Update on my autopilot project

Work has been progressing slowly, but should speed up in two weeks when I will have more time and be back to my equipment and machining facilities. I have a new version of the board coming that should facilitate better proccessing.

It is quite large right now as it is designed to fit on top of the XC-1A dev kit, but the final board will be able to fit into a footprint as little as 1.5"x1" (small size is a key goal here) with a 6 or even 8 layer board to accomodate the proccesor (144 BGA). I am thinking of adding a backup comm system based on a cellular module, which would also be added to the board (64 BGA).

A test stand for the helicopter is in the works. The stand will allow the helicopter to move freely in all directions with boundary limits to prevent crashing. The movement range will be 0-3 feet in the Z axis, and ~150 degrees in the x and y direction. It will add a little bit of weight, but should not matter much with a .30 size helicopter. Motion should not be constrained as it will use PTFE/oil impregnated bronze bearings. CAD files to come later.

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Comments

  • Just to be clear, I am talking about the heli test stand, not the board. It serves the same purpose as this:
    http://arri.uta.edu/acs/pestingu/UAV/Pictures/Pictures/helicopter_o...
    but I am trying for a lower profile.
  • I actually plan on using 0603 components, I just did not want to buy SMD for a proto. Cellular should not be a problem, at the very least it can just activate on or near the ground, I will look into it.

    I will have time for finishing the cad( it's a simple model) tonght, and I can un some FEA on it. As of right now, the range of tilt is too much, a bolt will act as an adjustable block.

    Mark: no can do, I work in my school. I am only interested in making two others, so make sure you can really use it. I will get a better cost estimate up today. I primarily bu from pierce metals since they are very cheap, I design around their limited stock.
  • Hi Ravi, I'm looking forward to the CAD model of your heli test rig. Do you have parts and vendors spec'd out yet?

    $50 is ridiculously cheap for something I'd trust to protect my $500+ investment of such a large helicopter. (Not to mention safety concerns with such a large heli.) Have you looked into doing any analysis beforehand, or are you just going to rig it up and stand back a ways?
  • Awesome - I really like the look of your board. Have you considered going with surface mount components for stuff like resistors and caps? 0805 size packages aren't that bad to solder - in my experience it's straightforward without any magnification aid. It seems like it might make routing easier, or at least keep some "picket fencing" from forming around your BGA.

    BTW, I see from your profile that you're in CONUS, so make sure you research the use of cellular technology; as far as I've been able to determine, the FCC strictly forbids airborne cellular operation. (See CFR Title 47, Part 22, Subpart H: § 22.925)

    All the best!
  • Developer
    I will need 30- 50 size test stand, thanks for offer, no need to ship, I live very close so maybe we can work on it together. I have access to many parts...
  • The current setup is rather large for a 450, and a bit heavy. I can design one that will work though, I will PM you for the information I need once the system lets me.

    I am not interested in making more than two extra for others due to time.
  • Developer
    Ravi - i'd be interested in getting a helicopter mount as well although I'd like to see it first if possible (maybe PM me?). A trex450 would fit in there ok right?
  • Mark,
    If your interested, I could make you one while I make mine (Ile be putting up CAD files tonight). I can scale it down if you have a different size helicopter and make the mount work for you.
    I can order the extra materials needed, and Ile just charge you that cost + shipping.
  • Developer
    $50 sounds good!
    All my proto boards have some "skywires" to correct these types of things ...
  • Thanks. The heli stand should not be expensive to make (I do not plan on producing them). Cost is around ~$50, if not less.

    Morli: Nothing, the board is routed to the outer white line. The gyros stick down in there.

    Im hoping the board will work on the first go, I had already found one error before recieving the board. Pin 24 on the ADC is not connected, the trace got deleted somehow (pin 24 is Chip select).
    http://there.Im/
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