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Full metal copter first flights

First test flight:First flight ends in a crash, but I attribute that to pilot error rather than a problem with the copter. This flight did bend one of the legs slightly. I believe the holes I drilled to reduce weight have compromised the strength of the leg. I will replace with solid pieces.Second flight. No crash, and quite a stable platform.
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Full Metal Copter

Thanks to all in AeroQuad and AduCopter communities for their inspiration and ideas. I submit this photo record of my build hoping that it may help others.


Here are the custom machined aluminum parts for my frame. I used Alibre Design to capture the design and create part drawings. I am fairly new amateur metal worker and I manually machined the parts in my home shop. The arms are made from Home Depot towel bar material, quite strong and light.

My hub design was inspired by the design seen in this quad: http://forum.mikrokopter.de/topic-15135-1.html but I have corrected a flaw in that design. You can see in that design that when the hub halves are bolted together, a good, tight, consistent fit between the arm and the hub is dependent upon tight tolerances between the arm and the cavity formed by the hub pieces. With normal variances in the size of the aluminum tubing, these tolerances cannot be maintained. In my design, each arm is individually captured and clamped into its hub slot by a small piece that distributes the bolt pressure over the end of the arm. It is very tolerant of arm material size variations. A possible advantage of this design over the more common “sandwich” designs (like the “official” arducopter frame) is that an individual arm can be removed and replaced without loosening the sandwich and affecting other arms. In any case, this design is super strong and rigid and I like the way it looks.

Here is the motor end of the arm showing my leg mounting design and how it makes for a strong motor mount. The leg mount slides into the end of the arm. A bolt passes all the way through the arm, also passing through the leg and motor mounts. The bolt can then be tightened, squeezing the arm tube securely against the leg mount without worry about crushing the aluminum tube. I am using the mounting piece that came with the motor and I hope it proves strong enough. If not, I will design and machine a custom piece.

Here is the assembled basic frame. The weight at this stage was about 660g. The legs are .125” aluminum and are stronger than they look. They slope down at a 45 degree angle and are long enough that they extend horizontally about an inch or so farther than the reach of the 12inch props I am using. This provides prop protection if the copter approaches an obstacle horizontally. The legs also provide a stable platform that will not tip over if I encounter the uneven motor starts at take off that I have seen documented on the forum. The arm/leg combination does provide a pretty long lever arm that might invite damage in a hard, one-legged landing, but I mitigate this as shown below with my “bow” approach.

Here is the completed copter ready for initial test flight. With its 4400maH battery, the ready-to-fly weight is 1455g.

Although kind of hard to see, this picture shows the bow design achieved by tying the end of the legs opposite each other together with 4 runs of high test fishing line. This should greatly reduce the likelihood of bending the legs, at least in one direction and it lends a sort of shock absorber action to the overall frame. The dabs of paint on the props were applied when balancing them using a magnetic prop balancer. The electronics pod is plastic ware from the dollar store. I have seen other designs, e.g., using CD packages, where the flat part is mounted to the frame and the pod part is fitted over the electronics after they are all wired up and secured somehow. I prefer this approach where the pod is mounted to the frame, providing an enclosure that the electronics can be placed into and then it is closed up by putting on the lid as in normal use. A hole in the bottom of the container is aligned with the hole in the middle of the hub for the ESC control wires to pass through.

This detail shows the foot approach using rubber hemispheres that are actually “popper” toys from Michaels attached with cable ties. This view also shows how the fishing line is attached.

This view show the battery mounting approach enables easy battery swap. Bolts inside the pod hold it to the frame by screwing into the threaded spacers that hold the battery mounting bits. One of the ESC control cables can be seen passing through the hub center hole.

This view shows how the motor power system and 30A ESCs are installed. I use a split power system with separate batteries for the ESC/Motors and the electronics pod. Only the ground and control signal wires from the ESCs are connected to the Mega while the +5V lines from the ESCs are not connected. With this approach, you can power the pod electronics from the either the pod battery or from the USB connection when loading software or configuring with the configurator (pod battery not connected when USB connected). You can also connect the main battery to the ESCs when the USB is connected without worry of “blowing your outputs”. This way, during testing, you can run motors just fine while the USB is connected. The power distribution from main battery to ESCs is via a harness I soldered up using 2 screw lugs for the center connections of the +V and ground “stars”.

The fishing line is also visible at the in the picture.

Above the battery, you can see the battery voltage monitor affixed to the bottom of the pod. It plugs into the main battery’s balance connector. The battery connects to the power harness with bullet connectors.

I mounted the electronics in foam packing inside the pod as shown here. Connecting the connectors shown applies power from the pod battery to the +V input of the Mega. Power from the Mega’s voltage regulator powers the RC receiver via the Mega-to-receiver servo type connections.

