EDSGN 460W SP2015

Boeing UAS Cargo Mission

DSR
For the period of January 2015 to April 2015

____________________________________________________
Submitted to
Dr. Wallace Catanach
as a part of
EDSGN 460W
by
Khushboo Patel, Andre Jones, Davendra Chatterpaul, Raja Akif Raja Zahirudin,
Wonsik Nam and Bolor-Erdene Zolbayar

The Pennsylvania State University

Department of Aerospace Engineering
University Park, PA 16802
1

TABLE OF CONTENTS
____________________________________________________
EXECUTIVE SUMMARY

CHAPTER 1: INTRODUCTION
1.1 Background
1.2 General Explanation

5
5

CHAPTER 2: CUSTOMER NEEDS

2.1 Method for Gathering Customer Needs
2.2 Analytic Hierarchy Process

6
7

CHAPTER 3: EXTERNAL RESEARCH

3.1 Patent search

CHAPTER 4: MATRICES
4.1 Target Specification
4.2 Needs/Matrices Matrix

11
11

CHAPTER 5: CONCEPT SELECTION

5.1 Brainstorming
5.2 Concept Selection
5.3 Selected Concept Design

13
19
20

CHAPTER 6: SYSTEMS ENGINEERING

25

CHAPTER 7: ADMINISTRATIVE NEEDS

7.1 Budget
7.2 Gantt Chart
7.3 Ethics
7.4 Environment
7.5 Communication
7.6 Risks and Safety

28
29
29
30
30
30

CHAPTER 8: Detailed Design

8.1 Manufacturer Process Planning
8.2 Analysis
8.3 Material and Material Selection Process
2

33
35
36

8.4 Component and Component Process

8.5 CAD Model
8.6 Test Procedure
8.7 Economic Analysis

37
41
43
43

EXECUTIVE SUMMARY
____________________________________________________
The Boeing Company has sponsored a Quad Copter Design Project at Pennsylvania State
University. The focus of this project is to design a quad copter to pick up and drop off payloads
of varying weight over a set distance. This project can prove to be extremely effective in
numerous real world situations. The objective of this project is to design a quad copter that is
capable of picking up tennis balls and dropping them in a specific zone within a time limit. There
will be three types of tennis balls each with a different weight. The heaviest ball will weigh 300g
and be worth 1 point each, the middle ball will be 180g and be worth 2 points each and the
lightest ball will be 60g and be worth 3 points. The goal is to transport as many tennis balls as
possible within the 15 minute time limit.
Before developing a design, several options were evaluated. It is essential to analyze the
problem because an efficient design is important. We summarized the problem and created a
project plan. Research was done on the design, construction materials, component dimensions,
pick up mechanisms and design efficiency. Using SolidWorks, we modeled our designs to test the
parameters listed above. The ability to transport the lightest ball will be our main goal due to two
reasons: the lightest ball being worth the most points. The lightest ball will also be the hardest to
pick up because of the downwash associated with the motors. Based on these stipulations, our
design is focused on reducing the downwash. By extending the spars of the quad copter we
reduced the downwash, thus making it easier to grab the ball/s. The quad copter will be
significantly lighter because of the material choice. We will also develop a pick up arm which
scoops the ball/s and release them in the drop off zone in a controlled manner.
As with any design project, there are risks involved. The highest risk is falling behind
schedule and missing important milestones. Technical abilities will also be challenged because
the construction and design are essential. Incorporating skills developed over our college careers
will ease us through the heavy calculations involved in this project. Another important parameter
to consider is our budget. Staying within our monetary budget is also important. Following the
project plan, the final prototype is scheduled to be tested on the 30th of April, 2015 at
Pennsylvania State University.

CHAPTER 1. INTRODUCTION
____________________________________________________
1.1 Background.
The Boeing Company is an American multinational Corporation that designs, manufactures and
sells airplanes, rotorcrafts, rockets and satellites. It is one of the major companies that believes in
investments that lead to innovative education. The CAPSTONE project is a clear archetype for
the same mindset.
Quadcopters were among the first successful heavier than air vertical takeoff and landing
(VTOL) vehicle. More recently, they have become popular in the unmanned aerial vehicle
(UAV) category. There is continuous research to increase the viability of quadcopters in everyday
tasks with the advancements in multi-craft communication, environmental studies, exploration of
new technologies and increasing maneuverability.

1.2 General Explanation.

The Boeing Company has provided 3D Robotics Quadcopter kits to the team. The kit will serve
as a platform to build upon with innovative ideas to produce a quad copter with the specific task
in mind. An integrated pick up and drop off design will be designed on a vertical lift flight
platform and be tested on weighted tennis balls in an indoor arena.
The teams will compete against each other to accomplish the mission within a 15 minute
timeframe. The mission is as follows: Pick up as many balls as possible and drop them in drop
zone while safely in the take-off/landing zone. The points varies with the weights of the ball. The
rules include one pilot per one vehicle and that the power supply for the flight system must be a
Turnigy Nano-tech Battery 4000mAh 3S 35-70C Lithium Polymer (LiPo).

