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Development of an Unmanned Aerial Vehicle - A Tricopter
Transcript of Development of an Unmanned Aerial Vehicle - A Tricopter
A Project Report On
Development of an Unmanned Aerial Vehicle - A Tricopter
by
RAMANN BHARADWAJ M (AM.EN.U4EEE09041)
Submitted to
AMRITA SCHOOL OF ENGINEERING
AMRITAPURI CAMPUS, CLAPPANA P.O., KOLLAM-690525, KERALA.
In partial fulfilment of the requirements for the award of the degree of B.Tech
Project work carried out at
Council of Scientific and Industrial Research
National Aerospace Laboratories,
Bangalore - 560017.
Under the guidance of
Internal Guides External Guide
Dr Balakrishnan Shankar, Mr S Santhosh Kumar,
Professor and HOD, Scientist C,
Mechanical Department. Propulsion Division,
Amrita School of Engineering, Kerala. NAL, Bangalore.
Mr. Joshua D Freeman,
Assistant Professor,
Electrical and Electronics Department,
Amrita School of Engineering, Kerala.
January-June 2013
AMRITA SCHOOL OF ENGINEERING
AMRITAPURI CAMPUS, CLAPPANA P.O., KOLLAM-690525, KERALA.
CERTIFICATE
This is to certify the project work entitled “Development of an Unmanned
Aerial Vehicle – a Tricopter” carried out by
Name REG No
RAMANN BHARADWAJ M AM.EN.U4EEE09041
Is a bonafide work carried out at Amrita School of Engineering, Kerala, in partial
fulfilment for the award of the degree of Bachelor of Technology in Electrical &
Electronics Engineering at Amrita University during the academic year 2012-
2013.The project report has been approved as it satisfies the academic
requirements in respect of project work prescribed for Bachelor of Technology
degree.
Signature of Guide Signature of Guide Signature of HOD
Dr.Balakrishnan Shankar, Mr. Joshua D Freeman Dr. Chandramohanan Nair,
Mechanical Department. Dept. of EEE Dept. of EEE,
Amrita School of Engg, Amrita School of Engg, Amrita School of Engg,
Kollam, Kerala. Kollam, Kerala. Kollam, Kerala.
External Viva
Name of the Examiners Signature & Date 1. 2.
DECLARATION
I, hereby declare that the entire work embodied in this dissertation has
been carried out by us and no part of it has been submitted for any
degree or diploma of any institution previously.
Place: Signature of the student
Date: (RAMANN BHARADWAJ M)
NATIONAL AEROSPACE LABORATORIES
National Aerospace Laboratories, Bangalore is a constituent institution under the Council
of Scientific and Industrial Research. NAL is a high technology oriented institution
concentrating on advanced topics in aerospace and related disciplines. Originally started as
National Aeronautical Laboratory, it was renamed National Aerospace Laboratories to reflect its
major involvement in the Indian space programme, its multidisciplinary activities and global
positioning. It is India's only civilian aerospace laboratory with a high level of competence and
the expertise of its scientists is globally acknowledged.
Additionally, NAL has sophisticated test facilities, which are the best in the country.
Composite Structure Facilities, 1.2m Trisonic Tunnel Complex, Full Scale Fatigue Facility,
Acoustic Test Facility, Engineer-in-Loop Facility, Advanced Turbo machinery, Combustion
Laboratories, Failure Analysis Laboratory and Electromagnetic Laboratory are among these. All
these are manned by specialized teams who operate the facilities, conduct experiments, analyze
the data and provide value added inputs to programs.
NAL over the years has made significant contributions to a large number of aerospace
programs like civil and military aircraft programs, space programs, engine development
programs, defense and strategic programs of the country and has also contributed vital industrial
and societal outputs. NAL is an acknowledged center for excellence in many fields including
Composite Structures, High Speed Wind Tunnel Testing, Aircraft Fatigue and Aerospace
Acoustics, Failure Analysis and Accident Investigation.
NAL is the harbinger of civil aviation design and development activities in India. NAL
designed HANSA trainer aircraft is flying in different flying clubs of India and is all set to reach
overseas market. The light transport aircraft SARAS is undergoing flight testing and is designed
to meet the critical need in the civil aviation segment.
Currently NAL is developing Fixed Wing Micro Air Vehicles that are capable of flying
for 30 minutes to a range of 2km with a span of 300mm and can give live video feed from that
distance. NAL has successfully given demonstration of this technology to varying agencies and
services. NAL is furthering this vehicle developing technology to smaller size of 150mm.
PROPULSION DIVISION
The Propulsion Division is involved in applied research pertaining to Turbo machinery,
Combustion and Heat Transfer, Mechanical Aspects of Turbo machinery as well as in the
Design/Development of Propulsion and Energy Systems. It gives R&D support to the country's
National Aerospace Programmes being carried out at the Gas Turbine Research Establishment
(GTRE), Defense Research and Development Laboratory (DRDL), Vikram Sarabhai Space
Centre (VSSC) and the Liquid Propulsion Systems Centre (LPSC) besides taking up grant-in-aid
projects from the Aeronautical Research and Development Board. International collaborative
programs with Pratt & Whitney, USA and Canada are also being carried out.
The Division has made significant contributions to the development of the Kaveri engine
for Tejas. These include development of the afterburner flame holder and igniter, main
combustion chamber, controlled diffusion aero foils for the fan and squeeze film dampers.
Advanced supersonic combustors for the High Mach Number Flight Demonstrator vehicles of
VSSC & DRDL have been developed. A versatile High-speed Combustor Test Facility has also
been setup. A National Test facility for Rolling Element Bearings with the dual purpose of
testing indigenously developed synthetic aviation lubricants and aerospace quality bearings has
been commissioned.
The current activities include the development of active magnetic bearings, micro-gas
turbines, and Wankel engines for UAVs, novel afterburners, advanced ramjet/scramjet
combustors, advanced compressors, ultra-light helicopters, micro-air vehicles and the testing of
synthetic aviation lubricants and rolling element bearings. The collaborations R&D programmes
with Pratt & Whitney Canada & USA on gas turbine technologies, specifically related to turbo
machinery aerodynamics, combustors and Heat transfer are being actively pursued.
Future activities will include development of technologies for advanced gas turbines and
ramjet/scramjet combustors pulse jet and foil/magnetic bearings. A small gas turbine test bed and
a versatile turbine test bed will be set up and the high speed combustor test facility will also be
augmented.
MAV DIVISION
Micro Air Vehicle (MAV) has attracted consider- able attention during recent years due
to their unique operational capabilities. Understanding of MAV aerodynamic characteristics is
significant for the improvement of their performance. Obtaining reliable and accurate
experimental data is challenging due to a number of factors such as the low Reynolds number
flight regime, small size with low aspect ratio, large propellers slipstream, gust environment,
light weight and flexible airframes etc. Wind tunnel testing has an important role to play in the
development of mission capable MAVs with high endurance. Micro air vehicle Aerodynamics
Research Tunnel (MART) at CSIR-NAL is being established to meet all the special requirements
for MAV studies. Some of the features of this low speed, suction type closed test section low
turbulence wind tunnel include open jet test section with a large Betz chamber and active gust
generation mechanism. The open test section has the advantage of having no boundary layer
effects and reflections due to wall during flapping/rotary wing studies. The Betz chamber helps
in maintaining the static pressure in the open jet test section. It also helps in recording the flight
trajectory of insects, butterflies, dragonflies etc. under varying gust conditions. The active gust
generation mechanism consists of oscillatory vanes to generate sinusoidal variation in the tunnel
flow velocity at different frequencies. For studies involving measurements of unsteady low
loads, 3D deformation on flexible/flapping wings and propulsive models, highly specialized
instrumentation is being developed; these include high precision low load balances, LDV, time
resolved stereo PIV, Digital Image Correlation (DIC) and NI based wireless data acquisition
systems. The facility and the advanced instrumentation is funded by AR&DB under the National
Program on Micro Air Vehicle (NPMICAV). This wind tunnel is the first of its kind in India and
is being made available to all the projects under NPMICAV and other research organizations,
academic institutions, industries to carry out research and development in MAVs.
ACKNOWLEDGEMENTS
On the successful completion of this project, I would like to acknowledge and extend my
heartfelt gratitude to the following people who have made the completion of this project
possible:
I have immense pleasure in expressing my deep sense of gratitude and indebtedness to
Mr. Santhosh Kumar S and Mr. Vinod Kumar N, Scientists, Propulsion Division, Mr.
Roshan Antony and Mr. Suraj C.S, Scientists, MAV Unit, National Aerospace Laboratories,
for their invaluable guidance and advice.
It is with utmost gratitude that I express my sincere thanks to Mr. Shyam Chetty,
Director, National Aerospace Laboratories and Dr. J.S. Mathur, Head KTMD for making me
part of their great research community and allowing me to pursue my work.
I extend my thanks to Mr. Jayaraman, Scientist „G‟, Head, Propulsion Division, for
extending me all research, computational and essential resources to carry out this work.
To extend my thanks to my beloved Principal Dr. Shankaran, for providing an ideal
atmosphere to pursue my objectives under his able administration.
I express my sincere thanks to Dr. Balakrishnan Shankar, H.O.D, Mechanical
Engineering department and Mr. Joshua D Freeman, Assistant Professor, Department of
Electrical and Electronics engineering for their encouragement, effective guidance and valuable
suggestions right from the beginning of the project till its completion, without which this project
work would not have accomplished.
I am also thankful to my H.O.D Prof. Dr. Chandramohanan Nair, Department of
Electrical & Electronics Engineering who has given valuable suggestions during the work and
his moral support and encouragement.
I would like to express my heart full thanks to all the lecturers, staff members and student
friends of the National Aerospace Laboratories and Amrita School of Engineering for
constructive suggestions and constant encouragement.