This view shows the IMU and its connections to the receiver, a Spektrum 2.4Gz unit. It shows how I mounted the magnetometer directly to the IMU as shown in the arducopter manual as an alternative configuration. After mounting it this way, I searched through the alpha arducoper code and libraries for the “set_orientation” calls that are described in the manual but could not find them. It is not clear to me if the orientation of the magnetometer shown in my picture is correct for the alpha code or not- I have seen conflicting information about the “standard” configuration of the magnetometer in relation to the IMU.

From the other side, you can see the 610maH pod battery peeking out from under the board stack. Both the receiver and pod battery are tucked into their own cavities in the foam.

This picture shows the Mega at the bottom of the board stack and gives a better idea of how the electronics are enclosed and protected by the hollowed out foam. The foam pieces were those that the motors came packaged in. I was originally intending this to only be a temporary approach, but after seeing how it came out and how secure and protected everything in the pod is, I may keep it permanently.

Another view showing everything all buttoned up. The wires to the left of the pod run from the main receiver to its satellite receiver. On the right you can see how the +5V lines from the ESCs were removed from the servo connectors that connect to the Mega and covered with heatshrink. I did this rather than just cutting them so I could return the ESCs to their original configuration if needed.

The prop mounting hardware is shown here. The lower two pieces came with the motor but I machined the doughnut piece at the top on my lathe. I made this piece to avoid having to ream out the prop hole to fit the non-threaded portion of the motor shaft. The next picture shows how these parts were used to mount the 12X3.8 props.

First test flights to follow!!

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HK GCS Proof of Concept

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I must be crazy throwing my hat in this ring... but here goes.

http://www.happykillmore.com/Software/HK_GCS/HK.zip

Yet another Ground Control Station project has begun. It's little more than a proof of concept. There is absolutely no documentation or error trapping and is not overly functional... but hey, you've got to start somewhere.

My hopes are to create a language file for this so I can get some friends from around the globe to help me translate this into a bunch of languages.

A few things to warn you about right from the start.

1) It's written in VB.NET so it won't run on Linux or Mac natively...so don't ask. If you're looking for something cross-platform, check one of these GCS programs out:

Andrew Matthews GCS http://www.millswoodeng.com.au/fd_gcs.html - Cross-platform - Written in "Processing."

Jaron http://www.diydrones.com/profiles/blogs/uav-playground-12-an-approach - Cross-platform - Written in Java and "Processing."

PixHawk http://pixhawk.ethz.ch/wiki/software/mavlink/ - Cross-platform - Written in QT

AP GCS - Soon to be cross-platform? - Written in Labview

2) More than likely, this program cannot become the "default" GCS program for AP/APM because of #1 and the general concensus among the APM developers that VB.NET is not the right way to go. For that reason I probably won't make this open source... but it's still "freeware."

My next functions I'm planning on adding are Google Earth integration, Live Camera feed (essentially done but I need to optimize and add some error trapping), KML file support and Recorded file playback.

Unzip the files into a folder and run the HK_GCS.exe file. The emulator is in there as well for testing.

Right now, I'm able to parse NMEA, uBlox, MediaTek, SiRF, ArduIMU binary and text and AP commands.

NOTE: This program requires .NET 3.0 and the "Interop Assemblies" in the links below

http://www.microsoft.com/downloads/en/details.aspx?FamilyID=10cc340b-f857-4a14-83f5-25634c3bf043

http://www.microsoft.com/downloads/en/details.aspx?familyid=3c9a983a-ac14-4125-8ba0-d36d67e0f4ad&displaylang=en

Once I get a little further, I'll have an installer so we won't have to worry about this stuff.

Steps to follow to get this thing to work:

1) Download and install the .NET 3.0 Framework

2) Download and install the interop assemblies

3) Download and install the GPS Emulator (this will give you the DX8VB driver) http://www.happykillmore.com/Software/GPSEmulator/Setup/Setup.exe

4) Download the HK.zip file above and unzip into a folder.

5) Run the GPS emulator. If you haven't already installed the com0com feedback ports, click the "Install Ports" button

6) Click options, setup feedback ports and select 2 unused port numbers (I like 254 and 255).

7) Wait for the ports to get added to your system (will take a minute and you'll have to click next)

8) Select one of your newly created ports in the Emulator but don't click connect yet.

9) Open the HK_GCS.exe and select the Serial Data tab. Click Search COM

10) On the emulator Click Protocols and select something. The 2 checkboxes for ArduIMU Binary are good choices.

11) Click Connect and Start on the main screen of the emulator.

You should see the plane moving on Google Maps and should be able to change pitch, roll, etc on the emulator and have it change things on the Instruments tab of the GCS.

Don't worry, it won't be this many steps in the future. Steps 1-5 will be part of a setup.