CHAPTER 2. CUSTOMER NEEDS

____________________________________________________
2.1 Method for Gathering Customer Needs
The initial customer needs were taken from the project description that can be found at
https://drive.google.com/file/d/0B7n73KcaMqwNU2pTamVPUmRHNlE/view?usp=sharing
.
Beyond the initial description of the projects mission and specifications, additional information
and updates regarding project requirements were received through weekly emails by the Boeing
representative, Mr. Gregory Liptak through Gmail.
During weekly status report meetings, new requirements and questions are brought to Mr.
Gregory Liptak and further discussed with Professor Wallace Catanach before continuing with
the project.
Below is the customer needs diagram made by Team Aurora can be seen in the Figure 1 below.

Figure 1: The Customer Needs Diagram

2.2 Analytical Hierarchy Process:

The customer needs from the previous section are to be weighed against each other in an
Analytical Hierarchy Process (AHP). This process takes the 10 different customer needs and also
the list given by the project description and compares them with one another. A score of 1.00
simply means that two needs are of equal importance. The goal is to achieve a weight for each
need as a measure of importance. The result of the AHP can be seen in the Table 1 below:
Table 1: Analytic Hierarchy Process
Controll
ed pickup

Drop
off
contr
ol

Weigh
ts

Stabili
ty &
Contr
ol

Belo
w
$100
0

Cann
ot
Crash

Safet
y

Execu
te
Missio
n in 15
minut
es

Carr
y at
leas
t1
ball

VTOL
Vehicl
e

Tota
l

Weig
ht

Controll
ed pickup

1.00

1.00

0.67

0.67

1.00

1.00

1.25

0.50

0.50

1.00

8.59

0.098
8

Drop off
control

1.00

1.00

0.67

0.67

1.00

1.50

1.00

0.50

1.00

1.00

9.34

0.107
5

Weights

1.00

0.67

1.00

0.67

0.5

1.25

0.50

0.50

2.00

0.50

8.59

0.098
8

Stability
&
Control

1.00

0.67

0.67

1.00

0.67

1.00

1.00

0.50

1.00

1.00

8.51

0.098
0

Below
$1000

1.00

1.00

0.50

0.67

1.00

0.50

0.50

0.50

0.50

1.00

7.17

0.082
5

Cannot
Crash

1.50

1.50

1.25

1.00

0.50

1.00

1.00

0.50

1.50

1.00

10.7
5

0.123
7

Safety

1.25

1.00

0.50

1.00

0.50

1.00

1.00

0.50

1.00

1.00

8.75

0.100
7

Execute
Mission
in 15
minutes

0.50

0.50

0.50

0.50

0.50

0.50

0.50

1.00

0.50

0.50

5.5

0.063
3

Carry at
least 1
ball

1.00

1.00

2.00

1.00

0.50

1.50

1.00

0.50

1.00

1.00

10.5

0.120
8

VTOL
Vehicle

1.00

1.00

0.50

1.00

1.00

1.00

1.00

0.50

1.00

1.00

9.00

0.103
6

AG
G
SU
M

86.7

The AHP is also a part of the Systems Engineering approach that Team Aurora used to undergo
7

the mission. The Systems Engineering approach will be further discussed in Chapter 6 of this
document.

CHAPTER 3. EXTERNAL RESEARCH

____________________________________________________
3.1 Patent Search
EP 2720948 A1 is a self-sustained drone freight and observation airplane. It has a fixed landing
gear, no windows and ramp for the cargo carrying capability. The airplane seen in Figure 2 has
relations with the quadcopter project in respect to the cargo carrying capability. As the
quadcopter designed by Team Aurora does not have a cargo ramp, it should not be an issue. It is
wise to make sure that the quadcopter does not infringe on this patent.

Figure 2: Patents
US 20140217230 A1 is a Drone Cargo helicopter. It has an elongated body with a low profile
construction using coupled struts. The aircraft has relations with the quadcopter project because
it is a VTOL aircraft; a helicopter. Team Aurora did not use the same structure and shape in the
design. Therefore, it is not an issue. It is important for Team Aurora to be careful and aware of
this patent.

Figure 3: US 20140217230 A1 Patent

US 20060266881 A1
This is a vertical takeoff and landing aircraft using a redundant array of independent rotors. A
vertical takeoff and landing aircraft, using for vertical lift and lateral thrust a redundant plurality
of essentially similar electrically-powered and electronically-controlled thrust units mounted in a
mechanically static or fixed fashion relative to one another in a substantially horizontal plane.
The thrust units are situated in this planar array in aerodynamically approximate pairs, such that
a complete failure of a single thrust unit would not substantially compromise the ability of the
aircraft to maintain flight.

Figure 4: US 20060266881 A1 patents

10

CHAPTER 4. MATRICES
____________________________________________________
4.1 Target Specifications
Table 2 shows the target specifications to be achieved for the project. The six quantities were
taken from the required specifications due to the mission limits as well as the customer needs.