Not to forget the outstanding support and encouragement from my parents throughout the
course of this project. I am greatly indebted to them.
TABLE OF CONTENTS
1 INTRODUCTION .............................. Error! Bookmark not defined.
1.1 HISTORY OF VERTICAL FLIGHTError! Bookmark not defined.
1.2 DEFINITION ............................. Error! Bookmark not defined.
1.3 HISTORY OF UAV ................... Error! Bookmark not defined.
2 ELECTRIC PROPULSION SYSTEMError! Bookmark not defined.
2.1 MOTOR SELECTION ............... Error! Bookmark not defined.
2.2 ELECTRONIC SPEED CONTROLLER (ESC)Error! Bookmark not
defined.1
2.3 BATTERY ............................... Error! Bookmark not defined.2
2.4 SERVO MOTOR ..................... Error! Bookmark not defined.4
2.5 MICROCONTROLLER .......... Error! Bookmark not defined.5
2.6 FLIGHT CONTROL BOARD ................................................... 18
2.7 TRANSMITTER & RECEIVER CONTROLS ......................... 20
2.7.1 FUTABA TRANSMITTER SETTINGS ............................ 21
2.8 MECHANICAL FRAME .......................................................... 22
3 CALCULATION AND SIMULATION RESULTS ................... 24
3.1 MOTOR...................................................................................... 24
3.2 BATTERY ................................................................................. 24
3.3 ELECTRONIC SPEED CONTROLLER .................................. 25
3.4 SIMULINK MODEL – BATTERY .......................................... 26
3.5 SIMULINK MODEL – BLDC MOTOR ................................... 27
4 PROPULSION THEORY AND ANALYSIS .............................. 31
4.1 INTRODUCTION TO PROPELLERS ..................................... 31
4.2 PROPELLER THEORY ............................................................ 32
4.2.1 MOMENTUM THEORY: .................................................. 32
4.2.2 BLADE ELEMENT THEORY: ......................................... 33
4.2.3 COMBINED BLADE ELEMENT MOMENTUM THEORY.....35
4.3 PROPELLER ANALYSIS: ....................................................... 38
4.3.1 BLADE ELEMENT THEORY(BET) ANALYSIS: .......... 44
4.3.2 STATIC THRUST BENCH ANALYSIS: .......................... 57
5 Conclusion ......................................... Error! Bookmark not defined.2
Appendix I ................................. Error! Bookmark not defined.4
LIST OF FIGURES
Figure 1-1Paul Cornu - 24hp Gasoline Flight VehicleError! Bookmark not
defined.
Figure 1-2N°2 quad rotor designed by OemichenError! Bookmark not defined.
Figure 1-3UAV Sector in the US (Autonomous Flying Robots)Error! Bookmark
not defined.
Figure 1-4BQM-34 Firebee UAV of the US Air ForceError! Bookmark not
defined.
Figure 1-5The Asctec Pelican ................. Error! Bookmark not defined.
Figure 1-6Draganflyer X6 ....................... Error! Bookmark not defined.
Figure 2-1Brushed DC motor ................. Error! Bookmark not defined.
Figure 2-2Design & Prototyping of Brushless Motor – MITError! Bookmark not
defined.
Figure 2-3Turnigy Aero Drive Motor ..... Error! Bookmark not defined.
Figure 2-4 APC Style Propeller (10X5) . Error! Bookmark not defined.
Figure 2-5Drive Calculator™ Results .... Error! Bookmark not defined.
Figure 2-6Propeller Calculator™ ResultsError! Bookmark not defined.
Figure 2-7Turnigy Plush 60/80A ESC .... Error! Bookmark not defined.
Figure 2-8Zippy Flightmax Li-Po batteryError! Bookmark not defined.
Figure 2-9Wiring Schematic ................... Error! Bookmark not defined.
Figure 2-10A mechanical Gyroscope ..... Error! Bookmark not defined.
Figure 2-11 A digital Head Lock gyro .... Error! Bookmark not defined.
Figure 2-12HK401B Gyro – A closer lookError! Bookmark not defined.
Figure 2-13ESC – Motor – Receiver Wiring, Castle Creations Inc.Error!
Bookmark not defined.
Figure 2-14HobbyKing KK 2.0 Flight Control BoardError! Bookmark not
defined.
Figure 2-15A typical transmitter outlook, Linkoping University.Error! Bookmark
not defined.
Figure 2-16 Futaba Transmitter .............. Error! Bookmark not defined.
Figure 2-17Talon Tricopter Frame ......... Error! Bookmark not defined.
Figure 2-18 Tail Servo Mount ................ Error! Bookmark not defined.
Figure 2-19Turnigy Digital Servo .......... Error! Bookmark not defined.
Figure 4-1 Propellers of various sizes ..... Error! Bookmark not defined.
Figure 4-2 Actuator Disk Model ............. Error! Bookmark not defined.
Figure 4-3 Geometry of propeller Blade ElementError! Bookmark not defined.
Figure 4-4 Blade Element Angle DefinitionError! Bookmark not defined.
Figure 4-5Sectioning of a propeller ........ Error! Bookmark not defined.
Figure 4-6Chord Distribution ................. Error! Bookmark not defined.
Figure 4-7Twist Distribution .................. Error! Bookmark not defined.
Figure 4-8Blade profile at 20mm section Error! Bookmark not defined.
Figure 4-9Blade profile at 40mm section Error! Bookmark not defined.
Figure 4-10Blade profile at 60mm sectionError! Bookmark not defined.
Figure 4-11Blade profile at 80mm sectionError! Bookmark not defined.
Figure 4-12Blade profile at 100mm sectionError! Bookmark not defined.
Figure 4-13Blade profile at 120mm sectionError! Bookmark not defined.
Figure 4-14 Lift Coefficient for various Angles of AttackError! Bookmark not
defined.
Figure 4-15 Drag Coefficient for various Angles of AttackError! Bookmark not
defined.
Figure 4-16 Thrust Coefficient Vs Advance Ratio at 4000 RPMError! Bookmark
not defined.
Figure 4-17 Torque Coefficient Vs Advance Ratio at 4000 RPMError! Bookmark
not defined.
Figure 4-18 Propeller Efficiency Vs Advance Ratio at 4000 RPM Error!
Bookmark not defined.
Figure 4-19 Thrust Coefficient Vs Advance Ratio at 5000 RPMError! Bookmark
not defined.
Figure 4-20 Torque Coefficient Vs Advance Ratio at 5000 RPMError! Bookmark
not defined.
Figure 4-21 Propeller Efficiency Vs Advance Ratio at 5000 RPM Error!
Bookmark not defined.
Figure 4-22 Thrust Coefficient Vs Advance Ratio at 6000 RPMError! Bookmark
not defined.
Figure 4-23 Torque Coefficient Vs Advance Ratio at 6000 RPMError! Bookmark
not defined.
Figure 4-24 Propeller Efficiency Vs Advance Ratio at 6000RPM . Error!
Bookmark not defined.
Figure 4-25 Thrust Coefficient Vs Advance Ratio at 7000 RPMError! Bookmark
not defined.
Figure 4-26 Torque Coefficient Vs Advance Ratio at 7000 RPMError! Bookmark
not defined.
Figure 4-27 Propeller Efficiency Vs Advance Ratio at 7000RPM . Error!
Bookmark not defined.
Figure 4-28 Thrust Coefficient Vs Advance Ratio at 8000 RPMError! Bookmark
not defined.
Figure 4-29 Torque Coefficient Vs Advance Ratio at 8000 RPM . Error!
Bookmark not defined.
Figure 4-30 Propeller Efficiency Vs Advance Ratio at 8000RPM . Error!
Bookmark not defined.
Figure 4-31 Thrust Coefficient Vs Advance Ratio at 9000 RPMError! Bookmark
not defined.
Figure 4-32 Torque Coefficient Vs Advance Ratio at 9000 RPMError! Bookmark
not defined.
Figure 4-33 Propeller Efficiency Vs Advance Ratio at 9000RPM Error!
Bookmark not defined.
Figure 4-34 Load Cell of 1.5kg Capacity Error! Bookmark not defined.
Figure 4-35Thrust Bench Apparatus ....... Error! Bookmark not defined.
Figure 4-36Thrust for various RPM ....... Error! Bookmark not defined.
Figure 4-37Thrust for varying Current ... Error! Bookmark not defined.
Figure 4-38Power for various RPM ........ Error! Bookmark not defined.
Figure 4-39 Comparison between Thrust Bench and BET resultsError! Bookmark
not defined.
ABSTRACT
Aerial robotics is an emerging field combining both aerospace and robotics. Tricopter, an
aerial robot, is an unmanned aerial vehicle which can be controlled from a remote location using
complex dynamic automation systems. The present work highlights construction and testing
aspects of a Tricopter. Unlike a helicopter that rises on a single column of air, the Tricopter rises
on 3 columns of air making it more stable. It uses three standard brushless out runner motors
with standard aerodynamically designed propellers. The configuration of the Tricopter
constructed is three arms spaced at 120 degrees separation to maintain continued stability even
while hovering. Speed controllers are employed to control the speed of each motor. The three
propellers connected to three DC brushless motors produce enough thrust so that the UAV takes-
off to desired heights varying the throttle. The throttle is reduced in steps so as to safe land the
UAV. System is made stable by using gyroscopes, which measure the orientations of the UAV in
three directions such as roll, pitch, and yaw. As the system is equipped with the closed loop
mechanism, the feed-back controller provides a necessary feed-back to the gyros so as to bring
the system back to stability.
