The Unique Challenges Of Aerial Robotics

June 10, 2022 by Tom Nardi 2 Comments

When we think of robotics, the first thing that usually comes to mind for many of us is some sort of industrial arm that’s bolted to the floor, or perhaps a semi-autonomous rover trudging its way across the dusty Martian landscape. While these two environments are about as different as can be, the basic “rules” are pretty much the same. Being on firm ground ground gives the robot a clear understanding of its position and orientation, which greatly simplifies tasks such as avoiding collisions or interacting with nearby objects.

But what happens when that reference point goes away? How does a robot navigate when it’s flying through open space or hovering in mid-air? That’s just one of the problems that fascinates Nick Rehm, who stopped by to host this week’s Aerial Robotics Hack Chat to talk about his passion for flying robots. He’s currently an aerospace engineer at Johns Hopkins Applied Physics Laboratory, where he works on the unique challenges faced by autonomous flying vehicles such as the detection and avoidance of mid-air collisions, as well as the development of vertical take-off and landing (VTOL) systems. But before he had his Master’s in Aerospace Engineering and Rotorcraft, he got started the same way many of us did, by playing around with DIY projects.

In fact, regular Hackaday readers will likely recall seeing some of his impressive builds. His autonomous ekranoplan designed to follow a target using computer vision graced the front page in April. Back in 2020, we took a look at his recreation of SpaceX’s Starship prototype, which used a realistic arrangement of control surfaces and vectored thrust to perform the spacecraft’s signature “Belly Flop” maneuver — albeit with RC motors and propellers instead of rocket engines. But even before that, Nick recalls asking his mother for permission to pull apart a Wii controller so he could use its inertial measurement unit (IMU) in a wooden-framed tricopter he was working on.

Discussing some of these hobby builds leads the Chat towards Nick’s dRehmFlight project, a GPLv3 licensed flight control package that can run on relatively low-cost hardware, namely a Teensy 4.0 microcontroller paired with the GY-521 MPU6050 IMU. The project is designed to let hobbyists easily experiment with VTOL craft, specifically those that transition between vertical and horizontal flight profiles, and has powered the bulk of Nick’s own flying craft.

Moving onto more technical questions, Nick says one of the most difficult aspects when designing an autonomous flying vehicle is getting your constraints nailed down. What he means by that is having a clear goal of what the craft needs to do, and critically, how long it needs to do it. How far does the craft need to be able to fly? How fast? Does it need to loiter at the target location, and if so, for how long? The answers to these questions will largely dictate the form of the final vehicle, and are key to determining if it’s worth implementing the complexity of transitioning from VTOL to fixed-wing horizontal flight.

But according to Nick, the biggest challenge in aerial robotics is onboard state estimation. That is, the ability for the craft to know its position and orientation relative to the ground. While high-performance computers have gotten lighter and sensors have improved, he says there’s still no substitute for having a ground-based tracking system. He mentions that those fancy demonstrations you’ve seen with drones flying in formation and working collaboratively towards a task will almost certainly have an array of motion capture cameras tucked off to the side. This makes for an impressive show, but greatly limits the practical application of these drone swarms.

Nick’s custom Raspberry Pi 4-powered quadcopter lets him test autonomous flight techniques.

So what does the future of aerial robotics look like? Nick says open source projects like ArduPilot and PX4 are still great choices for hobbyists, but sees promise in newer platforms which pair the traditional autopilot with more onboard computing power, such as Auterion’s Skynode. More powerful flight controllers can enable techniques such as simultaneous localization and mapping (SLAM), which uses 3D scans of the environment to help the robot orient itself. He’s also very interested in technologies that enable autonomous flight in GPS-denied environments, which is critical for robotic craft that need to operate indoors or in situations where satellite navigation is unavailable or unreliable. In light of the incredible success of NASA’s Ingenuity helicopter, we imagine these techniques will also play an invaluable role in the future airborne exploration of Mars.

We want to thank Nick for hosting this week’s Aerial Robotics Hack Chat, which turned out to be one of the fastest hours in recent memory. His experience as both an avid hobbyist and a professional in the field provided exactly the sort of insight the Hackaday community looks for, and his gracious offer to keep in touch with several of those who attended the Chat to further discuss their projects speaks to how passionate he is about this topic. We expect to see great things from Nick going forward, and would love to have him join us again in the future to see what he’s been up to.

The Hack Chat is a weekly online chat session hosted by leading experts from all corners of the hardware hacking universe. It’s a great way for hackers connect in a fun and informal way, but if you can’t make it live, these overview posts as well as the transcripts posted to Hackaday.io make sure you don’t miss out.

Autonomous Inflatable Canoe

May 29, 2022 by Tom Nardi 6 Comments

With the summer months nearly upon us, many are dreaming of warm afternoons spent floating on a quiet lake. Unless you’re [Kolins] anyway. Apparently his idea of a good time is controlling a full-sized inflatable canoe not from onboard with a pair of oars, but from the shore with a RC transmitter.