Table 2: Target specifications for the final platform

Number

Metric

Units

Value

Total Thrust

kg

5.22 @ 100%

Flight Time

min

8 - 17

Number of Pilots

Weight

kg

3.30

Only allowable Battery

Yes

Only allowable Receiver & Transmitter

Yes

4.2 Needs/Metrics Matrix

The Table 3 shows the target specifications on the horizontal axis and the customer needs on the
vertical axis. The different features that corresponds with the customer needs and the target
specifications are marked with an X. Some variables may be directly related, such as Weights
and Flight Time, while others may be indirectly related such as Carry at least one ball and
Flight Time. The table gives a guideline of relationships of the variables for the team to consider
if changes were to be made to the components.

Table 3: Relation of Customer Needs and Target Specifications

Total

Flight

Number
11

Weigh

Only

Only allowable

Thrust

Time

(5.22kg)

(8-17
minutes)

of Pilots
(One
Person)

t
(3.3
kg)

allowable
Battery

Receiver &
Transmitter
(No units)

(No units)

Controlled
pick-up

Drop off
control

Weights

Stability &
Control

Below $1000
Cannot
Crash

Safety

Execute
Mission in 15
Minutes

Carry at least
1 ball

VTOL
Vehicle

CHAPTER 5. CONCEPT SELECTION

____________________________________________________
5.1 Brainstorming
12

After the customer needs and the target specifications were realized, a brainstorming diagram is
made as a general plan to follow during the brainstorming process. The Figure 4 shows the
Brainstorming Process Diagram that contains the steps taken in the brainstorming process.

Figure 4: Brainstorming Process Diagram

Below were the ideas generated from the brainstorming process:

1. Velcro Concept

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Figure 5: Velcro Design

This idea is based on the famous product Velcro. The surface of both the tennis ball and Velcro
consists of small hooks. If the tennis ball and Velcro are pressed to each other, there is a binding
force created between them. This force is used as an opposing force to the gravitational force.
The pick-up mechanism for this idea included two tubes. The top tube is connected to the motor
which rotates clockwise while, the bottom tube is used to create pressure on the balls. With this
technique, the mechanism were able to pick up multiple balls. To drop the balls, small spaces
which are smaller than the size of the tennis balls are created in the solid body under the top tube

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in which the Velcro material goes through and the ball does not. The Velcro belt turns along a
circular path and goes through this small space. When the balls hit this surface, it will drop.
b. Extended Claw Crane Concept

Figure 6 & 7: Claw Concept

This idea is simply modified from the Claw Crane as shown in Figure 6 and Figure 7. To pick up
multiple balls, the mechanism was extended. The claws would open and close accordingly to
capture and release the balls.
15

c. Vacuum Concept

Figure 8: Vacuum Concept

The main goal of the vacuum pick-up mechanism is to suck the ball up using airflow generated
from the quadcopter motors. An operating small motor is placed inside the main body of the
pick-up mechanism. When the quad copter reaches the dropping zone, the operating motor will
stop and let the ball drop in the container.

d. Scoop Concept

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Figure 9 & 10: Scoop Concept

This brainstorm idea includes two scoops. As seen in Figure 9 and Figure 10, they are connected
on both ends of the wall as shown in the picture. With help of the motors located in both hinges,
the scoops put the balls inside of the box and is closed. Once the quad copter reaches the
dropping zone, both scoops open. When the quadcopter is tilted, the tennis balls roll down along
the floor of the box to the container.
e. Sliding Plane Concept

Figure 11: Sliding Plane Concept

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This idea is also to pick up multiple balls. Once the box drops on the tennis balls, the metal door
of the box is closed. To drop the balls, the door opens with an operation conducted from the
motors.
f. Elastic Box Concept

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Figure 12 & 13: Elastic Box Concept

When the quad copter lands on the tennis balls, the rubber bands of the bottom side gets pushed
by the tennis balls. Due to the force from the tennis balls, the elastic bands extends and the balls
get in the box. To drop the balls, two hinge mechanisms are placed to extend the rigid walls. By
extending the rigid walls, the spaces between the rubber bands increase and the balls will be able
to fall into drop zone.
g. Moving Box Concept

Figure 14, 15 & 16: Moving Box Concept

The moving box concept uses the same idea as the scoop but uses a rack and pinon setup to
move the box mechanism. The box will close after landing on top of the balls and open at the
drop zone to pick-up and release the balls respectively.

5.2 Concept Selection

The concepts undergo a selection through a concept selection matrix. Below is the matrix. The
concept with the highest score will be selected for the project.

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5.3 Selected Concept Design

Currently, the idea selected is the moving box design. This design surrounds the quad copters
ability to pick up the balls using a motorized box. This box is mounted on arms connected to a
gear which is powered by a servo motor. The basic layout of this design can be seen below with a
detailed description of each component.