Estimation of weight of the Tricopter pertaining to a specific application lays the basis for
selection of most of the components. A preliminary weight of 1000 grams with a payload
capacity of 500 grams has been chosen. The motors, ESC, battery and propellers were precisely
selected based on this assumption. For the propeller selection and performance both Combined
Blade Element Theory Analysis and Static Thrust Bench Analysis have been performed. The
components were thus validated and their selection justified using MATLAB SIMULINK
models. Several software analyses have been performed to simulate real flight environment and
behavior of different components under these circumstances has been analyzed. An onboard
flight controller is used to stabilize the UAV against turbulent orientations on the three arms. A 6
channel transmitter receiver pair is used to control and maneuver the Tricopter in different
directions.
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CHAPTER 01 – INTRODUCTION
1.1 HISTORY OF VERTICAL FLIGHT:
Manned flight takes its roots to the 1900‟s when Paul Cornu constructed a vertical flight
vehicle (Figure 1.1) reported to have carried a human off the ground for the first time ever.
Although, the sighting of such a machine over long distances has never been verified,
documentations suggest the vehicle made several tethered flights for a few seconds at low
altitudes. The machine was reportedly powered by a 24hp gasoline engine that could hardly
propel the vehicle to a hovered flight. In 1907, the Breguet brothers built the first helicopter N°1
– a quad rotor look-alike powered by a 40hp engine. This machine also suffered severe stability
problems and never flew freely.
Figure 1.1 Paul Cornu - 24hp Gasoline Flight Vehicle
In 1922, Peugeot engineer, Etienne Oemichen flew his indigenously designed 800kg
quad rotor - N°2 (Figure 1.2). In addition to its four main rotors, the N°2 featured five other
rotors – for lateral stability. A separate motor was specifically allotted for nose steering. On May
4th
, 1924, it became the first flight to complete the 1km closed circuit with an average speed of
2.2m/s. Vertical flight was in fact man‟s first experiments of the 20th
century. An insight into the
stability of these first vehicles led engineers to think of the modern highly stable, multi-purpose
Unmanned Aerial Systems (UAS). The term “robotic aircraft” picked up pace and thus laid the
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Figure 1.2 N°2 quad rotor designed by Oemichen
foundation for a new era of aerial robotics. Today, the United States defense budget allotment for
the development of UAS sector is close to 2 billion dollars. Although the primordial idea of
UAV development was limited only to the military sector, recent trends have opened their use to
civil applications also. Majority of the US UAV market share is contributed by companies like
Boeing, Lockheed Martin, Sikorsky, Lew Aerospace, and General Atomics etc. (Figure 1.3)
Figure 1.3 UAV Sector in the US (Autonomous Flying Robots, F. Kendoul, K. Nonami)
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1.2 DEFINITION:
The American Institute of Aeronautics and Astronautics (AIAA) defines an Unmanned
Aerial Vehicle as “An aircraft which is designed or modified, not to carry a human pilot and is
operated through electronic input initiated by the flight controller or by an onboard autonomous
flight management control system that does not require flight controller intervention.” Although
the AIAA doesn‟t differentiate between an Unmanned Aerial Vehicle (UAV) and a Micro Aerial
Vehicle (MAV), the Defense Advanced Research Projects Agency (DARPA) of the United
States Department of Defense (DOD) classifies an MAV as an aerial vehicle of dimensions of
15cm or less. A pilot is not carried by an Unmanned Aerial Vehicle and only the power source
that produces dynamic lift is controlled by pre-programmed flight operation center. Hence,
neither a rocket nor ballistic cruise missiles belong to this category. Unmanned airships powered
by lightweight gases are also not included in this category. (Autonomous Flying Robots, F.
Kendoul, K. Nonami)
1.3 HISTORY OF UAV:
The first UAV was developed by Americans Lawrence and Perry in 1916. An auto-pilot
with a gyroscope was developed to stabilize thevehicle. This came to be known as “attitude
control.” The device was named as “Aviation Torpedo” and it flew 30 miles before staging its
first halt. Development of UAV‟s began in full scale at the advent of the Vietnam War with the
defense community emphasizing on military scale applications. The BQM-34 Firebee UAV
(Figure 1.4) of the US Air Force played spoilsport creating devastating effects during the war.
Figure 1.4 BQM-34 Firebee UAV of the US Air Force
Currently, companies like Ascending Technologies (Asctec), Dragon Fly, DIY Drones
etc. manufacture multi copter vehicles (Figure 1.5 and Figure. 1.6) for civil applications.
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Figure 1.5 The Asctec Pelican
Figure 1.6 Draganflyer X6
Applications range from aerial surveillance, first respond operations, environmental
research, crop optimization techniques, terrain inspection etc. UAV platforms are categorized as:
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Fixed Wing UAV – Refer to airplanes that require a runway to take-off and land. Can
also be launched by catapulting. These generally have high endurance and can cruise at
great speeds.
Rotary Wing UAV – Also called rotorcraft UAV‟s or Vertical Take-off and Land
(VTOL) UAV‟s. Have great maneuvering capability and hovering capacity. Most multi-
copter vehicles with coaxial rotors come under this category.
Flapping Wing UAV – Most often treated to be MAV‟s with flexible and/or morphing
small wings generally inspired by insects and birds.
Blimps – Balloons and airships that have high endurance and fly at low speeds.
There are some hybrid conFigureurations that can take-off vertically and tilt their rotors.
These have been designed to account for one or more flying factors such as endurance and
cruising speeds. Typical examples include the High Altitude and Long Endurance (HALE –
Northrop Grumman‟s Global Hawk), Medium Altitude and Long Endurance (MALE – General
Atomics‟ Predator) etc.
Thus, aerial robotics is a fast emerging field that has revolutionized both the fields of
aeronautics and robotics. Its application in both the civilian world and the military sector has
been the sole inspiration for this project. The construction of the tricopter was intended for relief
and first respond operations.
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CHAPTER 02 – ELECTRIC PROPULSION SYSTEM
2.1 MOTOR SELECTION:
Typically, most unmanned aerial vehicles (UAV‟s) are either propelled by electric motors
or internal combustion engines (IC Engines). Since IC engines are a lot heavier than electric
motors, their use is limited to specific applications. Direct Current (DC) motors are basically
categorized as brushed and brushless motors. Irrespective of the classification, electrical motors
consist of two main significant parts – a stationary part most often referred to as a stator and a
rotating part, a rotor. The stator can also be referred to as an armature and the rotor as field or
vice-versa, depending on the position and alignment of the magnets and windings on the stator
and rotor. When a voltage is applied across the terminals of the motor, current flows through the
winding and due to the presence of magnetic poles produces a turning effect. In order to facilitate
rotation of the motor shaft in the same direction, brushed DC motors use carbon brushes for
commutation in every half cycle. A typical brushed DC motor is shown in Figure. 1.1 below.
Though this serves the purpose to a great extent, the brushes wear out over a period of time and
hence require constant maintenance.
Moreover, when the rotor poles are aligned at an angle of 90 degrees to the stator poles,
the torque produced is zero. The motor cannot start in this position and hence poses a grave
threat when employed in aerial vehicles. Also, in such a position, the carbon brushes would come
in contact with each other and hence lead to sparking. This is highly undesirable and eliminates
the option of using brushed DC motors. The recent trend in aerial robotics is to employ brushless
DC motors or BLDC motors owing to their wide range of advantages over their brushed
counterparts. An insight into the working of these motors reveals their high torque to weight and
high torque to watt ratios that give them an extra edge over the conventional motors. Moreover,
the electronic commutation system in these motors proves less susceptible to mechanical wear
and tear, thereby reducing the cost of servicing and use of complex electronics. Although the
term “Brushless motors” encompasses a wide range of motors including the AC induction
motors, Permanent Magnet Synchronous motors and other motors that technically don‟t have
brushes; the term is largely limited and confined to Brushless DC motors. BLDC motors usually
have stators that contain the windings and rotors that carry the magnets. The position of the rotor
can either be “inside” or “outside” thus bringing up a classification as “inrunners” and
“outrunners”.
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Figure 2.1 Brushed DC motor
Figure 2.2 Design & Prototyping of Brushless Motor and Motor Controls – Shane W. Colton, MIT
However, in both these cases (inrunners & outrunners), it is the rotor that rotates and the
stator remains stationary. Since this report is based on the underlying assumption that weight
8
forms the basis for the selection of all other components of the tricopter, motor selection plays a
pivotal role as the thrust produced by the motor is what is responsible for vertical take-off and
landing (VTOL). Most international competitions like the “International Aerial Robotics
Competitions (IARC)” conducted by Association for Unmanned Vehicle International (AUVSI)
specify a total weight limit of 1500 grams. To comply with international testing standards, the
weight of the tricopter was also set at 1500g. Standard aerodynamically designed propellers with
pre-determined pitch and diameter sizes were considered. As per the usual convention, the first
number in the propeller size denotes the diameter in inches and the second number signifies the
pitch (also in inches). A number of motor-propeller combinations were analyzed and the thrust
produced by each combination was tabulated as per the Abbott equation for propellers described
below:
Thrust (kg) = Pitch∗(Diameter)³∗(RPM)²∗10¯¹°∗0.02835
MOTOR
PROPELLER
THRUST
KD 36-22S
BRUSHLESS
OUTRUNNER
1440KV
APC STYLE (10X5)
1440g
GRAUPNER SLOWFLY (9X6)
1259.9g
APC STYLE ELECTRIC (10X4.5)
1296.2g
POLYMAX (8X5)
737.4g
KD 36-12M
BRUSHLESS
APC STYLE (10X5)
3278g
GRAUPNER SLOWFLY (9X6)
2867.6g
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OUTRUNNER
1370KV
APC STYLE ELECTRIC (10X4.5)
POLYMAX (8X5)
NTM PROP
DRIVE SERIES
1400KV
APC STYLE (10X5)
3420g
GRAUPNER SLOWFLY (9X6)
2994.5g
APC STYLE ELECTRIC (10X4.5)
3080.8g
POLYMAX (8X5)
1752.6g
TURNIGY AERO
DRIVE SK3
1340KV
APC STYLE (10X5)
3136g
GRAUPNER SLOWFLY (9X6)
2743.3g
APC STYLE ELECTRIC (10X4.5)
2822.4g
POLYMAX (8X5)
1605.6g
Motor – Propeller Combinations
As evident from the table, the Turnigy Aero drive SK3 motor (Figure 2.3) and the APC
Style propeller (Figure. 2.4) provide the highest thrust. Though the Abbott equation is not
precise, it gives an account of the static thrust produced by a given motor-propeller combination.