The linkage design allows the motor to be adjusted vertically.

Of course, as the video after the break shows, just because the canoe is powered by a remotely operated electric trolling motor doesn’t mean it can’t still carry human occupants. In fact, with the addition of a Matek F405-Wing flight controller running the rover variant of ArduPilot, the boat can even take you on a little tour of the lake while you kick back and relax.

We like that this project took the path of least resistance wherever possible. Rather than trying to spin up his own custom propulsion unit, and inevitably dealing with the challenge of waterproofing it, [Kolins] built his system around a commercial trolling motor. A clever servo mechanism physically turns the motor in much the same way a human operator would, while the speed is controlled with a suitably beefy ESC from Traxxas placed between the motor and its lead-acid battery.

It doesn’t look like there’s been any permanent mechanical or electrical changes made to the motor, which makes the whole thing a lot easier to replicate. We’ve talked in the past about the relative rarity of low-cost robotic watercraft, so a “bolt-on” propulsion module like this that can turn a cheap inflatable boat into an autonomous platform for research and experimentation is very interesting.

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Hydrofoils Love This One Simple Trick

March 4, 2022 by Matthew Carlson 9 Comments

Earlier in the year, [rctestflight] created an active hydrofoil RC craft but found the actual performance very lacking. Luckily for him and for us, he continued to tweak it and one tweak suddenly turned it from a nightmare to a dream.

That tweak was adding ArduPilot’s airplane model. The design had three servos, which each actuated the angle of a foil underneath one of the three pontoons. The ship propelled itself via some propellers mounted near the top. If you know much about ArduPilot, you notice that active hydrofoil boat doesn’t show up on the list of supported platforms, and you’re right. [rctestflight] points out that the three servos actually function as a plane underwater. The front two are ailerons and the back one is an elevator, all things that ArduPilot knows how to handle with a tightly controlled loop except for one thing; there’s no altitude data.

So he stole a trick he developed earlier for his ground effect plane and used a distance sensor to let ArduPilot know how to adjust things. He used a sonar sensor instead of lidar as it works better with water and he was pleasantly surprised when he took it out on the lake and it just worked wonderfully. The original goal with the active stabilization was to have the efoil immune to choppy waters, and we’re sad to say that it didn’t quite reach that lofty target. The single sonar sensor follows the wave in front of it beautifully but can’t handle the complex waves being thrown at it. Perhaps some sort of sensor fusion algorithm could provide the necessary data to be truly resilient. But we love watching the foil glide across the water and it is hard to remember that it’s actively flying rather than just floating that way.

Others have tried and failed to 3D print a hydrofoil while others have succeeded. We love that [rctestflight] came back to finish the fight and came away a champion. Video after the break.

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Autonomous Ground Effect Vehicle Demonstrator Aims To Speed Up Maritime Shipping

October 10, 2021 by Danie Conradie 35 Comments

Ground effect vehicles, or ekranoplans, have the advantage of being more efficient than normal aircraft and faster than boats, but so far haven’t been developed beyond experimental prototypes. Fortunately, this doesn’t stop companies from trying, which has led to a collaboration between [ThinkFlight] and [rctestflight] to create a small-scale demonstrator for the Flying Ship Company.

The Flying Ship Company wants to use unmanned electric ekranoplans as high-speed marine cargo carriers that can use existing maritime infrastructure for loading and unloading. For the scale model, [rctestflight] was responsible for the electronics and software, while [ThinkFlight] built the airframe. As with his previous ekranoplan build, [ThinkFlight] designed it in XFLR5, cut the parts from foam using a CNC hot wire cutter (which we still want a better look at), and laminated it with Kevlar for strength. One of the challenges of ground effect vehicles is that the center of pressure will shift rearward as they leave a ground effect, causing them to pitch up. To maintain control when moving into and out of ground effect, these crafts often use a large horizontal stabilizer high up on the tail, out of ground effect.

A major feature of this demonstrator is automatic altitude control using a LIDAR sensor mounted on the bottom. This was developed by [rctestflight] using a simple foam board ekranoplan and [Think Flighs]’s previous airframe, with some custom code added to ArduPilot. It works very well on smooth, calm water, but waves introduce a lot of noise into the LIDAR data. It looks like they were able to overcome this challenge, and completed several successful test flights in calm and rough conditions.

The final product looks good, flies smoothly, and is easy to control since the pilot doesn’t need to worry about pitch or throttle control. It remains to be seen if The Flying Boat will overcome the challenges required to turn it into a successful commercial craft, and we will be following the project closely.