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Figure 17: Moving Box Concept

Above you will find the breakdown with all the parts in the design. The name of the part, the
description of the part and the quantity is shown. This design serves to provide stability and
security. The only concern is the weight of the material and their effects on the lifting capability
of the quad copter. The servo will turn the spur gear and the gear will force the arms to translate
on opposite directions. This translation will result in a lateral movement of the box. The box will
close. To open the box, the servo motor is reversed and the payload is discharged.
Below, the components of this pick up mechanism are specified with the respective weights. It is
important to know the weights and the composition of the parts because these parameters directly
influence the flight dynamics of the quad copter. Structural stability and support is also a major
variable. The mechanism must perform well within the allotted the factor of safety. Using
aluminum alloy gives the mechanism a high tensile strength and makes each component better
able to resist the induced strains during the operation.

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Figure 18: Moving Box Concept Parts

Having a reliable design that will be able to perform under demanding situations is extremely
important. Now that the material has been specified, it is necessary to test the design and address
the two main issues. The first main obstacle faced was the structural capability of the craft and
the second obstacle related to the structural stability is the presence of downwash. Moving
forward to address these issues, Finite Element Analysis (FEM) was conducted on the stock
spars to determine the maximum stress, the maximum strain and the maximum displacement
endured. Below is a detailed FEM model showing the displacement of the stock 9.5 inch spar.

Figure 19: FEM Analysis of Spar

22

The image above shows the stock spar displacement with two forces acting on the element. First,
we have a gravitational body force acting throughout the structure and we have an upward force
equal to the thrust produced by the 880kV motor. The maximum observed displacement
surmounts to be .016 mm. This displacement is extremely small and thus proves to be negligible.
To address the issue of the prop-wash, the spar structure was evaluated. FEM testing was now
done on a spar with an increased 50% in length. The new test length surmounted to be 14.25
inches. Intuitively, the displacement will increase; however, the magnitude of that displacement
was unknown. The FEM analysis gave us a displacement of .788 mm. The Figure below is a
model showing the stress distribution over the surface along with the maximum displacement.

Figure 20: FEM Analysis of Spar

The model only experienced .778 mm of displacement with a 50% increase in length.
Structurally, this serves as a perfectly capable spar for the purposes of this project. Again, the
forces that act on this model is the gravitational body force and the vertical thrust force due to the
23

motor. It is important to understand that the model in Solidworks is evaluated with the fixed end
of the spar as an infinitely rigid joint. In reality, there is no such fixture as an infinitely rigid
joint. This means that the displacement will be slightly higher than what the FEM model
suggests.
Analyzing the joints is extremely important because there will be a greater force exerted on the
center plate due to the increased spar length. The moment at the fixed end will increase because
the moment arm increases while the external force stays constant.

Figure 21: FEM Analysis of Center Plate

Looking at the joint analysis of the fiberglass center plate, the reaction forces were computed to
be approximately .782 N or 79.8 grams. The joints are fully capable of withstanding these forces.
Now that the structural stability and structural response is validated, attention can be paid to the
second issue: downwash.

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Figure 22: Downwash Reduction Concept

To address the issue of downwash and to provide improved stability, we looked at increasing the
spar length and also at testing the angle of attack of the rotors. By tilting the rotors approximately
5 degrees, the wash will be deflected approximately one inch from the center of the craft. The
vertical thrust component will be reduced by a miniscule 8.7 percent. Last but not least, it is
important to look at flight characteristics and calculations. Below is a detailed breakdown of the
flight calculations.

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CHAPTER 6. SYSTEMS LEVEL DESIGN

____________________________________________________
After placing our top three designs through our condensing matrix, the decision was made to
combine the rigid box and the elastic box. The design that is currently being pursued is a
combination of the rigid box design and the elastic box design. Within this section of the report,
the solidworks drawings and the detailed description can be found. Before explaining the
workings of the design, it is important to understand why the decision was made to combine the
two ideas.
Analyzing the rigid box design, it quickly became apparent that the main issue with such
a design would be the weight of all the components. The pick-up box and the arms along with the
sprocket proved to be significantly higher than we anticipated. In addition to the weight, the
pickup device provided major stability issues purely because it was very difficult to mount to the
quad copter. Refer to section (5.3) for a refreshing image of this rigid box design. Lastly, the
issue of opening and closing the box became an issue. The original plan was to land on the box;
however, the mechanism would not be able to operate smoothly. This design would require
additional landing platforms onto the good aspects of this design. The rigidity and the real-estate
capability of the rigid box was a major plus. The "box" shape of the pick-up device would allow
the quad to carry more balls. The box provided a cushion that the quad can land on in normal
operation and in the event of a crash.
The second design that was used is the elastic box idea shown in section (5.1f). There
were some flaws however. Firstly, this design had no appropriate war to be mounted to the quad
copter. The joints where the quad copter will mount to the device were extremely inefficient.
Secondly, the design incorporated a moving wall. The moving wall would tension and loosen the
elastic bands which would hold and release the ball respectively. The problem with the moving
wall is that the wall has a natural tendency to stay in a state where the elastic bands hold the least
tension. The amount of energy required to move the wall would also be significant. The weight
of this system was also a concern. Although the elastic box idea proved to be somewhat
inconsistent, there were some valuable design characteristics. First, the incorporation of elastic
bands means the weight of the craft would be significantly less, this would enable us to carry
more payload. Secondly, the simplicity of the design would ensure a lower probability of failure.
`Our pursued design is depicted below, in addition, the function and design of each part is
explored.

