Automating RC Motor Efficiency Testing

April 4, 2016 by 9 Comments

Small brushless motors and LiPo batteries are one of the most impressive bits of technology popularized in recent years. Just a few years ago, RC aircraft were powered by either anemic brushed motors or gas. Quadcopters were rare. Now, with brushless motors, flying has never been easier, building electric longboards is simple, and electric bicycles are common.

Of course, if you’re going to make anything fly with a brushless motor, you’ll probably want to know the efficiency of your motor and prop setup. That’s the idea behind [Michal]’s Automated RC Motor Efficiency Tester, his entry to the 2016 Hackaday Prize.

[Michal]’s project is not a dynamometer, the device you should use if you’re measuring the torque or power of a motor. That’s not really what you want if you’re testing brushless motors and prop configurations, anyway; similarly sized props can have very different thrust profiles. Instead of building a dyno for a brushless motor, [Michal] is simply testing the thrust of a motor and prop combination.

The device is very similar to a device sold at Hobby King, and includes a motor mount, microcontroller and display, and a force sensor to graph the thrust generated by a motor and prop. Data can be saved to an SD card, and the device can be connected to a computer for automatic generation of pretty graphs.

Brushless motors are finding a lot of uses in everything from RC planes and quadcopters, to robotics and personal transportation devices. You usually don’t get much of a data sheet with these motors, so any device that can test these motors will be very useful.

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Licence-Exempt Network Has High Ambitions

March 20, 2016 by 18 Comments

It’s safe to say that the Internet of Things is high on the list of buzzwords du jour. It was last seen rapidly ascending towards the Peak of Inflated Expectations on the Gartner Hype Cycle, and it seems that every startup you encounter these days is trying to place an IoT spin on their offering. Behind all the hype though lie some interesting wireless technologies for cheaply making very small microprocessors talk to each other and to the wider world.

Today we’d like to draw your attention to another wireless technology that might be of interest to Hackaday readers working in this area. UKHASnet is a wireless network developed from within the UK high-altitude ballooning community that uses cheap licence-exempt 868MHz radio modules in Europe and 915MHz in the Americas. The modules they are using have a surprisingly usable power output for licence exempt kit at 100mW, so the system has been designed for extensibility and bridging through nodes mounted on balloons, multirotors, or even seaborne buoys.

All UKHASnet packets are sent as human-readable plaintext ASCII, and the system borrows some of the features of amateur radio’s APRS. All packets are considered unreliable, all nodes repeat the packets they receive with their own node ID appended, and there are gateway nodes that make the packets available to the internet. There is a repeat number built into each packet to stop packets continuing ad infinitum.

Building a node is a simple process, requiring only the radio module, a microcontroller, and a battery. As examples they provide an implementation for the Arduino, and one for the LPC810 microcontroller. Their preferred radio module is the HopeRF RFM69HW, however the system will be capable of running on other modules of the same type.

So far the UKHASnet people have proven the system over a 65km range, created nodes on the sea, attached it to quadcopters, and built a host of other nodes.

This network differs from its commercial counterparts in that it has no proprietary IP or licencing from a standards body. And despite the name, you don’t have to be in the UK to use it. All data is in the clear, and thus it is likely that you won’t see it in mass-market commercial products. But it is exactly these features that are likely to make it attractive to the maker community. Your scribe will probably not be the only person who goes away from this article to suggest that their local hackspace finds the space for a UKHASnet node.

This is the first time we’ve featured UKHASnet here at Hackaday. Plenty of projects using licence-free radio modules have made it onto these pages, though, including this extreme-range remote controller for model aircraft, and this weather station sensor network that could have probably found UKHASnet useful had its creator had it to hand.

FAA Reauthorization Bill Includes Provisions For Hobbyists

March 15, 2016 by 62 Comments

Every year, Congress passes bills directing the funding for various departments and agencies. Sometimes, this goes swimmingly: congress recently told NASA to attempt a landing on Europa, Jupiter’s ice-covered moon. Sometimes, it doesn’t go as well. The draft of the FAA Reauthorization act of 2016 (PDF) includes provisions for drones and model airplanes amid fears of privacy-encroaching quadcopters.

As would be expected, the 2016 FAA Reauthorization act includes a number of provisions for unmanned aerial systems, a class of aircraft that ranges from a Phantom quadcopter to a Predator drone. The draft of the act includes provisions for manufacturers to prevent tampering of modification of their product, and provide the FAA with a statement of compliance, and prohibit these devices from being sold unless these conditions are met.

For a very long time, the Congress and the FAA have had special rules for model aircraft. Since 2012, the special rules for model aircraft have been simple enough: model aircraft are flown for hobby or recreational use, must operate in accordance with community-set safety guidelines, weigh less than 55 pounds, give way to manned aircraft, and not be flown within five miles of an airport. The 2016 FAA Reauthorization bill adds several updates. No model aircraft may be flown higher than 400 feet above ground level, and the operator of a model aircraft must pass a knowledge and safety test administered by the FAA. Under this draft of the FAA Reauthorization bill, you will have to pass a test to fly a quadcopter or model plane.

While this is only a draft of the 2016 FAA Reauthorization bill, there is a considerable risk flying model planes could quickly go the way of amateur radio with a Morse requirement for the license. This, of course, is due to Congress’ fears of the impact drones and model airplanes could have on safety, despite recent studies that show a 2kg drone is likely to cause injury to a human passenger once every 187 million years of operation. In other words, politicians don’t understand statistics.

