Clever Control Loop Makes This Spinning Drone Fault-Tolerant

November 9, 2022 by Dan Maloney 18 Comments

Most multi-rotor aircraft are about as aerodynamic as a brick. Unless all its motors are turning and the control electronics are doing their thing, most UAVs are quickly destined to become UGVs, and generally in spectacular fashion. But by switching up things a bit, it’s possible to make a multi-rotor drone that keeps on flying even without two-thirds of its motors running.

We’ve been keeping a close eye on [Nick Rehm]’s cool spinning drone project, which basically eschews a rigid airframe for a set of three airfoils joined to a central hub. The collective pitch of the blades can be controlled via a servo in the hub, and the whole thing can be made to rotate and provide lift thanks to the thrust of tip-mounted motors and props. We’ve seen [Nick] manage to get this contraption airborne, and hovering is pretty straightforward. The video below covers the next step: getting pitch, roll, and yaw control over the spinning blades of doom.

The problem isn’t trivial. First off, [Nick] had to decide what the front of a spinning aircraft even means. Through the clever uses of LED strips mounted to the airfoils and some POV magic, he was able to visually indicate a reference axis. From there he was able to come up with a scheme to vary the power to each motor as it moves relative to the reference axis, modulating it in either a sine or cosine function to achieve roll and pitch control. This basically imitates the cyclic pitch control of a classic helicopter — a sort of virtual swashplate.

The results of all this are impressive, if a bit terrifying. [Nick] clearly has control of the aircraft even though it’s spinning at 250 RPM, but even cooler is the bit where he kills first one then two motors. It struggles, but it’s still controllable enough for a bumpy but safe landing.

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3D Printed ROV Is The Result Of Many Lessons Learned

November 2, 2022 by Danie Conradie 10 Comments

Building an underwater remotely operated vehicle (ROV) is always a challenge, and making it waterproof is often a major hurdle. [Filip Buława] and [Piotr Domanowski] have spent four years and 14 prototypes iterating to create the CPS 5, a 3D printed ROV that can potentially reach a depth of 85 m.

FDM 3D prints are notoriously difficult to waterproof, thanks to all the microscopic holes between the layers. There are ways to mitigate this, but they all have limits. Instead of trying to make the printed exterior of the CPS 5 waterproof, the electronics and camera are housed in a pair of sealed acrylic tubes. The end caps are still 3D printed, but are effectively just thin-walled containers filled with epoxy resin. Passages for wiring are also sealed with epoxy, but [Filip] and [Piotr] learned the hard way that insulated wire can also act as a tube for water to ingress. They solved the problem by adding an open solder joint for each wire in the epoxy-filled passages.

For propulsion, attitude, and depth control, the CPS 5 has five brushless drone motors with 3D printed propellers, which are inherently unaffected by water as long as you seal the connectors. The control electronics consist of a PixHawk flight controller and a Raspberry Pi 4 for handling communication and the video stream to a laptop. An IMU and water pressure sensor also enable auto-leveling and depth hold underwater. Like most ROVs, it uses a tether for communication, which in this case is an Ethernet cable with waterproof connectors.

Acrylic tubing is a popular electronics container for ROVs, as we’ve seen with an RC Subnautica sub, LEGO submarine, and the Hackaday Prize-winning Underwater Glider.

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3D Printing With A Drone Swarm?

October 18, 2022 by Dave Rowntree 14 Comments

Even in technical disciplines such as engineering, there is much we can still learn from nature. After all, the endless experimentation and trials of life give rise to some of the most elegant solutions to problems. With that in mind, a large team of researchers took inspiration from the humble (if rather annoying) wasp, specifically its nest-building skills. The idea was to explore 3D printing of structures without the constraints of a framed machine, by mounting an extruder onto a drone.

As you might expect, one of the most obvious issues with this attempt is the tendency of the drone’s to drift around slightly. The solution the team came up with was to mount the effector onto a delta bot carrier hanging from the bottom of the drone, allowing it to compensate for its measured movement and cancel out the majority of the positional error.

The printing method relies upon the use of two kinds of drone. The first done operates as a scanner, measuring the print surface and any printing already completed. The second drone then approaches and lays down a single layer, before they swap places and repeat until the structure is complete.

Multiple drones can print simultaneously, by flying in formation. Prints were demonstrated using a custom cement-like material, as well as what appeared to be expanding foam, which was impressive feat to say the least.

The goal is to enable the printing of large, complex shaped structures, on any surface, using a swarm of drones, each depositing whatever material is required. It’s a bit like a swarm of wasps building a nest, into whatever little nook they come across, but on the wing.

We’ve been promised 3D printed buildings for some time now, and while we’re not sure this research is going to bring us any closer to living in an extruded house, we’re suckers for a good drone swarm here at Hackaday.

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[Tom Stanton] Builds An Osprey

October 8, 2022 by Dan Maloney 20 Comments

The V-22 Osprey is an aircraft like no other. The tiltrotor multirole military aircraft makes an impression wherever it goes; coincidentally, a flight of two of these beasts flew directly overhead yesterday and made a noise unlike anything we’ve ever heard before. It’s a complex aircraft that pushes the engineering envelope, so naturally [Tom Stanton] decided to build a flight-control accurate RC model of the Osprey for himself.