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Solar Powered Autonomous Tugboat For Rescuing Autonomous Vessels

September 18, 2021 by Danie Conradie No comments

[rctestflight] has built several autonomous boats, and with missions becoming longer and more challenging, he bought an inflatable kayak to serve as a dedicated rescue vessel. Instead of relying on outdated manual paddling, he built an autonomous solar-powered tugboat.

Towing test with kayak — ♪ “Rum, treasure, ArduRover, Pixhawk 4 and so much solar, break of dawn till the day is over, the ship will surely go…” ♪

The tugboat uses a pair of molded fiberglass hulls in a catamaran configuration. The wide platform allows a pair of 100W solar panels to be mounted on top. It was [rctestflight]’s first time molding anything out of fiberglass, so there was quite a bit of trial and error going on. The mold was 3D printed in sections, aligned with dowel pins, and glued together. After the epoxy had cured, the mold halves could be split apart for easier removal of the hull.

As with most of [rctestflights] autonomous vehicles, control is handled by a Pixhawk 4 running ArduPilot/ArduRover. A pair of 76 mm brass propellers powered by brushless motors provide propulsion and differential steering. The motors get power from six LiFePO4 batteries, which charge from the solar panels via MPPT charge controllers. The hulls are covered with plywood decks with removable hatches and inspection windows. After a bit of tuning, he took the boat for a few test runs, the longest being 5.1 km with himself in tow in the kayak. At less than 5 km/h (3 mph) it’s no speedboat, but certainly looks like a relaxing ride. Many of [rctestflight]’s previous vessels were airboats to avoid getting underwater propellers tangled in weeds. It was less of an issue this time since he could just haul the tugboat close to the kayak and clear the propellers.

[rctestflights] are always entertaining and educational to watch, and this one certainly sets the standard for sea-shanty soundtracks at 13:32 in part two.

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Eliminate Vertical Stabiliser With ArduPlane

July 9, 2021 by Danie Conradie 5 Comments

Flying wings are popular options for fixed-wing FPV flying, but they have one rather annoying characteristic: yaw wag. The flying wing will wobble on the yaw axis while flying, and this side-to-side movement is visible on the pilot’s FPV video feed. With a combination of split rudders and ArduPilot, [Think Flight] eliminated wing wag without using any vertical stabilizers.

Yaw wag usually occurs on flying wings that use a pair of small winglets instead of a large vertical stabilizer on the centerline. Split rudders, also known as differential spoilers, can be used for active yaw control by increasing drag on either wing independently. However, this requires very rapid corrections that are very difficult to do manually, so this is where ArduPilot comes in. [Think Flight] used its yaw dampening feature in combination with differential spoilers to completely eliminate vertical stabilizers and yaw wag. This is the same technique used on the B-2 stealth bomber to avoid radar reflecting vertical stabilizers. [Think Flight] also used these clamshells spoilers as elevons.

Using XFLR5 airfoil analysis software, [Think Flight] designed built a pair of flying wings to use these features. The first was successful in eliminating yaw wag, but exhibited some instability on the roll axis. After taking a closer look at the design with XFLR5, he found air it predicted that airflow would separate from the bottom surface of the wing at low angles of attack. After fixing this issue, he built a V2 to closely match the looks of the B2 bomber. Both aircraft were cut from EPP foam with an interesting-looking CNC hot wire cutter and laminated with Kevlar for strength. Continue reading “Eliminate Vertical Stabiliser With ArduPlane” →

Ground Effect Drone Flies Autonomously

May 24, 2021 by Bryan Cockfield 14 Comments

There are a number of famous (yet fictional) sea monsters in the lakes and oceans around the world, but in the Caspian Sea one turned out to be real. This is where the first vehicles specifically built to take advantage of the ground effect were built by the Soviet Union, and one of the first was known as the Caspian Sea Monster due to the mystery surrounding its discovery. While these unique airplane/boat hybrids were eventually abandoned after several were built for military use, the style of aircraft still has some niche uses and can even be used as a platform for autonomous drones.

This build from [Think Flight] started off as a simple foam model of just such a ground effect vehicle (or “ekranoplan”) in his driveway. With a few test flights the model was refined enough to attach a small propeller and battery. The location of the propeller changed from rear-mounted to front-mounted and then back to rear-mounted for the final version, with each configuration having different advantages and disadvantages. The final model includes ~~an Arudino running~~ an autopilot program called Ardupilot, and with an air speed sensor installed the drone is able to maintain flight in the ground effect and autonomously navigate pre-programmed waypoints around a lake at high speed.

For a Cold War technology that’s been largely abandoned by militaries in favor of other modes of transportation due to its limited use case and extremely narrow flight tolerances, ground effect vehicles are relatively popular as remote controlled vehicles. This RC ekranoplan used the same Ardupilot software but paired with a LIDAR system instead of GPS to navigate its way around its environment.

Thanks to [TTN] for the tip!

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