The actual thrust produced is determined by an experimental setup called “Thrust Bench
Analysis” discussed in the subsequent sections. However, the thrust produced by a given motor
and propeller combinations has also been verified by the Drive Calculator™ and Propeller
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Calculator™ software. The results have been displayed below (Figure 2.5 and Figure 2.6). Thus,
the motor-propeller combination is now assumed to provide the required thrust, thereby paving
way for the selection of the battery and Electronic Speed Controller (ESC).
Figure 2.3 Turnigy Aero Drive Motor Figure 2.4 APC Style Propeller (10X5)
Figure 2.5 Drive Calculator™ Results
11
Figure 2.6 Propeller Calculator™ Results
2.2 ELECTRONIC SPEED CONTROLLER (ESC):
An electronic speed controller is a stand-alone unit employed to vary the speed of a
motor. Brushless ESC‟s consist of a 6 step inverter circuit used to drive a 3 phase motor. The
motor requires an analog signal for operation and the microcontroller‟s computation power
wouldn‟t be sufficient to control the motors. Thus the need for an external controller arises. The
ESC is powered by a battery and the DC signal from the battery is fed to the inverter circuit in
the ESC resulting in three output signals that are given to the motor. The direction of rotation of
the motor can be varied by interchanging any two output signals from the ESC. ESC‟s are often
classified based on the input current drawn from the motor and the programmable features,thus
enabling its use in various applications. A battery eliminator circuit (BEC) is a DC-DC voltage
regulator equipped in most ESC‟s to supply the receiver and other equipment from the main
battery pack. Absence of this circuit in the ESC necessitates the need for an additional power
source to power the receiver and servo motors. The Turnigy Aero drive SK3 motor draws a
maximum input current of 28A. Thus the ESC for this motor needs to be rated a little higher than
the input current rating of the motor to account for any unforeseen losses. To accommodate a
higher current rating and programmable features into the ESC, the TURNIGY Plush 60A ESC
(Figure 2.7) has been selected. The ESC is rated for 60A continuous current and 80A burst
current. Though the availability of a much smaller rating ESC of 40A cannot be denied, the
requirement of a BEC and programmable features demands the selection of the 60A rating. The
12
ESC receives input Pulse Width Modulated (PWM) signals ranging from 1000 – 2000
microseconds (µs). The pulse width 1000 corresponds to zero throttle and 2000 to full throttle.
Figure 2.7 Turnigy Plush 60/80A ESC
2.3 BATTERY:
The battery plays a very significant role in the construction of an unmanned aerial
vehicle. Flight endurance, agility, capability to hover and a host of other factors are determined
by the capacity of the battery. Conventional batteries include the Nickel metal hydride (Ni-Mh),
Lithium Ion and Lithium Polymer (Li-Po) configurations. Most batteries are rechargeable and
are usually composed of multi-cells. The energy density of Li-Po batteries is around 20% higher
than Li ion batteries and approximately 45% higher than Ni-Mh batteries. Moreover, Li-Po
batteries have a much slower discharge rate than Nickel hydride cells (Propulsion system
Optimization for an unmanned lightweight quad rotor – Eva Saade Latorre). Thus, Li-Po seems
to be the obvious choice. A cell measures a nominal voltage of 3.7V and when fully charged
should measure 4.2V. However, when fully discharged the voltage should not fall below 3V.
Multi-cell batteries have cells wrapped in a foil pouch called “pouch cell” and stacked together
thus avoiding the need for metal cans. This also ensures less weight, making them the obvious
choice in weight specific applications. Thus, a 3cell battery inadvertently implies a voltage of
3∗3.7V = 11.1V and hence most often expressed as “3 Cell” or “3 Li-Po” in case of Lithium
Polymer. Most battery capacities are either expressed as mAh (milliamp/hr.) or Ah (Amp/hr.) to
indicate the battery size. A higher capacity battery runs for a longer time than a lower capacity
battery. When speaking of batteries, discharge current is usually expressed as C-rate to normalize
the measure against battery capacity. 1C literally means that the discharge current discharges the
entire battery in one hour. Thus, when a battery is rated as 1000mAh and 20C, it implies that the
battery pushes 1∗20 = 20A of discharge current. When the same battery is rated for 1C, the
battery discharges 1A in one hour. Although in the former case, the battery discharges 20A, it
does so at the cost of endurance. The battery discharges quickly and hence results in reduced
13
flight time. To ensure longer flight time, higher batteries are chosen and thus the increase in
weight. Thus a compromise between battery capacity, weight and flight endurance is inevitable.
It is always better to run a higher C-rated battery at a lower C-rate than to run it the other way
round, the most plausible reason being improved battery performance.
Since, the Turnigy Aero drive SK3 motor draws 28A burst current, the three motors in
the tricopter collectively draw 84A. Now, the battery in consideration should be able to provide a
slightly higher value than that required and at the same time ensure long endurance. A number of
batteries were analyzed for this purpose and the results stated in the table below:
BATTERY
RATING
CURENT OUTPUT
Zippy Flightmax 3S1P
2200mAh, 25C
55A
Zippy Flightmax 3S1P
2650mAh, 40C
106A
Turnigy Nano Tech
2650mAh, 35~70C
185.5A at 70C
Battery Feasibility Check Table
The Zippy Flightmax 2650mAh, 40C battery (Figure 2.8) seems to be the most profitable
choice among the three. Although the 70C configuration provides a higher current output, its
weight being too large, eliminates it from the fray.
14
Figure 2.8 Zippy Flightmax Li-Po battery
Thus the flight time can be calculated as:
Flight time = (60 minutes)/(C rating)
= (60)/40
= 1.5 minutes.
Though this seems to be too low, the flight time is expected to be much more than this
value since the motor does not consume 28A at all times. The motor draws 28A during the initial
take-off but later settles down to a lower value when it climbs up to a certain height. Flight time
during experimental tests was found to be around 6-7 minutes.
2.4 SERVO MOTOR:
The tricopter configuration in this paper necessitates the rotation of all the three motors in
the same direction. This produces enough torque causing the entire body to rotate in the direction
of rotation of the motors. A tricopter exhibits 3 directional tendencies while in the air – roll, pitch
and yaw as explained below. In order to control the yaw motion, the tail motor mount is linked to
a servo gear. The bidirectional movement of the servo gear enables movement of the tail mount
in either direction thus controlling the yaw motion as and when desired. There are two types of
servo motors that can be used in such applications – Digital servos and Analog servos. The servo
motor under consideration should be able to produce enough torque to rotate the motor mount
quickly. The size and weight of the servo motor also play an important role and are largely
dependent on the tricopter servo frame allotments. More on this in the subsequent sections.
15
2.5 MICROCONTROLLER:
The microcontroller can be considered to be the “heart” of the electronic stability system.
The wiring schematic is shown below in Figure. 2.9. As per the Figure, the three motors are
connected to the three ESC‟s and are rested on three arms placed 120° apart. The three ESC‟s are
connected to the battery in parallel either through a printed circuit board (PCB) or by direct
connection.
Figure 2.9 Wiring Schematic
A Gyroscope is a device used to measure angular orientation (Figure 2.10). With stark
relevance to the tricopter, three gyros (as shown in Figure. 2.9) are placed on three arms to
measure the orientation in the respective axial directions. On an otherwise perfectly stable plane,
the gyros wouldn‟t initiate any action. When the vehicle tends to orient in a particular direction,
the gyro pertaining to the arm subjected to orientation, calculates the error (measured in degrees)
and sends the error signal in the form of a digital pulse width modulated signal to the ESC. The
ESC then either reduces or increases the speed of the concerning motor to match up with the
other motors. The magnitude of the error signal would be translated into an equivalent PWM
signal of appropriate pulse width and thus the change in speed would either be added or reduced
as per the requirement. The gyro again measures the error and continues to do so until the error is
zero which in other words would mean the tricopter to be stable.
16
Figure 2.10 A mechanical Gyroscope
However, choosing the right gyro for an application still poses various questions about
the different features available on different models. Four gyros are required for the current
application – three on three arms and one for the yaw rate control. The three gyros for the three
arms can include the basic features and not much thought is needed for their selection. The yaw
gyro demands careful introspection into its features and working principle. There are basically
two types of yaw control gyros – the yaw rate gyro and the heading hold gyro (Figure 2.11 and
Figure 2.12).
Figure 2.11 A digital Head Lock gyro Figure 2.12 HK401B Gyro – A closer look
17
A yaw rate gyro dampens the yaw motion to a certain extent by sending a command to
the tail servo. The servo then initiates necessary action by moving in the appropriate direction to
control the yaw motion. However, these gyros would only be able to dampen the yaw motion but
cannot eliminate it completely. The head lock gyros are a superior class in such scenarios. They
use complex software to accurately calculate the angular measurement required by the servo to
completely control the yaw motion. Once in action, the vehicle would be perfectly stable despite
strong winds and irregular change in rotor speeds. However, the gyro would suspend action
when the pilot wishes to create some sort of yaw. Most RC pilots refer to this function as
“heading hold” or “head locking”. Digital head lock simply implies more precision on the head
locking function.