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Open Source Business Model

Looking for constructive feedback on OSBM - Hard or Soft I suspect.

My motion is that successful Open Source brands, such as Arduino, DIY, Linux etc... are the natural distributors of derived works, and should (therefore) encourage derived works specifically by hosting a marketplace for them - in which they charge a fee.

The argument in favor is that google searches and other reflections of mindshare will gravitate to the Copyright holders; derivative works are therefore discouraged a priori because they lack a level market. Providing an informed market for derived works would encourage derived works with a revenue component - which revenue would feed into the parent open source project.

In a sense, many Open Source projects are competing with their natural allies by trying to monopolize the distribution chain with a solitary embodiment of the shared IP; while this makes sense in some cases, I recently did some work for an Open Source company trying to do this, and came away with the impression that they may well be sacrificing the better opportunity (think ebay for derived works) in order to make a play at monopolizing the Open Source IP - fueling certain frictions in the bargain.

Does this OS community think that Open Source projects are better funded by:

A. The project initiators monopolizing the collective goodwill to sell derived works - to fund Ops & development.

or

B. The project initiators opening up the collective goodwill for any useful derived work (an atom-store) - whilst keeping a percent to fund Ops & Development.


(btw, i can list subtle examples of these themes in place already. I'd say Sparkfun is moving the fastest towards b. especially in their BatchPCB side, which was inspired by Seeed studios OS discount etc... DIY does have 3rd party modules (ir sensors) in its store, but has yet iirc to formalize a market policy.)


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Opened Overdrive

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Well after some hours of playing around with the jlx overdrive, heres what I've got for now...

Removed wheels from Overdrive, opened chassis and pcb cover:



next, unsoldered the tech 1 rc brain ;) and added some screw contacts (dont know the correct english words)



ok, ive done the first preparations, next thing is to go to the elctronics shop to buy better fittng contacts and cables with correct colors, but now ...

... to find out how those optocouplers work, I played around with a bread board and (pervert I am) a singel power source. I attached one led to each (theoreticaly separated) circuit. Here switch is off and so are LEDs ...



.. here I press the button and both LEDs are on ..


Well time for bed now. cu tomorow.


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T3

Pteryx UAV photo mapping from Krzysztof Bosak on Vimeo.



After completing testign campaign and delivering the first examples we haverushed to publish a short documentary.
Pteryx is an UAV designed for civilianuse, together with its mission-oriented autopilot.
Our focus is in reliableoperation and single button interface. basically you have to put UAV on the
rails, select missions with rotary knobs, hold takeoff button until the
autopilot completes propulsion test, pull the bungee lock.
Pteryx can lift800g compact digital SLR in roll-stabilised head, providing superior quality
photography unachievable by other means: Better flying precision than manned
crafts, inaudible electric propulsion, very few parts to break (only 2 control
surfaces, folding propeller).

Endurance up to 120min, parachute landing,protected propeller.
Possible takeoff from hand and manual piloting.
By law,limited to visual range (some 500m) what yields 1km x 1km map.


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Developer

Full autonomous UAV flight with the ArduPilot/IMU on Cularis from Jean-Louis Naudin on Vimeo.

Total mission distance 2.3 km with 5 waypoints.

Setup:

- Electric Glider: Cularis from Multiplex

- ArduPilot firmware v2.7.4 JLN

- ArduIMU v1.6

- GPS Ublox

- Shield v2

- Battery: Lipo 3S1P 2500 mAh

- Engine: Brushless motor: Spitz 45

- Camera: Kodak ZX1 HD
by Jean-Louis Naudin on October 2010

http://diydrones.com/profile/JeanLouisNaudin

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Moderator
Hello everyone,
quadfox v3 is ready to be tested for integration with the magnetometer and GPS functions . This is my first prototype configuration. In the coming days I will start to conduct the tests. The reference code is:

http://code.google.com/p/lnmultipilot10/source/browse/#svn/branches/Redfox74/quadfox_v3_gps

Thanks to all Arducopter DEV TEAM members.

The components are :
Firmware:
  • Arducopter MP rev. 3
Core:
  • Multipilot 1.0A http://code.google.com/p/lnmultipilot10/wiki/multiboard
  • 3 Gyro ADXLrs 610
  • BL-CTR 20 AMP i2c
  • reciver graupner 1 wire PPM modificata.
  • Diydrones Magnetometer HMC5843 con level shifter 3.3 volt 5 volt
  • GPS Skytrack 65 Channel 10 HZ
  • Sonar range until 6 metri.
  • Barometer 20 cm until 1500 m .
Video:
  • GoProHD Full HD CAMERA

Telemetry:
  • Xbeepro 2.4 Ghz
Frame:
  • Standard FOX Fiber Carbon Frame without enclosure and landing gear for testing.