26

Figure 22 & 23: Quadcopter Frame and Frame of Pickup Mechanism

As you can see from the figure above, the current design has elements of both the rigid box
design and the elastic box design. The "box" is now framed in Chlorinated polyvinyl chloride
(CPVC) and elastic bands are still employed. The use of the CPVC pipe reduced the total weight
of the craft and provides the same, if not a better cushion to land on. The flexibility of the CPVC
provides a margin of safety for the craft while the elastic bands stand to reduce weight. As for
mounting the device to the quad copter, the spars of the quad will act as lifting hooks and support
the load of the device. Because the CPVC frame is symmetric, the center of gravity remains in
the center of the craft adding stability. Below is a detailed breakdown of the pickup mechanism
and how it works.

27

Figure 24: CPVC Box

As you see from the figure above, (1) represents the frame of the CPVC box. (2) Is the
rotating arm. The CPVC is secured to the rotating arm which, as the name states will rotate
clockwise to tension the elastic cables (3) and then release the tension by rotating counter
clockwise. The location of the servo motor is at position (4).The approximate diameter of the
CPVC is one half inch. This diameter selection was done on purpose because the smaller
diameter implemented means the less torque required based on the equation:
M = Fr
In the equation, Moment/Torque is equal to the Force required (the tension in the cables), which
is constant, multiplied by the radius of the cylinder (rotating arm). The elastic bands are
represented by (3). These expand and contract to hold the payload in place.

Figure 25 & 26: Mounted Quadcopter

In the above graphic, the actual prototype in progress is illustrated. Note the mounting pattern
and the overall simplicity of the design.

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CHAPTER 7. ADMINISTRATIVE NEEDS

____________________________________________________
7.1 Budget
The team budget is set according to the Senior Design Project Purchases and Reimbursements
Guidelines and is defined by the course syllabus. All purchases must be made by the team
members as determined by the guideline. As of 19th February 2015, the budget balance sheet of
Team Aurora is as in the Table 3 below
Table 3: Budget Balance Sheet
Boeing VTOL Team 1 : Team Aurora
Budget Balance Sheet
Assets
EDSGN 460W

Amount (USD)
1000.00

Liabilities

Amount (USD)

Material Purchase

219.20

Tax & Shipping

29.27

Total

Budget Balance

248.47

751.53

The highest cost up to March 19th, 2015 was the material purchases. This was because the quadcopter kit that Team Aurora received was lacking necessary flight components for the
quadcopter. A detailed list of the purchases of the quad copter components can be seen in the
table below. The flight components were bought from Hobby King and HobbyTown. There were
also the cost of tax and shipping that was necessary when ordering the flight components. The
material purchases also encompassed the cost of materials to make the rapid prototypes of the
conceptual designs. These materials were bought at Michaels and The Home Depot. Moving
forward more purchases will be made as more prototyping will occur.

7.2 Gantt Chart

The team came up with a Gantt Chart to plan out tasks to be done for the project. The tasks could
be seen below in Figure 27.
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Figure 27: Project Plan progress

7.3. Ethics
The team must satisfy safety, health, and welfare requirements of the course agreement while
testing their design. Team members must act in professional manners for each other as faithful
peers or trustees and avoid conflicts of interest. The Boeing Company allows all three teams to
collaborate and share ideas and resources throughout the project.
An issue could arise if one team uses concepts developed from another team without permission
or acknowledgement.
Lastly, the team must have basic knowledge regarding patent laws of engineering design.

7.4. Environment

30

All decisions made in the design, build and test of the quad copter will reflect what is best for the
environment. All products, once not usable, will be correctly recycled and disposed of so that
nothing is wasted.

7.5. Communication
Meetings with the Boeings technical team is held at 8:30 pm on every Tuesdays via Google
Hangouts. Project designs, weekly status reports, and updated Gantt Charts are shared in the
Google drive of Aurora Team. Communication through e-mails were used through G-mail as
well as the Penn State e-mail system. The Boeing sponsor, Mr. Gregory Liptak, may come up to
the Penn State University for the weekend of February 21st or 28th to give technical advices to the
teams.