Figure 2.13 ESC – Motor – Receiver Wiring, Castle Creations Inc.
The above Figure (Figure 2.13) depicts the connections pertaining to the ESC, motor and
the receiver. When an actions, say, as an increase in throttle is initiated in the transmitter, an
equivalent signal in binary form is sent to the receiver. The gyros which are connected to the
receiver receive the given signal and pass it to the ESC. The ESC translates the input signal into
an appropriate signal based on the pulse width and feeds it to the motor. The motor thus revolves
at the desired speed. But the use of the gyroscopes still remains unexplained at this point. As
discussed earlier, tricopters tend to orient in three different directions – roll, pitch and yaw. In
order to move forward, the speed of the two motors in the front is reduced allowing it to lean
forward. Thus the forward motion is made possible. The gyros on these two arms ensure the
forward lean to be within limits – just to produce forward motion. Excessive leaning leads to
excessive thrust exhibited by the tail rotor thus resulting in flipping. Similarly, during right
banking, the gyro on the right arm ensures the right motor‟s speed is within limits so as to
18
produce a change in direction, specifically towards right. Again, the absence of gyro eliminates
boundary limits and can cause the tricopter to flip to the right. Thus gyros play an important role
in stabilizing the vehicle while ensuring smooth flight. The microcontroller now hosts the
limitations for all the gyro orientations, the maximum and minimum speeds of the rotor and the
signal translations from the transmitter to the other components onboard. Moreover, transmitter
configurations can be effectively calibrated in the microcontroller to suit the flyers needs and
experience. For example, in the case of an amateur flyer, the transmitter can be configured to
control only the four basic movements of forward, backward, right and left motions. In the case
of experienced RC pilots, the transmitter can be configured accordingly to include extra set of
commands such as reverse flying, inverted flying, acrobatic stunts etc. The latter case is just
beyond the scope of this project as it is confined and limited to basic flying features. However,
advanced flying options would require more computing power and programming skills and thus
the need for higher microcontrollers. Most aerial vehicles in the RC world make use of flight
controllers such as the ArduPilot™ from DIY drones, KK flight control boards etc. The
ArduPilot is a hardware platform that requires an open source control program such as the
ArduCopter™. Most of these boards require a constant upgrade of 256kB flash memory and thus
an updated firmware for stabilization. Due to lack of superior programming skills, the idea of
manual programming was given up and the KK 2.0 flight control board has been employed as
the sole stabilizing unit.
2.6 FLIGHT CONTROL BOARD:
The KK 2.0 Multi-Rotor LCD Flight Control Board (Figure. 2.14) is the state of the art
stabilizing unit for aerial vehicles designed by Rolf R. Bakke, grandfather of KK revolution, for
HobbyKing™. The board houses up to 8 different configurations of aerial vehicles ranging from
single copter to octacopter. Of these wide varieties of aerial vehicles, multiple designs of quad
rotors and tricopters like the “+” and “X” configurations are also included.
19
Figure 2.14 HobbyKing KK 2.0 Flight Control Board
The circuit design of the board is similar to Figure 2.9 except that it also carries external
modules such as a 3 axis Analogue Devices™ accelerometer and a piezo buzzer. In contrast to
the four gyro system described above, the KK 2.0 consists of two InvenSense™ Gyros and an
Atmel™ Mega 324 microcontroller. It consists of 8 motor layout pins to the right and 5 receiver
outputs to the left. The transmitter - receiver channels and options will be explained later. The
LCD board displays outputs and allows calibration of ESC‟s, sensor modules such as the gyro‟s
and accelerometer and helps the user to choose from a variety of motor layouts. The Proportional
Integrator (PI) gain values can also be adjusted with the help of four buttons provided at the
bottom. The transmitter channels can be adjusted as per the convenience of the flyer and the
maximum and minimum values for each channel can also be set. The servo gain values can be
adjusted based on the type of servo chosen. Self-leveling option in the board allows the user to
stabilize the tricopter as desired. The board can be armed by moving any of the four channels on
the transmitter provided a suitable setting has been configured prior to arming it. The settings on
the board can be changed as long as the board is unarmed. This is indicated by a glow of a red
LED followed by a beep. The sensors on the board have to be calibrated by placing it on a flat
surface. After a few seconds, all the sensor values are calibrated to the initial measurement
values recorded while on the flat surface. The KK board settings with reference to the tricopter
will be explained in detail in the next chapter.
20
2.7 TRANSMITTER & RECEIVER CONTROLS:
The transmitter and receiver occupy a very significant role in the control of any
unmanned aerial vehicle. Typical receivers have 4 channels and the number varies depending on
the vehicle configuration and the flying style. The 4 basic channels of a receiver are Aileron,
Elevator, Throttle and Battery. While using an ESC equipped with a BEC, the receiver need not
be powered separately and any ESC connected to one of the channels powers the receiver. Thus
for ESC‟s with built-in BEC, the battery channel can be configured for any other purpose. In the
case of a tricopter, a 6 channel receiver is required to account for the rudder and AUX options.
Thus, a 6 channel receiver would inadvertently require a 6 channel transmitter at the least and
there is no higher limit to the number of channels on the transmitter.
Aileron accounts for the roll motion and can be controlled by moving the right stick to
cyclic left and right (Figure 2.15). Thus, when intending to move right, the right stick is moved
to cyclic right reducing the speed of the motor on that arm. The tricopter bends to its right and
banks in the desired direction. Similarly, moving the right stick on the transmitter to cyclic left
reduces the speed of the motor on the left arm and the tricopter banks left. When looking for
forward motion, the right stick on the transmitter is moved up, thus reducing the speed of the
front motors. The tricopter leans forward and produces forward motion. For backward motion,
the right stick on the transmitter is pushed back. The front two motors rotate at a greater speed
than the tail motor and hence the vehicle moves backward. This motion of moving forward and
backward is termed as pitching and is controlled by the Elevator channel on the transmitter.
Figure 2.15 A typical transmitter outlook. Fig 2.16 Tricopter Transmitter
Similarly, pushing the left stick up increases the throttle and all the three motors pick-up
speed. Pushing it down decreases the speed of the motors. Moving the left stick on the
transmitter to cyclic right controls the motion of the servo motor on the right. Thus, the tail rotor
mount is tilted to its right producing anti-torque to oppose the yaw motion. Similarly, the tail
21
rotor mount can be tilted to its left by moving the transmitter stick to its left. This is known as
rudder.
2.7.1 FUTABA TRANSMITTER SETTINGS:
REVR 1rev
2rev
3rev
4rev
5nor
6rev
DR1 up 50 down40
2 up 50 down40
4 up 100 down100
EP A1 30%
2 30%
3 100%
4 100%
5 35%
630%
NTH on 0 25 50 75 100
NPI on 0 25 50 75 100
ITH inh
IPI off
HOLD inh
REVO inh
GYRO -35%
SWT inh
22
SWSH a -40%
e +40 %
p +100%
FS channel 3 20%
In case of a flight control board, all the above settings are configured by default and any
PI gain values can be changed in the KK board itself. However, it is highly recommended that
novice RC pilots refrain from making any changes and fly using the default values.
2.8 MECHANICAL FRAME:
The mechanical frame has been purchased from HobbyKing™. The Talon Tricopter V1.0
Carbon fiber frame (Figure 2.16) is a cheap, well-fabricated structure equipped with a camera
mount and flexible arms. The frame weighs only 350g and is the ideal choice for amateur pilots.
The frame also provides provision for a servo motor on the tail arm. The tail rotor mount is
connected to the servo gear by two link rods which are held together by 4.8mm ball cups (Figure
2.17).
Figure 2.17 Talon Tricopter Frame
23
Figure 2.18 Tail Servo Mount Figure 2.19 Turnigy Digital Servo
The servo mount only allows enough space for a micro servo and hence a digital servo of
suitable dimensions has to be selected. The Turnigy MG90S metal gear servo (Figure 2.18) fits
in exactly in the mount and weighs only 13.4g. The output PWM rate for digital servos is quite
high, around 400Hz and hence a higher operating speed. Taking all the above factors into
consideration, the MG90S has been finalized to control the yaw motion.
The structure houses a two plate design for any external modules such as GPS, XBEE
etc. All in all, the frame is the most cheap and durable of all the ready-made frames available in
the market. Any unforeseen losses during flight tests can be reinforced by frame parts available
on the HobbyKing website.
24
CHAPTER 03 – CALCULATION AND SIMULATION
RESULTS
3.1 MOTOR:
TURNIGY AERODRIVE SK3-3530-1340KV BRUSHLESS OUTRUNNER
Turns – 24
Voltage – 2~3S LiPo
Operating Current = 20A
RPM/V – 1340KV
For 1V – 1340 rpm
For 11.1V, Speed = 14,874 rpm.
Power (in Watts) = 11.1V X 20A = 222W
For 3 motors, total power produced = 222X3 = 666W.
From Blade Element Momentum Theory:
Thrust (each motor) = 5000* 14,874 * 10 *0.02835
= 3.136kg/motor.
Total thrust produced by three motors = 9.4kg.
3.2 BATTERY:
ZIPPY FLIGHTMAX 2650mAh 3S1P 40C LiPo BATTERY
Continuous AMP Draw = (mAh)*0.001*(C Continuous Rating)
AMP Draw = 2650*0.001*40 = 106A Continuous.
25
Motor‟s Burst Amperage = 28A
Total Burst Current = 28*3 = 84A.
Verdict : Good to go !!!