Sharp-eyed readers will no doubt note that [Tom] built an Osprey-like VTOL model recently to explore the basics of tiltrotor design. But his goal with this build is to go beyond the basics by replicating some of the control complexity of a full-scale Osprey, without breaking the bank. Instead of building or buying real swash plates to control the collective and cyclic pitch of the rotors, [Tom] used his “virtual swashplate” technique, which uses angled hinges and rapid changes in the angular momentum of the motors to achieve blade pitch control. The interesting part is that the same mechanism worked after adding a third blade to each rotor, to mimic the Osprey’s blades — we’d have thought this would throw the whole thing off balance. True, there were some resonance issues with the airframe, but [Tom] was able to overcome them and achieve something close to stable flight.

The video below is only the first part of his build series, but we suspect contains most of the interesting engineering bits. Still, we’re looking forward to seeing how the control mechanism evolves as the design process continues.

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Winged Drone Gets Forward Flight Capability

October 2, 2022 by Bryan Cockfield 17 Comments

Drones are pretty common in the electoronics landscape today, and are more than just a fun hobby. They’ve enabled a wide array of realtors, YouTubers, surveyors, emergency responders, and other professionals to have an extremely powerful tool at their disposal. One downside to these tools is that the power consumption tends to be quite high. You can either stick larger batteries on them, or, as [Nicholas] demonstrates, just spin them really fast during flight.

We featured his first tests with this multi-modal drone flight style a while back, but here’s a quick summary: by attaching airfoils to the arms of each of the propellers and then spinning the entire drone, the power requirements for level flight can be dramatically reduced. This time, he’s back to demonstrate another benefit to this unique design, which is its ability to turn on its side and fly in level flight like an airplane. It’s a little bizarre to see it in the video, as it looks somewhat like a stationary propeller meandering around the sky, but the power requirements for this mode of flight are also dramatically reduced thanks to those wings on the arms.

There are a few downsides to this design, namely that the vertical wing only adds drag in level flight, so it’s not as efficient as some bi-wing designs, but it compromises for that loss with much more effective hover capabilities. He also plans to demonstrate the use of a camera during spin-hover mode as well in future builds. It’s an impressive experiment pushing the envelope of what a multi-rotor craft can do, and [Nicholas] still has plans to improve the design, especially when it comes to adding better control when it is in spin-hover mode. We’d expect plenty of other drones to pick up some of these efficiency gains too, except for perhaps this one.

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A Drone For The Rest Of Us

September 29, 2022 by Bryan Cockfield 23 Comments

As anyone who’s spent Christmas morning trying to shake a quadcopter out of a tree can attest, controlling these fast moving RC vehicles can be tricky and require a bit of practice to master. [Erik] wanted to simplify this a little bit so his children and friends could race with him, and the end result is a drone that only needs two inputs to fly.

The results of his experimentation with simplifying the controls resulted in a “speeder” type drone which attempts to keep a certain distance off of the ground on its own thanks to an extremely fast time-of-flight sensor. The pilot is then left to control the throttle and the steering only, meaning that [Erik] can use pistol-style RC controllers for these machines. They have some similarities to a quadcopter, but since they need to stay level in flight they also have a fifth propeller on the back, similar to an airboat. This allows for a totally separate thrust control than would normally be available on a quadcopter.

The resulting vehicle is immediately intuitive to fly, behaving more like an RC car than a quadcopter. This also required quite a bit of processing power to compute the proper roll and yaw from a single steering input, but after many prototypes the result is impressive, especially since it was also built to use FPV as a means of control. One of the videos below demonstrates this video, and looks extremely fun to fly, and we wouldn’t mind seeing a race with these types of speeders much like we saw in the past with a group of pod-racing quadrotors.

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24 Hours Of Le Airplanes

September 27, 2022 by Bryan Cockfield 22 Comments

There’s no more famous road endurance race than the 24 Hours of Le Mans, where teams compete to see how far they can drive in a single 24-hour window. The race presents unique challenges not found in other types of racing. While RC airplanes may not have a similar race, [Daniel] a.k.a. [rctestflight] created a similar challenge for himself by attempting to fly an RC airplane non-stop for as long as he could, and a whole host of interesting situations cropped up before and during flight.

In order for an RC plane to fly for an entire day, it essentially needs to be solar powered. A large amount of strategy goes into a design of this sort. For one, the wing shape needs to be efficient in flight but not reduce the amount of area available for solar panels. For another, the start time of the flight needs to be balanced against the position of the sun in the sky. With these variables more or less fixed, [Daniel] began his flight.

It started off well enough, with the plane in an autonomous “return to home” mode which allowed it to continually circle overhead without direct human control. But after taking a break to fly it in FPV mode, [Daniel] noticed that the voltage on his battery was extremely high. It turned out that the solar charge controller wasn’t operating as expected and was shunting a large amount of solar energy directly into the battery. He landed and immediately removed the “spicy pillow” to avoid any sort of nonlinear event. With a new battery in the plane he began the flight again.

Even after all of that, [Daniel] still had some issues stemming from the aerodynamic nature of this plane specifically. There were some issues with wind, and with the flight controller not recognizing the correct “home” position, but all in all it seems like a fun day of flying a plane. If your idea of “fun” is sitting around and occasionally looking up for eight and a half hours. For more of [Daniel]’s long-term autonomous piloting, be sure to take a look at his solar tugboat as well.

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