7.6 Risks and Safety

The quadcopter being assembled in this project is primarily evaluated for performance
characteristics as well as, a foundation for building future quadcopters. Although this project
being worked on is easily assembled and operated by students with minimum experience
piloting, there are still risk and safety issues that need to be issued.
To begin with, before trying to actually fly the quadcopter, make sure to that all the component
of the quadcopter are securely fastened--especially the motors and the frame components. Before
the first flight experiment, all the screws on the quadcopter must be securely fastened with a
thread seal tape or a liquid thread lock in order to ensure that the screws dont become loose.
Furthermore, the propellers, frame and the spars should be checked for integrity--essentially
checking whether the metal contains any cracks or splits. Finally, the batter power supplies
should be re-examined and verified so that there is sufficient amount of power available in the
battery in order to prevent damage to the LiPo cells.
The LiPo batteries should be handled with caution so that there is no harm done. A failure to
properly handling the batteries could result in puncture. If LiPo cells become punctured, there is
a high probability of the cells catching on fire, which would be a disaster. In addition, the
batteries should be charged in a safe location where there is a minimum risk of the cells catching
on fire. In the case of a fire actually happening, the charger should immediately be removed from
the power supply when it is safe to do so. After safely removing the charger, it should be placed
in a safe location where it can cool down the temperature of the charger.
Make sure that the LiPo batteries are never discharged below 3.0 volts, as the batteries will not
be able to accept full charges, and thus resulting in a failure to maintain proper voltage use.
Moreover, if the battery cables have to be changed in order to accept new connectors, one must
make sure that the connectors do not create a short circuit--as this would create a fire.
Next, when the quadcopter is fully prepared and ready to fly, the quadcopter instantly becomes a
cutting hazard to anyone in the vicinity. During the flight, no one should touch the rotor blades at
any time. When the motors are powered on and the rotors do not spin, simply turn the system off
and investigate the problem with the rotors, so that it prevents anyone from getting hurt when the
rotors suddenly start spinning with the power still on. Furthermore, if the quadcopter suddenly
31

breaks and falls apart in mid-air, it is imperative that everyone stands far away due to flying
debris in the air. In most cases, the loss of power is the most commonly experienced source of
failure due to the maximum limits overrun of the LiPo cell. Thus, the pilot should know the
limits of how long the battery can last at full thrust and safely land the quadcopter in order to
prevent any sort of crash landing.

Risk

Risk
level

Actions to minimize risk

Fall Back Strategy

Down wash

High

Spars made 50% big

Spars operating at 5
degree angle

Safety

Moderate

15 ft belt between control

area and action area

Safety checklist

Flight stability

Moderate

Change the strategy for

flying

Design overview

Parts falling apart

Low

Simple design

Change the material

used

Schedule delays

Moderate

Constantly track progress

report, accelerate tasks

Build in safety time

Order delays and shipment

delivery

Moderate

Make sure all parts are in

stock, track shipment

Drive to nearest
location to receive

Pick up mechanism does not

function as predicted

Low

Test first and do it frequently

Alternative material
and design

The table above displays our risks for this project. There are problems that may arise that
would cause the project to fail. Those are in the left column. Each risk is ranked low, moderate,
or high depending on the probability it will hinder the progress of the project. Down wash is
ranked high because it is necessary to account for in the midst of the mission. Most of the other
risks can be accounted for with fail-safes and predictive planning.

32

CHAPTER 8. DETAILED DESIGN

____________________________________________________
8.1 Manufacture Process Planning
The manufacturing process planning provides precise descriptions about structure of the
product and how the product is to be routed and fabricated for mass production. The main
concern of manufacture process planning is to make the product simple and cost effective as
possible while meeting the product performance needs.

33

The pick-up mechanism must be able to pick up multiple balls, carry over distance, and drop
them off on specific zone. To successfully perform this duty, the main body parts need to be
light, symmetric, and simple because the quadcopter must be easily maneuverable, stable in
flight, and strong enough to withstand hard landing and physical contacts. The most
recommended materials for multi-rotor frame are Carbon fiber, Plexiglas, Polyvinyl Chloride,
and Aluminum.
In the process of manufacturing, we have to consider two main concerns: Design for
Assembly (DFA) and Design for Manufacturing (DFM). Design for Assembly is concerned with
reducing product assembly cost. For DFA, we came up the idea to reduce our product assembly
cost by minimizing number of assembly operations and making individual parts less complex in
design. Design for Manufacturing is concerned with reducing overall production cost. For DFM,
we concerned to minimize complexity of manufacturing operations and use common datum
features and primary axes for the design.
In general, the lightweight and simplicity are the most important characteristics of our design
for mass production. Since our design is based on box shape, we avoid to build solid walls and
ceils for it. The box frame consists of 6 and 18 tubes and 3-way corner connectors as shown in
the figures below.

34

To avoid additional weights from the connectors, we directly connected the box frame to our
quadcopter. The elastic bands and servo motor are connected to the tubes of the box bottom side.
To make the structure stable, we use glues in the 3-way corner connectors.