Battery Discharge Time = (2.65*11.1)/(666)
= 0.04416 hours
= 2.65 min
3.3 ELECTRONIC SPEED CONTROLLER:
TURNIGY PLUSH 60A SPEED CONTROLLER
Continuous Current – 60A
Burst Current – 80A
BEC Mode – Switching
BEC – 5V/3A
26
3.4 SIMULINK MODEL – BATTERY:
The above figure depicts the MATLAB SIMULINK™ model of the LiPo battery. The
specifications of the battery used in this project have been imported into the model to observe
various changes encountered during the actual battery operation. The results thus obtained from
the simulation are attached below.
27
The above figure illustrates the plot of voltage, speed of the motor (DC machine depicted in the
model) and armature current versus time. SOC is the state of charge of the battery. It is initially
charged to 100% and decreases over time due to battery operation. The charge reduction of the
battery is limited to 40%, which implies that the SOC is set at a threshold decrease of 40, to
avoid rapid discharge and unwanted results.
3.5 SIMULINK MODEL – BLDC MOTOR:
The block diagram shown above represents the SIMULINK™ model of the DC motor. The
characteristics of the Turnigy SK3 3530-1340 kv have been imbibed into the model to replicate
actual DC motor operation. The maximum speed limit was set to 14000 rotations per minute and
its characteristics were observed.
The figures below depict the plot of line-line voltage, stator current, back EMF, rotor current and
torque versus time. Since the DC motor has been modeled using a permanent magnet
synchronous motor with trapezoidal input, the line-line voltage has been observed to trace a
trapezoidal waveform. Similarly, all the other waveforms have been observed to show
satisfactory results, if not accurate, to validate the selection of the motor.
30
Torque:
Thus the selection of the DC motor and battery has been justified using MATLAB
SIMULINK™ models.
31
CHAPTER 04 – PROPULSION THEORY & ANALYSIS
4.1 Introduction to Propellers
Aircraft propellers, also known as Airscrews are devices that convert rotary motion from
engines or electric motors (in this case) for providing propulsive force. All the propellers
available in the market will be similar in shape and design. They do vary in minor ways one from
the other. They all look similar with a taper from central hub to the outer tip. The width varies
slightly from hub to the outer tip and the blades are also twisted over the whole length. The
primary purpose of a propeller is to convert rotary motion of an electric motor to axial thrust via
torque transfer to the propeller. The rotating propeller produces thrust by capturing air and
expelling out at the back. The more air it expels over time, it consumes more power and generate
greater thrust. In order to push the air, the blades need to capture the air and hence they will be
twisted so that they can propel into the air. The main objective is to make every part of blade
along its length to advance axially the same distance in a revolution. This way each section of
blade produces maximum amount of thrust at same time. A propeller is generally defined by its
diameter and pitch. For example APC 10 x 5 propellers, it implies the propeller is 10inch in
diameter and has a pitch of 5inch. Diameter is one the crucial parameters in determining the
amount of power the propeller consumes to produce the thrust. The pitch is defined as the
forward distance travelled in one revolution. The angle of the blade increases from tip inward to
the hub. This angle is called blade angle. The hub region is thick as high stresses will be acting
near the hub. The Figure shows general COTS (commercial-off-the-shelf) propellers.
Figure 4.1 Propellers of various sizes
32
4.2 Propeller Theory
As there is no provision for experimental wind tunnel analysis for in-flight performance
test, the theoretical methods were opted instead to predict the performance of the propeller.
Various propeller theories are presented and discussed in this section.
Various propeller theories are:
1. Momentum theory
2. Simple Blade- element theory
3. Combined Blade-element momentum theory
4.2.1 Momentum theory:
Momentum theory is the simplest theory which explains the operation of a propeller. In
this theory, the propeller is assumed to be replaced by uniformly loaded actuator disk with
infinite number of blades (which implies the disk with infinitesimal thickness). The inflow and
outflow are assumed to be uniform. The Figure below illustrates the situation.
Figure 4.2 Actuator Disk Model
Far in front of the disc the static pressure and speed conditions are given by p and V. At
the disc, the velocity of air is assumed to be V+v. the pressure in front of the disc is assumed to
be p while the pressure behind the disc is assumed to be p p . The increase in pressure p is
caused by the propeller that adds energy to the flow. Now the Bernoulli equation is applied in
two stages: first to flow ahead of the propeller and then to the flow behind the propeller.
Ahead of the disc
2 20.5 0.5 ( )p V H p V v
Behind the disc
33
2 2
1 10.5 ( ) 0.5 ( )p V v H p p V v
Where H is total pressure ahead of the disc
1H is total pressure behind the disc
1v is induced velocity increase far downstream
Solving the above two equations for p ,
2 2 11 1 10.5 ( ) ( 0.5 )
2
vp H H p V v p V V v
If the propeller disc area is A then the thrust produced by the propeller is
11
2
vT A p A V v
Where T is thrust
A is the area of the actuator disc
p is the pressure jump
is density of the fluid
V is the free stream velocity
1v is the induced velocity
The serious drawback with this theory is that it does not consider the geometry of the
propeller in calculating its performance. It is not very useful in predicting the propeller
performance and hence momentum theory was not chosen as the main theoretical method to
predict the performance of the propeller.
4.2.2 Simple Blade Element Theory:
Another theoretical tool to predict the propeller performance is Simple Blade Element
theory developed by William Froude. It differs from the momentum theory by considering the
airfoil geometry and aerodynamic characteristics of propeller blades. In this theory, the whole
blade is divided into a large number of elements, each with its own width and chord.
Here the blade element at radius r is moving with a spin velocity of 2 rn , where n is the
propeller rotational velocity is revolutions per second. In addition, the propeller has forward
velocity V, or propeller advance velocity. The Lift and Drag forces on each element are dL and
dD respectively. The thrust and torque of a blade element are dT and dQ respectively. The angle
34
is called the geometric pitch angle. The rotational speed r is much less at the hub than at
the tip of the propeller. As advance velocity is same across the propeller blade, the local angle of
attack of a blade element at the hub is much less than that at the tip and could become even
negative, if the blades are not twisted. That is the reason to increase the geometric pitch angle at
the hub such ass to maintain efficient angle of attack. Hence, the propellers are twisted form
central hub to the outer tip.
Figure 4.3 Geometry of propeller Blade Element
The lift and drag components of the blade element can then be resolved to obtain the
respective thrust (T) and torque (Q) from the blade element, where
2cos sin 0.5* * * * *( cos sin )R l ddT dL dD V c dr C C
2( sin cos ) 0.5* * * * *( sin cos )R l ddQ dL dD r V c rdr C C
Where is the helix angle
c is the blade chord at radius r
35
The above equations are integrated over the entire propeller to determine the total thrust
T and total torque Q. But, for this calculation the sectional aerodynamic characteristics of each
blade must be known, which can be calculated accurately if we know the induced velocity due to
lift production on each blade element. But this theory doesn‟t account for induced velocity
distribution. Although such a method can give good results, a better theory will be combined
blade element momentum theory.
4.2.3 Combined Blade Element Momentum Theory:
This theory combines both Momentum theory and Simple Blade Element Theory in
predicting the propeller performance. The main problem of Blade Element theory is solved by
combining Momentum theory which calculates the induced velocity required for Blade element
theory.
If the number of blades of propeller is B , then the total elemental thrust from Blade
Element theory ( Neglecting the Drag term) is
00
0
cossin sin( ) sin cos i
R
V V
V
Where 0 and 0RV are shown in the Figure below.
Figure 4.4 Blade Element Angle Definition
The induce velocity component in the thrust direction is iV 0cos .
From momentum theory, the total elemental thrust may also be written as
0 0*(2 )*( cos )*(2 cos )i iBdT rdr V V V
From the above two equations
36
2
0
0
* * *( )
8 *( cos )
l Ri
i
B C c VV
r V V
Assuming the induced angle to be small,
00
0
cossin sin( ) sin cos i
R
V V
V 0
tan i
R
V
V
And replacing 0 *( )lC a
Where 0a is section lift curve slope of the blade airfoil.
Hence the above equation can be re-written as
0 *( )* *
8 (sin cos )
acB
r
Now we can replace 2
* * *
* *
B c R B c
R R , solidity ratio of propeller.
The solidity ratio of a propeller is defined as the ratio of total blade area to the area of the disc.
And the blade section is non-dimentionalized as r
xR
We can re-write the above equation as
2 0 0cos sin ( ) 08 8
a a
x x
For relatively low thrust conditions, the above equation can be solved by neglecting 2 -term.
0
( )
8 sin1
x
a
And 0
2cos cos
cosR R
nrV V
Finally from the Figure above, the elemental thrust and elemental torque of B-bladed propeller is
given by
2 2 22
0 02
2* * cos * *( cos sin )
cosl d
n rdT B cdr C C
37
2 2 32
0 02
2* * cos * *( sin cos )
cosl l
n rdQ B cdr C C
The above equations are integrated over the entire propeller to determine the total Thrust T and
total Torque Q.
The Thrust Co-efficient and Torque Co-efficient are defined as
2 4T
TC
n Dand
2 5Q
QC
n D
The Following step-by-step procedure is suggested to determine the magnitudes of TC andQC .
Step 1: 1tan2
V
nr
Step 2: Bc
r
Step 3: r
xR
Step 4:
0
( )
8 sin1
x
a
Step 5: ( )
Step 6: ,l dC C values are determined
Step 7: 0
Step 8: 2 2 2
2
0 02
2* * cos * *( cos sin )
cosl d
n rdT B cdr C C
2 2 3
2
0 02
2* * cos * *( sin cos )
cosl l
n rdQ B cdr C C
Step 9:
2
1
( )
r
r
dT f r dr and
2
1
( )
r
r
dQ f r rdr
38
Step 10: Using Trapezoidal Rule for integration ( ) ( )
( ) ( )2
b
a
f a f bf x dx b a
4.3 Propeller Analysis:
Selection of a propeller can be based on either Blade-Element theories explained earlier
or by performing propulsion tests. In this section, we briefly discuss the prediction of propeller
performance using BET and propulsion tests.
