Wednesday, March 23, 2016

Setbacks and progress

Hey everyone, it's been a couple weeks and I don't have a funny or interesting title this time. I don't have any tragic setbacks or huge things. Only steady progress, and that's not a bad thing. The parts list and design are finished. Everything is going according to plan and staying relatively on schedule but the hardest parts have yet to come. We still need to get all the parts, 3D print the limbs and frame. Then comes the hardest part of bringing all of the expensive, oddly shaped, puzzle pieces together into a working quadcopter.


The limb is about nine and a half inches long with the truss like system to keep it strong and light with a slight curve on the bottom to distribute the weight evenly. The landing gear only adds a little weight and keeps the main body about 4 inches off the ground. This should be efficient with the material and weight being a decent compromise between strong, light, and aesthetically pleasing.



The total length of the quadcopter is about twenty five inches on the diagonal. The base consists of the center joints of the four limbs, the bottom aluminum plate, and the top 3D printed plate. The four bases of the limbs interlock to create a space at the center of the quadcopter. Inside this is where most of the electronics and such will be housed while the battery will be strapped on top. 


We were hoping to do most of the assembly and testing over spring break, however it turns out that the shipping for the control board and other main electronics could take up to three weeks. It's going to be a time crunch to finish this and make it operational but it's doable. 

Wednesday, March 9, 2016

Some salt and batteries.



Gollly-gee-wiz, take off your socks, because you’re going to need your toes to count the number of hours we researched quadcopters to have any real idea of what we’re doing. It most likely did not help that we chose a project that neither one of knew anything about so we had to learn everything from the ground up. Richard and I have both researched hours on hours by ourselves and probably about eight hours together. There's probably twenty four to thirty hours of research between the two of us if not more, hence why you are now sockless. 

We started by just finding general information and reading guides on quadcopter builds, what types of motors are used, what variables affect the propellers, what frames are made of, and the options for the control board, etc. We had 5 snow days since the start of this so we’ve had some time to work on learning what we need to. We set the high goal of creating a comprehensive parts list for this Wednesday and we did pretty good, but boy was it a long, snowy road.

We started the whole thing off by laying down a maximum budget, how much would both of us be willing to put forward to build a fairly high end quadcopter? We decided on a combined budget of $400 as Richard has “a good amount of money.” As we read we created a list of the major components that we’d need:

>Brushless motors/ Propellers/ speed controllers
>Frame
>Battery
>R-C Transmitter+ Receiver
>Flight Control Board
               
Now this may not seem like much, it's only five items right? WRONG. People write books just on the function of the motors and how to find the right ones. We had to calculate the approximate weight of a quadcopter we hadn’t built in order to find the right motors, so we had to find the weight of the components that we didn’t know we wanted to find the weight of the quadcopter we didn’t have. Confusing, right? We decided on designing and 3-D printing the frame, found several batteries to narrow down, looked for the cheapest R-C transmitter, and found different options for the control board.

The rough estimates for weight with the motor systems we were looking at were upwards of 1700 grams. That’s too much. That’s crazy heavy for a quadcopter the size we’re building and we didn’t know where the weight was coming from. Turns out it was my fault. I had grossly overestimated the weight of the frame at almost 1000 grams and after many recalculations and estimates we found it to be less than 500. We continued to narrow down the list of things we wanted, making sure the puzzle pieces could all fit as we went, and things were looking good. Then my computer broke. Failure of the hard drive. Unrecoverable (I'm still salty about that). Luckily I had made backups of all the quadcopter files regularly but it still took me a while to be fully operational again. We eventually got it done though. A finished list of the price and weight of all the main components. 1100-1200 grams and $300. Well within weight limitation and budget. Awesome.

Air Gear 350 Motor, Prop, and ESC Combo Pack
This is the picture of the motors we're going to use. We're getting higher end ones to give us more wiggle room with weight and power. If you'd like to read more about them you can click the caption to go to the website. We're going to outfit the control board with GPS so we can program auto functions in and hopefully make it easier to fly. We also decided on the biggest battery we could afford, because why not?


I apologize for such a long post, however there is a lot that got done over the past few weeks and even this barely scratches the surface of the information. Over the next couple weeks we hope to finish and refine the design and have a complete CAD model of the quadcopter.