8.2 Analysis
First calculation was based on the amount of thrust that a design would generate and so the
allowable weight for the frame and the pickup mechanism were estimated based on the
efficiency of 100%, 75% and 50% at the least. Details can be seen in Figure 27 below. The
biggest problem in using a VTOL vehicle is the amount of downwash created by the propellers
and analysis was done using the Solidworks detailed design and simulation where length of the
spars were increased by 50 %. FEM analysis showed a .788554 mm of displacement for each
spar which was negligible.
When dealing with Airborne vehicles weight is always considered and efforts are made to make
it as least as possible. Testing was done on metal framed foam using the beam bending concepts
and it was found to be stronger than predicted. After assembly of the electronic components that
35

run the arduino on the quadcopter, pickup mechanism prototype was made. Using CPVC pipes a
similar model of the pickup mechanism was made using the elastic bands and tested manually
with tennis balls. Positive response was obtained and the further process included testing of
motors spinning and downwash created .Currently the team is working on getting the controlled
motion of the propellers and controlling the downwash. The torque calculations for holding the
elastic bands in place on the CPVC box frame is in process.
POWER
USAGE

POWER
%

THRUS
T

TOTAL WEIGHT
(Rigid Box +
Copter)

PAYLOAD CAPACITY

6.1A/ 70W

50%

2600 g

3372.4 g

-772.4 g

14.2A/160W

75%

5160 g

3372.4 g

1787.6 g

20.0A/120W

100%

5220 g

3372.4 g

1847.6 g

8.3 Material and Material Selection Process

Material selection process is one of the main steps in the process of designing our pick up
mechanism. The main goal of material selection is to minimize manufacture cost while satisfying
the product performance requirements. Systematic selection of the best material for our project is
based on the selection matrix evaluated by properties and costs of candidate materials:
Plexiglass, Carbon fiber, Polyvinyl Chloride, and Aluminum
The two main concerns of the product performance requirements are weight and stability.
As mentioned before, the quadcopter must be easily maneuverable, stable during flight, and
strong enough to withstand hard landing and physical contacts.

36

After we went through selection matrix, the polyvinyl chloride was the best material for
our mass production. As described in the table 1, polyvinyl chloride (pvc) is the cheapest
material comparing to the other three materials. Although the density of the Plexiglas is less than
pvc, its price is 6 times higher than the price of the pvc. Also, Plexiglas is hard to manufacture,
assemble, and recycle in the industry comparing to the other three candidates.

Since the stiffness of the PVC is less than the stiffness of the other three, the other important
property we have to consider in our product is torsion of stressed tube. We have to find out if the
PVC is reliable while the servo motor is rotating the PVC tube.
For this design problem, we will establish a standard for selection of light and strong
materials for the tube. The twisting moment is specified by the servo motor while the lengths of
the tubes are given 6 and 12. We develop an expression for the mass of material required in
terms of twisting moment, tube length, and density and strength of the material. Using this
expression, it will be possible to evaluate the performancethat is, maximize the strength of this
torsionally stressed tube with respect to mass and, in addition, relative to material cost. Length of
tube and radius are L and r, respectively. The application of twisting moment (or torque)
produces an angle of twist Shear stress at radius r is defined by the equation. Mt is twisting
moment.

The Equation 1 is able to define that the best materials to be used for a light shaft that can
safely sustain a specified twisting moment are those having low ratios of density over stress to
the power of 2/3. After plugged all variables of the CPVC in the equation, the shear strength was
found safe when the servo motor is working at its highest power.

8.4 Component and Component Selection Process

What components were chosen for the major parts of the prototype? Describe the process you
went through for picking the components for the prototype, i.e., what trade-offs (availability,
cost, ergonomics, features, speed, size, green material, etc.) were the driving factors.

37

The two main parts of the quadcopter are the pickup mechanism seen in Figure (2) and the
main structure of the quadcopter seen in Figure (1).

(1) Quadcopter main structure

(2) Pickup Mechanism of the quadcopter

For the quadcopter main structure, there are several components that Team Aurora has chosen.
The components are the 3DR aluminum spars and the 3DR aluminum plate. Both items were
received as part of the kit provided by Boeing. As it was the prototype, the team opted to use the
given kit first to test out the design. The trade-off of this choice was that the kit items were
38

heavy. Weighing in at 1.7 kilograms, the frame is heavier than a carbon fiber would be. The key
advantage to this configuration is that the aluminum is rugged enough to withstand pounding and
crashes during flight testing. Besides that, it is also easier to set up as there are clear instructions
on how to assemble the frame kit online. Team Aurora did a FEM analysis of the stock spars to
see the displacement of the spar under the load provided by the 880kV motors. This can be seen
in Figure (3). The FEM testing showed that the maximum observed displacement was 0.016mm.
This is very small. The center plate also was modelled and tested on Solidworks. It will be able
to withstand 79.8 grams of force associated with the loads and the motor thrust. For the purpose
of making a prototype, these would be sufficient.

(3) FEM analysis of the stock spars

On the Quadcopter main structure, 880kV motors were to be put at each end of the spar as seen
in Figure (4). Team Aurora chose the 880kV because of the shear power of the motor. As the
intention was to pick-up multiple balls, powerful motors were needed to create lift to the
quadcopter. The 880kV motor produced a significant amount of thrust at 2.6kg at 50% power and
5.2kg at 100% power. Table () gives a picture of the motor specification chosen for the
prototype. The motors was also coupled to the Electronic Speed Controllers (ESC). The team
opted to use 200mA ESCs for the quadcopter. These ESCs were sufficient for the prototype of
the quadcopter.