As mentioned in earlier section, the theoretical method of propeller analysis deals with
propeller‟s thrust generation and power consumption. And we need to know the propeller
geometry data and airfoil data. The commercial propeller manufacturers do not provide us with
any such data and therefore, the required data was measured by sectioning the propeller, which is
unpractical and inaccurate approach. But, we can get accurate results of thrust and power
consumption from static propulsion tests using Thrust-Bench.
The sectioning of the propeller can be illustrated with the help of the Figure below.
Figure 4.5 Sectioning of a propeller
In this project, APC 10*5 propeller has been selected. The geometry data of this propeller
was taken from CMM (co-ordinate measuring machine) available at metrology lab of NAL .As
illustrated in the above Figure, the propeller blade of 5inch i.e.,127mm has been sectioned
accordingly along the blade length in steps of every 20mm i.e., 20mm, 40mm, 60mm, 80mm,
100mm and 120mm.
39
The geometry data can be represented as below:
r(mm) Chord(c) Angle(β) Radius(mm) c/R r/R
20 17.89 39.17 127 0.140866 0.15748
40 25.01 28.43 127 0.196929 0.314961
60 25.7 20.49 127 0.202362 0.472441
80 21.83 15.08 127 0.17189 0.629921
100 15.92 11.37 127 0.125354 0.787402
120 10.98 5.48 127 0.086457 0.944882
The CMM machine provided us with the coordinates of each section of the propeller
blade. The coordinates obtained are inaccurate with sharp edges and lengthy chord lengths due to
slip of the measuring tool over the blade profile. These coordinates have been smoothened using
CAD Software packages available. The sharp edges have been removed providing a smooth
radius at both leading and trailing edges. The modification of the coordinates has been done very
accurately as they need to be imported into XFLR5 to obtain lift coefficient and drag coefficient
values over various angle of attacks. The operation of XFLR5 is discussed in detail in later part
of this section.
After modifying the obtained coordinates, the chord and blade twist of each section have
been measured using SOLIDWORKS software package and tabulated as shown above.
From this data, the chord distribution and twist distribution of the propeller is plotted.
From the chord distribution graph plotted, we can clearly understand how the chord length varies
along the blade i.e, gradually increasing and then decreasing, and the maximum chord
distribution occurs at r/R=0.5. And from the twist distribution graph plotted, we can infer that the
blade twist gradually decreases from the central hub to the outer tip of the propeller.
40
Figure 4.6 Chord Distribution
Figure 4.7 Twist Distribution
0
0.05
0.1
0.15
0.2
0.25
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
c/R
r/R
Chord Distribution
0
5
10
15
20
25
30
35
40
45
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
β
r/R
Twist Distribution
41
The modified coordinates are plotted as shown below. The coordinates for 20mm section of
propeller is attached in Appendix.
Figure 4.8 Blade profile at 20mm section
Figure 4.9 Blade profile at 40mm section
-14-13-12-11-10
-9-8-7-6-5-4-3-2-10123456789
1011121314
-14-13-12-11-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
r=20mm
-14-13-12-11-10
-9-8-7-6-5-4-3-2-10123456789
1011121314
-14-13-12-11-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
r=40mm
42
Figure 4.10 Blade profile at 60mm section
Figure 4.11 Blade profile at 80mm section
-14-13-12-11-10
-9-8-7-6-5-4-3-2-10123456789
1011121314
-14-13-12-11-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
r=60mm
-14-13-12-11-10
-9-8-7-6-5-4-3-2-10123456789
1011121314
-14-13-12-11-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
r=80mm
43
Figure 4.12 Blade profile at 100mm section
Figure 4.13 Blade profile at 120mm section
-14-13-12-11-10
-9-8-7-6-5-4-3-2-10123456789
1011121314
-14-13-12-11-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
r=100mm
-14-13-12-11-10
-9-8-7-6-5-4-3-2-10123456789
1011121314
-14-13-12-11-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
r=120mm
44
4.3.1 Blade Element Theory (BET) Analysis:
As explained in the previous chapter about the BET, it divides the whole propeller blade
into various elements. And at each element, elemental thrust and elemental torque will be
calculated. They are integrated over the entire element to get the component of thrust and torque
each element provides. After calculating the thrust and torque for each blade element, the total
thrust and total torque are obtained by summing up the components from all blade elements.
Even though Combined Blade Element Theory predicts the propeller performance
accurately, the calculations are quite tedious, esoteric and time consuming. Hence, Simple Blade
Element Theory has been used instead of CBEMT. The process is explained as follows.
Firstly, we have no idea about the flight forward velocity or RPM of the propeller. So, for
the calculation of BET, we have considered a velocity range of 2m/s to 14m/s and RPM varying
from 4000 to 9000. For each RPM selected, for every section, varying the velocity from 2m/s to
4m/s, the Reynolds number values have been calculated. These Reynolds number values vary
along the blade for each section for a particular RPM. Now, we need to know the coefficient of
lift and coefficient of drag of each section for various angles of attack for considered RPM and
forward velocity to input into BET calculations. For this, software named XFLR5 has been
used.XFLR5 is an analysis tool for airfoils, wings and planes operating at low Reynolds
Numbers. It gives the polar of the airfoils in 2D environment. This software imports propeller
section coordinates and then de-rotates and normalizes the profile. Then a batch analysis has
been run varying both Reynolds number and angle of attack. Then coefficient of lift vs angle of
attack and coefficient of drag vs angle of attack plots and values has been obtained from the
simulation results of XFLR5. These values are taken as an input for BET calculations. So, for a
particular section, with specified RPM and forward velocity, Reynolds number has been
calculated and for that Reynolds number coefficients of lift and drag are taken from XFLR5
results. Now, with all the inputs, thrust and torque of a propeller for given RPM and Velocity
are calculated by following the step-by-step procedure explained below.
A sample calculation of overall BET is done for 9000RPM.
Input Values
APC Propeller (10‟‟ x 5‟‟) Radius, R 0.127 m
Angular Speed , n 150 rev/s
Air density, ρ 1.225 kg/m3
45
Step 1: 1 1 2tan tan 0.105761
2 2 *150*0.02
V
nr
Step 2: 0.02
0.157480.127
rx
R
Step 3: ( ) 0.68329 0.105761 0.577529( ) 33.1(deg)rad
Step 4: ,l dC C values for this angle of attack are obtained from XFLR5 results
The curves obtained will be as shown below
Figure 4.14 Lift Coefficient for various Angles of Attack
-1-0.9-0.8-0.7-0.6-0.5-0.4-0.3-0.2-0.1
00.10.20.30.40.50.60.70.80.9
1
-24-22-20-18-16-14-12-10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Lift
Co
effi
cie
nt
Angle of Attack
Cl VS AOA
Re 10000
Re 20000
Re 30000
Re 40000
46
Figure 4.15 Drag Coefficient for various Angles of Attack
For Given Angle of Attack lC = 0.7884 dC =0.30826
Step 5:
21* *( ) * *( cos sin )
2R l ddT V cdr C C
21*1.225*(18.945) *0.0178* 0.7884cos(0.105761) 0.30826sin(0.105761)
2
2.9407dT dr
21* *( ) *( * ) *( sin cos )
2R l ddQ V c r dr C C
21*1.225*(18.945) *(0.0178*0.02) *(0.7884sin(0.105761) 0.30826cos(0.105761))
2dQ dr
00.020.040.060.08
0.10.120.140.160.18
0.20.220.240.260.28
0.30.320.34
-24-22-20-18-16-14-12-10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Dra
g C
oef
fici
en
t
Angle of Attack
Cd Vs AOA
Re 10000
Re 20000
Re 30000
Re 40000
47
0.030506dQ dr
Step 6:
2
1
( )
r
r
dT f r dr and
2
1
( )
r
r
dQ f r rdr
2 0.04
1 0.02
( ) ( )
r
r
dT f r dr T f r dr
Where f( r)= 2.9407 for r=0.02
Similarly we can calculate for r=0.04, f( r)=19.2476
2 0.04
1 0.02
( ) ( )
r
r
dQ f r dr Q f r dr
Where f( r)=0.030506 for r=0.02
Similarly we can calculate for r=0.04, f( r)=0.309168
Step 10: Using Trapezoidal Rule ( ) ( )
( ) ( )2
b
a
f a f bf x dx b a
For the Integration process, the trapezoidal rule has been taken. According to this formula,
2.9407 19.2476(0.04 0.02)* 0.221883
2T N
Similarly adding up the thrust components for all the elements, the total thrust is =5.011149N
1000(5.011149)* 510.82
9.81T g
And for torque, using the same formula,
0.030506 0.309168(0.04 0.02)* 0.003397
2Q Nm
48
Similarly adding up the torque components for all the elements, the total torque is =0.049055Nm
This whole process of BET has been done for various RPM and forward velocities.
The Propeller Performance characteristics i.e,
2 4T
TC
n Dand
2 5Q
QC
n D for Various Advance Ratios,
VJ
nD have been plotted.