Polyhedrone

March 4, 2016 by 6 Comments

[Brainsmoke] had a simple plan. Make a quadcopter with lots of addressable LEDs.

Not just a normal quadcopter with ugly festoons of LED tape though. [Brainsmoke] wanted to put his LEDs in a ball. Thus was born the polyhedrone, the idea of a flying deltoidal hexecontahedron covered as you might expect with all those addressable LEDs.

polyhedrone-PCB-kicadA Catalan solid makes a good choice for the homebrew polyhedron builder because its faces are all identical. Thus if you are making PCBs to carry LEDs, for example, you need only create a single PCB design to use on all faces. A bit of work in KiCAD, and a single face design with interlocking edges was ready. The boards were tested, a wiring layout was worked out, and the polyhedron was assembled.

But [Brainsmoke] didn’t stop there. He produced a flight case for the polyhedron, in the form of a larger polyhedron from what looks like lasercut thin ply.

Having a finished polyhedron, the next thing was to hook up a Raspberry Pi and write some software. First in Python, then in Go.

polyhedrone-light-1The results are simply stunning. If the mathematics and construction of a polyhedron were not enough to make this project worth a second look, then the gallery of images should be enough. You’ll notice that this is ostensibly a quadcopter project, yet no mention of flying has been made on this page. That’s because this is still a work in progress at Tech Inc Amsterdam, and there is more to come. But it honestly doesn’t matter if this project never moves a millimeter off the ground, as far as we are concerned [Brainsmoke] has created a superbly built thing of beauty in its own right, and we like that.

As you might expect, this is just the latest of many projects featured here that have involved addressable LEDs or quadcopters. Of note among them is this LED polyhedron that cleverly closes in all its bits, and this LED-equipped quadcopter that generates very pleasing patterns with a hi-res cross of pixels.

Anti-Cogging Algorithm Brings Out The Best In Your Hobby Brushless Motors

February 23, 2016 by 31 Comments

Cheap, brushless motors may be the workhorses behind our RC planes and quadcopters these days, but we’ve never seen them  in any application that requires low-speed precision. Why? Sadly, cheap brushless motors simply aren’t mechanically well-constructed enough to offer precise position control because they exhibit cogging torque, an unexpected motor characteristic that causes slight variations in the output torque that depend rotor position. Undaunted, [Matthew Piccoli] and the folks at UPenn’s ModLab have developed two approaches to compensate and minimize torque-ripple, essentially giving a cheap BLDC Motor comparable performance to it’s pricier cousins. What’s more, they’ve proven their algorithm works in hardware by building a doodling direct-drive robotic arm from brushless motors that can trace trajectories.

Cogging torque is a function of position. [Matthew’s] algorithm works by measuring the applied voltage (or current) needed to servo the rotor to each measurable encoder position in a full revolution. Cogging torque is directional, so this “motor fingerprint” needs to be taken in both directions. With these measured voltages (or currents) logged for all measurable positions, compensating for the cogging torque is just a matter of subtracting off that measured value at any given position while driving the motor. [Matthew] has graciously taken the trouble of detailing the subtleties in his paper (PDF), where he’s actually developed an additional acceleration-based method.

Hobby BLDC motors abound these days, and you might even have a few spares tucked away on the shelf. This algorithm, when applied on the motor controller electronics, can give us the chance to revisit those projects that mandate precise motor control with high torque–something we could only dream about if we could afford a few Maxon motors. If you’re new to BLDC Motor Control theory, check out a few projects of the past to get yourself up-and-running.

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Mini Quadcopter Becomes Paper Airplane

February 20, 2016 by 12 Comments

Several of us got Cheerson CX-10 mini quadcopters last year. We even bought some more to hand out as Christmas gifts. If you haven’t seen them, they are diminutive little flyers about the size of an English muffin. Thee’s no denying they are fun to fly around the house, and they do annoy the dogs.

However, like all cute toys, you eventually get bored just buzzing the dogs and cats. [JustforFun Media TK] decided that his needed a facelift, so he converted it into a paper airplane. This isn’t the paper airplane you folded up in school, either. This is a slick-looking jet aircraft.

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A Quadcopter Controlled By A Pi Zero

February 16, 2016 by 57 Comments

Flight controllers for quadcopters and other drones are incredible pieces of engineering. Not only do these boards keep an aircraft level, they do so while keeping the drone in one place, or reading a GPS sensor and flying it from waypoint to waypoint. The latest of these flight controllers is built on everyone’s favorite $5 computer, the Raspberry Pi Zero.

The PXFmini controller and autopilot shield is the latest project from Erle Robotics that puts eight servo outputs on the Pi, barometer and IMU sensors, a power supply, and all the adapters to turn the Raspberry Pi Zero into a capable flight controller. Since the Pi Zero will have some computational horsepower left over after keeping a quadcopter level, there’s a possibility of some very cool peripherals. Erle Robotics has been working with depth cameras and Lidar on more than a few drones. This makes for some interesting applications we can only imagine now.

The schematics for the PXFmini are open source in the best traditions of the RC and drone community and will be available soon. You can check out a video of the FXPmini flying around an office below.

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