(4) Quadcopter frame with 880kV motors mounted

39

Next, is the pickup mechanism of the quadcopter. The components of the pickup mechanism are
only the frame of the pickup mechanism and the motor tightening system that will be used to
tighten the elastic bands that hold the balls. As stated in section 8.3, the material used for the
frame is CPVC. The CPVC is rigid enough and very cheap for the purpose of prototyping. It is
also very light and can be swapped or replaced in a short period of time if need be. The trade-off
is that, the CPVC is not as strong as aluminum or metal frames. Team Aurora would test this
material out in the flight tests, to test out the plausibility. Based on the calculations, it is seen that
the CPVC frame would be able to sustain the loads from picking up several tennis balls.
The motor tightening system was built using servo motors. The torques were first estimated with
calculations and based on those calculations the servo motors were chosen. The servo motors
would turn and hold the tension. The trade-off is that the servo motors require constant current
draw. This reduces the battery life and thus, translates to less flight time. The servo would be the
best option for the prototyping as they are easily available at the hobby stores. Other options
such as the motor with a brake and a stepper motor would be more expensive and some may
require programming to function properly.

40

8.5 CAD models

Basic Model of Quad copter Structure

12 inch by 4.5 inch prop design

41

Carbon Fiber Base Plates

Aluminum Alloy Spar

42

8.6 Testing Procedure

In order to make sure the quadcopter works, we must have a startup procedure checking all the
parts. The first step is to calibrate the ESCs. This is done through connecting the battery and
position the throttle to 100%. After the motors beep, the throttle is put down to zero and the
battery is to be disconnected. The batter is then reconnected and all ESCs will be calibrated to
the same settings as each other. Once that is complete, the ardupilot is connected to mission
planner so that the settings for the ardupilot can be calibrated. Once complete, the batter is
connected to the quadcopter and the transmitter is armed by putting both throttle and position
controls down and to the right. To make sure everything is working properly, the throttle is eased
up so the power of the downwash does not gain height too quickly and an instability does not
cause the copter to crash. After the quad is in the air, basic direction controls will be tested
during hover. The quad must be able to rotate both clockwise and counter clockwise. Then
strafing is tested to make sure that forward, backward, left, and right movement are all
functional.
The pickup mechanism testing procedure is simpler. Once the quadcopter is armed, the motor
connected to the PVC is tested to make sure it can torque the load required. The motor is also
checked to make sure that it torques the load in a reasonable time. When the elastic bands are
holding a tennis ball inside the box, the motor is stopped. The torqued rod is to be held in place
by a stopping mechanism. If the bands hold their tension and the rod does not un-rotate then the
pick-up mechanism is successful.

8.7 Economic Analyses - Budget and Vendor Purchase Information

Components and materials purchases were made including some basics parts for the quadcopter.
A detailed list of the items purchased until 03/18/2015 is shown in Table 4.
Table 4: Detailed purchases up to 18th March 2015
Number

Date of
Purchase

Product

Place of
Purchase

Quantit
y

2.5.2015.

20A ESC 3A
UBEC

Hobby King

8.72 52.32

2.5.2015.

10CM Male to
Male Servo Lead
26AWG(10pcs/set)

Hobby King

4.94

4.94

2.5.2015.

XT60 Female w/
12 AWG Silicon
Wire 10cm
(5pcs/bag)

Hobby King

5.24

5.24

2.5.2015.

Hobby King

2.62

2.62

Nylon TConnectors Male

43

Price per
Unit

Total Tax &

Price Shipping

(10pcs/Bag)
5

2.5.2015.

Turnigy 5mm Heat

Shrink Tube-RED

Hobby King

1.05

1.05

2.7.2015.

Hemp Cotton
Twist

Michaels

2.49

7.47

2.7.2015.

Elastic Necklace

Michaels

4.99

9.98

2.7.2015.

Foam Can Holder

Michaels

2.7.2015.

E-6000 2.0oz

Michaels

3.99

3.99

10

2.7.2015.

500pc Primary CA

Michaels

3.99

3.99

2.7.2015.

Brick Wet Foam

4pc

Michaels

6.99

6.99

The Home
Depot

8.97 17.94

8.84

The Home
Depot

9.27

9.27

10.21

The Home
Depot

3.97

3.97

6.7

The Home
Depot

5.48

5.48

2.19

28 gauge

The Home
Depot

2
1

7.97

7.97
2.97

11

Sheet Metal
Aluminum
12

2.8.2015.

21 gauge 6 x 18
Velcro Strap

13

2.8.2015.

3/4 inch x 12 ft
Velcro Strap

14

2.8.2015.

7/8 inch x 23 inch

Foamular Projet
Panel

15

2.8.2015

2 ft x 2 ft
Sheet Metal Steel

16

2.17.2015.

10.98 21.96

17

2.17.2015.

Wood Glue

The Home
Depot

18

2.17.2015.

loctite Spray

The Home
Depot

2.97

19

2.18.2015

Gold Bullet Conn

HobbyTown

2.89 11.56

44

Set
20

2.18.2015

Bc Heat Shrink
Tube

HobbyTown

1.59
Total
Final

45

1.59

0.79

210.2
1

28.73
238.94