The thrust coefficient and torque coefficient for various advance ratios.
i. For 4000RPM
Figure 4.16 Thrust Coefficient Vs Advance Ration at 4000 RPM
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0.016
0.018
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Ct
J
Ct Vs J
49
Figure 4.17 Torque Coefficient Vs Advance Ration at 4000 RPM
Figure 4.18 Propeller Efficiency Vs Advance Ration at 4000 RPM
0
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.008
0.009
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Cp
J
Cp Vs J
0
0.1
0.2
0.3
0.4
0.5
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
ƞ
J
ƞ vs J
50
ii. For 5000RPM
Figure 4.19 Thrust Coefficient Vs Advance Ration at 5000 RPM
Figure 4.20 Torque Coefficient Vs Advance Ration at 5000 RPM
0
0.005
0.01
0.015
0.02
0.025
0.03
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Ct
J
Ct Vs J
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Cp
J
Cp Vs J
51
Figure 4.21 Propeller Efficiency Vs Advance Ration at 5000 RPM
iii. For 6000RPM
Figure 4.22 Thrust Coefficient Vs Advance Ration at 6000 RPM
0
0.1
0.2
0.3
0.4
0.5
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
ƞ
J
ƞ Vs J
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
0.045
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Ct
J
Ct Vs J
52
Figure 4.23 Torque Coefficient Vs Advance Ration at 6000 RPM
Figure 4.24 Propeller Efficiency Vs Advance Ration at 6000 RPM
0
0.005
0.01
0.015
0.02
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Cp
J
Cp Vs J
0
0.1
0.2
0.3
0.4
0.5
0.6
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
ƞ
J
ƞ Vs J
53
iv. For 7000RPM
Figure 4.25 Thrust Coefficient Vs Advance Ration at 7000 RPM
Figure 4.26 Torque Coefficient Vs Advance Ration at 7000 RPM
0
0.01
0.02
0.03
0.04
0.05
0.06
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
Ct
J
Ct VS J
0
0.005
0.01
0.015
0.02
0.025
0.03
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Cp
J
Cp VS J
54
Figure 4.27 Propeller Efficiency Vs Advance Ration at 7000 RPM
v. For 8000RPM
Figure 4.28 Thrust Coefficient Vs Advance Ration at 8000 RPM
0
0.1
0.2
0.3
0.4
0.5
0.6
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
ƞ
J
ƞ VS J
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
Ct
J
Ct VS J
55
Figure 4.29 Torque Coefficient Vs Advance Ration at 8000 RPM
Figure 4.30 Propeller Efficiency Vs Advance Ration at 8000 RPM
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
Cp
J
Cp Vs J
0
0.1
0.2
0.3
0.4
0.5
0.6
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
ƞ
J
ƞ Vs J
56
vi. For 9000RPM
Figure 4.31 Thrust Coefficient Vs Advance Ration at 9000 RPM
Figure 4.32 Torque Coefficient Vs Advance Ration at 9000 RPM
0
0.02
0.04
0.06
0.08
0.1
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Ct
J
Ct Vs J
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
0.045
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Cp
J
Cp Vs J
57
Figure 4.33 Propeller Efficiency Vs Advance Ration at 9000 RPM
4.3.2Static-Thrust Bench Analysis:
A thrust bench is a vertical retort stand to which a horizontal fixture is attached. A motor mount
is fixed to the horizontal fixture paving way for the motor to be mounted onto it. As shown in
Figure 2.13, the motor is connected to an ESC and the ESC is connected to a receiver. When
powered by the battery, the motor speed can be varied by using any user interface program such
as the EagleTree System‟s data logger or National Instrument‟s power analyzer. By varying the
voltage in the UI, the speed of the motor is varied and the thrust at each speed is tabulated in the
data logger. Apart from motor speed and thrust, input current, power delivered by the motor can
also be recorded. We have conducted a static analysis of propeller on Thrust bench at MAV
department of NAL. Here the thrust is measured using a pre-calibrated load cell of 1.5kg
capacity.
Figure 4.34 Load Cell of 1.5kg Capacity
0
0.1
0.2
0.3
0.4
0.5
0.6
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
ƞ
J
ƞ Vs J
58
Figure 4.35 Thrust Bench Apparatus
The results obtained are tabulated as below
Throttle
(%)
Voltage(v) Current(A) RPM Thrust(Kgf) Power Consumed
(w)
0 NA NA NA NA NA
10 NA NA NA NA NA
20 11.95 0.26 2150 0.032 3.107
30 11.86 2.2 5150 0.21 26.092
40 11.64 6.85 7675 0.495 79.734
50 11.3 15 9825 0.83 169.5
60 10.875 25.15 11275 1.108 273.50625
70 10.365 37.8 12150 1.315 391.797
80 10.1 39.5 14100 1.498 398.95
90 NA NA NA NA NA
100 NA NA NA NA NA
59
Figure 4.36 Thrust for various RPM
From the above graphs, as the speed of the motor increases, thrust increases gradually. And after
the 12000RPM, there was an aberration in the thrust value due to the motor damage.
Figure 4.37 Thrust for varying Current
In a similar fashion, current also increases with increasing thrust and reaches maximum at1.4kg.
However, the motor cannot rotate at a higher speed beyond this point as higher currents would
damage motor windings.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 2000 4000 6000 8000 10000 12000 14000 16000
Th
rust
(K
g)
RPM
Thrust Vs RPM
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 5 10 15 20 25 30 35 40 45
Th
rust
(Kg
)
Current(A)
Thrust Vs Current
60
Figure 4.38 Power for various RPM
Power also increases with speed and reaches maximum value at the highest speed. At
12000RPM it consumes a power of 400W.
Now we can compare Thrust Bench and BET results.
Figure 4.39 Comparison between Thrust Bench and BET results
0
50
100
150
200
250
300
350
400
450
0 2000 4000 6000 8000 10000 12000 14000 16000
Po
wer
Co
nsu
mp
tio
n (
W)
RPM
Power Vs RPM
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 5000 10000 15000
Th
rust
(k
g)
RPM
Thrust Vs RPM
Thrust Bench
BET
61
The BET results almost coincide with the experimental Thrust Bench analysis results. The
discrepancy in the results is due to various reasons such as
i. The airfoil coordinates obtained from CMM are not accurate.
ii. The XFLR5 results obtained are only for 2D flow whereas the Thrust Bench analysis
deals with the 3D flow over the propeller blade.
iii. The Static Thrust Bench Analysis is done on static propeller, but we are comparing these
results with BET results at 2m/s.
iv. We can obtain more accurate results if we predict the propeller performance using
Combined Blade Element Momentum Theory (CBEMT).
Finally, we can conclude from the above graph that, results predicted by BET are fairly good and
in accordance with experimental results. We can also infer that the theoretical methods are quite
good at low Reynolds number applications. Wind tunnel tests can be compared with BET
calculation with appropriate test setup in future.
62
CONCLUSION
An unmanned aerial vehicle, a tricopter, has been developed using dynamic automation and
control systems. The components used in the development of the UAV have been modeled and
validated using various software analyses. Despite meticulous and precise calculations, stabilized
flight could not be achieved due to a broken servo link rod (shown below).
63
The servo link rod is vital to control the yaw motion and its absence tends to rotate the tricopter
in the direction of rotation of the motors. The same has been experienced in this case also.
Various flight tests have been conducted and the main objective of developing a full-fledged
tricopter has been partially fulfilled.
The prospects of the project can be extended to mount a camera for real time video transmission
of affected areas. Digital image processing and wireless data transmission could be taken up as
another major project.
64
APPENDIX I
Coordinates at r = 20mm
4.214 -6.669
4.085 -6.253
3.956 -5.837
3.79012 -5.52313
3.62425 -5.20925
3.45838 -4.89537
3.2925 -4.5815
3.12662 -4.26763
2.96075 -3.95375
2.79488 -3.63987
2.629 -3.326
2.49925 -3.136
2.3695 -2.946
2.23975 -2.756
2.11 -2.566
1.97275 -2.3825
1.8355 -2.199
1.561 -1.832
1.418 -1.64925
1.275 -1.4665
0.989 -1.101
0.84 -0.92575
0.691 -0.7505
0.393 -0.4
0.23375 -0.21975
65
0.0745 -0.0395
-0.244 0.321
-0.5495 0.65
-0.855 0.979
-1.024 1.15125
-1.193 1.3235
-1.362 1.49575
-1.531 1.668
-1.699 1.837
-1.867 2.006
-2.203 2.344
-2.35 2.4785
-2.497 2.613
-2.644 2.7475
-2.791 2.882
-2.93625 2.9885
-3.0815 3.095
-3.372 3.308
-3.53125 3.404
-3.6905 3.5
-4.009 3.692
-4.17525 3.77025
-4.3415 3.8485
-4.674 4.005
-4.84875 4.064
-5.0235 4.123
-5.373 4.241
-5.73525 4.31825
66
-6.0975 4.3955
-6.45975 4.47275
-6.822 4.55
-7.0395 4.567
-7.257 4.584
-7.4745 4.601
-7.692 4.618
-7.906 4.6255
-8.12 4.633
-8.334 4.6405
-8.548 4.648
-8.758 4.633
-8.968 4.618
-9.139 4.5305
-9.31 4.443
-9.481 4.3555
-9.54988 4.04688
-9.44775 3.82575
-9.34563 3.60462
-9.2435 3.3835
-9.14138 3.16237
-9.03925 2.94125
-8.93713 2.72013
-8.835 2.499
-8.664 2.14
-8.493 1.781
-8.39075 1.602
-8.2885 1.423
67
-8.084 1.065
-7.8475 0.7
-7.611 0.335
-7.3965 0.058
-7.182 -0.219
-6.9285 -0.4735
-6.675 -0.728
-6.361 -1.0005
-6.047 -1.273
-5.7215 -1.512
-5.396 -1.751
-5.021 -1.985
-4.646 -2.219
-4.2345 -2.468
-3.823 -2.717
-3.421 -2.941
-3.019 -3.165
-2.6055 -3.382
-2.192 -3.599
-1.7385 -3.8335
-1.285 -4.068
-0.8675 -4.282
-0.45 -4.496
0.012 -4.725
0.474 -4.954
0.8815 -5.158
1.289 -5.362
1.7405 -5.562