FOX TEAM CLAN : http://www.virtualrobotix.com
for more info contact me to skype contatcs : virtualrobotix
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Excerpt from Model Aviation Magazine

Just FYI...

Excerpt from "President's Perspective," Model Aviation magazine, November 2010


FAA Ruling May Be Challenging to AMA

Things continue to move forward, albeit relatively slowly, with the FAA regulatory process for small unmanned aircraft systems (sUAS) that will have some collateral impact on model aviation.

AMA’s internal workgroup, comprising members with considerable experience representing a number of modeling disciplines, continues to draft an initial set of standards that we will present to the FAA. The purpose of these standards is to create a path in which model aviation enthusiasts may operate outside of the "default" set of regulations that were [proposed] to the FAA by an Aviation Rulemaking Committee (ARC) in March 2009.

Rich Hanson, AMA’s Government Affairs Representative, and the Safety Committee chairperson, Jim Rice, traveled to Washington in early September to meet with representatives from the FAA’s Unmanned Aircraft Program Office (UAPO). The purpose of that meeting was to share with the UAPO the direction that we are taking with our standards and to ask for guidance to ensure that the form and format of our work was moving in the right direction.

The results of that meeting have raised some additional concerns for us. We have scheduled a follow-up meeting with UAPO manager Rick Prosek. This meeting will have taken place by the time this issue of MA reaches you. I will update you on the results of this meeting next month.

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QGroundControl Visual Designer wanted!

We are looking for a visual designer (contact) to improve QGroundControl's look and feel. QGroundControl is improved in it's functionality almost on a daily basis (please note the new 3D aerial view) and we want to keep the visual design improving as well. As the application is written in Qt 4.7, the look and feel can be controlled via the application's CSS stylesheet and the icon SVG vector graphics. No in-depth C++ knowledge is therefore needed. Most forms are designed using the Qt designer, which would allow the new contributor to work mostly with CSS, the visual editor and image files. QGroundControl has a simulation mode enabling the designer to test the live-behaviour without UAV. It supports through the open MAVLink protocol several autopilots.

If you're interested, please follow our one-minute open-source contributors tutorial and let us know once you have an improved proposal for the look-and-feel. Please use a new folder for image files and back up the old CSS file, so that users can eventually choose between different "skins". In general we made good experiences with the current coloring, but we're open for completely new ideas.
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The Chris Flyer....about to fly....

Well its pretty late here (11:13), and all of the sudden, I REMEMBERED! The story goes something like this...it was probably about a good 3-4 years ago when I was a young'n ;) and I was bombarding Chris with questions. He was getting a little bit finicky but, alas, I had one more question. So I told him something to the effect of "If you answer this final question I'll name my airplane the Chris flyer." I gave my airplane its maiden flight the other day (the one I have been tinkering with for 3+ years and probably cost a fortune) and it crashed...

so I bought an easy star and decided to do things right and use it as a surrogate body with a little forgiveness. So, without further adieu, I present to you all! The CHRIS FLYER! Which should hopefully be flown tomorrow (without GPS) (http://www.diydrones.com/forum/topics/baud-rate-change?xg_source=activity)

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Panther UAV

This is a recent video of the IAI Panther UAV


that combines vertical take off with conventional fixed wing flight. This video is apparently of the miniPanther weighing 12kg and with 2hour endurance.

Peter
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3D Robotics

DIY Drones featured on the Robots Podcast

DIY Drones is featured in this week's installment of my favorite tech show, the excellent Robots Podcast, which interviewed me a few weeks ago. From the writeup:


"The [DIY Drones] community relies on a development team of more than 100 active developers contributing to about a dozen projects, both hardware and software. One of their products, the ArduPilot autopilot, can be strapped to your flyers for autonomous control. In a rather new twist in the industry, DIY Drones focusses on making open source hardware that can be used by all in the same spirit as open source software.

Anderson covers all the questions you ever had about making flying robots, including safety and legal aspects. He also discusses risks in putting this technology in the wrong hands and some anecdotes of crazy projects coming out of the community."


Check it out here. And subscribe to hear all the podcasts, which cover loads of ground of interest to this community, from other UAV issues to basis research on AI and locomotion. It really is a must-listen production from a crack team of researchers at a top Swiss robotics lab. Highly recommended.

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UAS TAAC 2010 Conference

New Mexico State will be playing host to the 2010 UAS TAACConference.http://psl.nmsu.edu/uav/conferences/2010/index.phpAt the TAAC's 12th annual conference, we again anticipate speakers and attendees from many federal agencies (DoD, NASA, DHS, NOAA, BLM, USGS), aviation user groups such as AOPA, AIA, universities, and private industry. The TAAC conference offers an eclectic composition of attendees and topics, presented in both classified and open venues.
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