing their marbles—figuratively and literally. Starting with color detection, [Engineezy] used an RGB color sensor and Euclidian math to determine each marble’s color. After trying several different mechanical sorting mechanisms, he settled on a solenoid and servo-actuated dump tube to drop the marble into the appropriate hopper.

After sorting, he faced challenges with designing a mechanism to transport marbles from the bottom hoppers to the top of the machine. While paddle wheels seemed promising at first, they tended to jam—a problem solved by innovating with Archimedes screws that move marbles up smoothly without clogs. The marbles are pushed into clear tubes on either side of the machine, providing a clear view of their parade to the top.

Perhaps most ingenious is his use of constant-force springs as a flexible funnel to guide the marbles to a moving slider that drops them into the correct column of the display. When a picture is complete, sliding doors open on the bottom of the columns, dumping the marbles into a chain lift which feeds them into the sorting section. Each of the mechanisms has a mirrored version of the other side, so the left and right halves of the display operate independently.

The final product is slow, satisfying and noisy kinetic testament to [Engineezy]’s perseverance through countless iterations and hiccups.

Marble machines can range from minimalist to ultra-complex musical monstrosities, but never fail to tickle our engineering minds. Continue reading “Automated Pixel Art With Marbles” →

Single Rotor Drone Spins For 360 Lidar Scanning

October 4, 2024 by 9 Comments

Multiple motors or servos are the norm for drones to achieve controllable flight, but a team from MARS LAB HKU was able to a 360° lidar scanning drone with full control on just a single motor and no additional actuators. Video after the break.

The key to controllable flight is the swashplateless propeller design that we’ve seen a few times, but it always required a second propeller to counteract self-rotation. In this case, the team was able to make that self-rotation work so that they could achieve 360° scanning with a single fixed LIDAR sensor. Self-rotation still needs to be slowed, so this was done with four stationary vanes. The single rotor also means better efficiency compared to a multi-rotor with similar propeller disk area.

The LIDAR comprises a full 50% of the drone’s weight and provides a conical FOV out to a range of 450m. All processing happens onboard the drone, with point cloud data being processed by a LIDAR-inertial odometry framework. This allows the drone to track and plan its flight path while also building a 3D map of an unknown environment. This means it would be extremely useful for indoor or underground environments where GPS or other positioning systems are not available.

All the design files and code for the drone are up on GitHub, and most of the electronic components are off-the-shelf. This means you can build your own, and the expensive lidar sensor is not required to get it flying. This seems like a great platform for further experimentation, and getting usable video from a normal camera would be an interesting challenge. Continue reading “Single Rotor Drone Spins For 360 Lidar Scanning” →

The Challenges Of Charging Drones From Power Lines

October 1, 2024 by 17 Comments

Drones that charge right on the power lines they inspect is a promising concept, but comes with plenty of challenges. The Drone Infrastructure Inspection and Interaction (Diii) Group of the University of South Denmark is tackling these challenges head-on.

The gripper for these drones may seem fairly straightforward, but it needs to inductively charge, grip, and detach reliably while remaining simple and lightweight. To attach to a power line, the drone pushes against it, triggering a cord to pull the gripper closed. This gripper is held closed electromagnetically using energy harvested from the power line or the drone’s battery if the line is off. Ingeniously, this means that if there’s an electronics failure, the gripper will automatically release, avoiding situations where linemen would need to rescue a stuck drone.Accurately mapping power lines in 3D space for autonomous operation presents another hurdle. The team successfully tested mmWave radar for this purpose, which proves to be a lightweight and cost-efficient alternative to solutions like LiDAR.

We briefly covered this project earlier this year when details were limited. Energy harvesting from power lines isn’t new; we’ve seen similar concepts applied in government-sanctioned spy cameras and border patrol drones. Drones are not only used for inspecting power lines but also for more adventurous tasks like clearing debris off them with fire. Continue reading “The Challenges Of Charging Drones From Power Lines” →