FINAL PROJECT REPORT : R & D STATUS

1. Project I.D.

: UG2015010

2. Project Title

: Design and Fabrication of MALE Type Solar Powered UAV

3. Name of the Investigator

: S. Robert Caldwel, R.Nivas, and G.Mohamed Abdul Kader

a. E-mail : robertcaldwels@gmail.com
Nivas994@gmail.com

Mobile No. : 9894531427

Mobile No.: 7845419808

b. Contact Address : Aerospace Engineering Department,

B.S. Abdur Rahman University, Chennai - 48
4. Name of the Institution of which Investigator is attached : B.S. Abdur Rahman University.
5. Name and Designation of the Guide / supervisor : Dr.P.N.Kadiresh, Professor
a. E-mail : kadiresh@bsauniv.ac.in

Mobile No. : 09444226195

b. Contact Address : Aerospace Engineering Department,

B.S. Abdur Rahman University, Chennai - 48
6. Name of the Director / Principal of the Institution : Dr.V.Murugesan (Registrar)
7. Date of Release of R & D Grant

: 17th Feb, 2015

8. Date of Commencement of the Project

: Feb 2015

9. Amount of R & D Grant

: Rs.20,000/-

10. Date of Receipt of R & D Grant

: 23.04.2015

11. How much work is yet to be completed with the reason of delay : Nil
a) Percentage of work completed

: 100 %

b) Amount utilized till date

: Nil

12. How much work is yet to be completed with the reason of delay : Nil
a)

Work yet to be completed with details : Nil

b)

Reason for delay

13. Probable date of completion of the project

: Nil
: Project Completed

14. Amount of matching grant :

a) Name and address of the organization
b) Date of receipt :

23.04.2015

: B.S. Abdur Rahman University, Chennai - 48

c)

Amount received : Rs.20,000/-

d) Amount utilized till date : Rs.20,000/15. Name of the organizations providing support to the project : NA
a. Name of the organization :
b. Nature of support e.g. financial, technical and infrastructural :
c.

Support yet to be received :

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16. Project Achievements in brief

: Report Enclosed

17. Expected beneficiaries of the project

: Students got hands on experience in building a

Solar Powered Aircraft Model.

18. Any other information to be furnished regarding progress of project:

This is project could be extended further by fitting camera for campus surveillance purpose.

PROJECT I.D.: UG2015010

CERTIFICATE

Certified that:

1.

The above progress report is correctly and duly audited:

2.

The necessary infrastructure is available for completion of the project by the due date:

3.

The balance amount is readily available for completion of the project by the due date:

4.

The technical report on the project has been enclosed:

5.

The project has been completed by the due date:

Sign of the Investigator

Sign of the Guide

Sign of the Director / Registrar

Page 2 of 22
Form no. Tech/R&D/04 Rev: 00/00000000

A Project Report on

Design and Fabrication of MALE Type

Solar Powered UAV

Submitted to
The Institution of Engineers, India
N0 8, Gokhale Road, Kolkatta 700 020

B.S.ABDUR RAHMAN UNIVERSITY

(B.S. ABDUR RAHMAN INSTITUTE OF SCIENCE & TECHNOLOGY)
(Estd. u/s 3 of the UGC Act. 1956)

Vandalur, Chennai, Tamil Nadu

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Form no. Tech/R&D/04 Rev: 00/00000000

B.S.ABDUR RAHMAN UNIVERSITY

(B.S. ABDUR RAHMAN INSTITUTE OF SCIENCE & TECHNOLOGY)
(Estd. u/s 3 of the UGC Act. 1956)

BONAFIDE CERTIFICATE
Certified that this project report DESIGN AND FABRICATION OF MALE
TYPE SOLAR POWERED UAV is a bona fide work of ROBERT CALDWEL
S, MOHAMED ABDUL KADER G, NIVAS R who carried out their project work
under our supervision.

Dr.P.N.Kadiresh
Supervisor & Professor
Department of Aerosapce Engineering
B.S.Abdur Rahman university
Vandalur
Chennai 600048

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ACKNOWLEDGEMENT
We express our gratitude to our guide Mr. Magesh.M and Dr.P.N.Kadiresh
Professors at the Department of Aerospace Engineering, for providing their guidance,
support and encouragement for carrying out the project on Design and fabrication of
MALE type solar powered UAV.

We record our sincere thanks to Institution of Engineers, India for sponsoring

this project under R&D Grant in aid fund (Rs.20,000/-). And we also thank our
management for generously supporting us to complete this project in stipulated time.
We thank all the teaching and non teaching faculty members of Aerospace
Engineering Department for their support.

We also thank our parents for their encouragement and support.

NIVAS R
ROBERT CALDWEL S,
MOHAMED ABDUL KADER G,

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ABSTRACT

The achievement of a solar powered aircraft capable of continuous flight was

still a dream some years ago, but this great challenge has become feasible today. In
fact, significant progresses have been realized recently in the domains of flexible
solar cells, light weight batteries.
The concept is quite simple; UAV equipped with solar cells covering its wing,
it retrieves energy from the sun in order to supply power to the propulsion system and
the control electronics and charge the battery with the energy in ground. The major
interdisciplinary effort is necessary to optimize and integrate concepts and
technologies to a fully functional system.
As a matter of fact, the major issue is the combination and sizing of the
different parts in order to maximize a certain criterion, for example the endurance,
one parameter being the embedded payload. Solar panel alone doesnt give enough
power to the propulsion system, but electric current from solar panel can get extra
flying time about 15 minutes to 30 minutes.

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1.0 Introduction - Uses of UAV

In the 1960s, the US started to develop drones, which were unmanned vehicles built for
spying and reconnaissance. This was after they lost a manned spy aircraft to the Russians and a U-2
to Cuba. The first such drone was the Firebee drone, a jet propelled by an engine made by Ryan
Aeronautical Company. They were initially used heavily over Communist China in the 1960s, when
major flaws were discovered and corrected.
The Vietnam War was the first time that UAVs, the drones in particular, were used
extensively in reconnaissance and combat roles. A large number of Firebee drones, were launched
for simple day reconnaissance activities. At first, they had simple cameras on them. Later, they
were equipped with night photos, communications and electronic intelligence.
Over the last few years, it has been Israel that has been responsible for much of the
development that has happened in the UAV sector. The Hunter and the Pioneer, which are used
extensively by the US military, are direct derivatives of Israeli systems. The Pioneer was used in the
Gulf War to good effect.
Following the Gulf War, officials recognized the importance of unmanned systems. The
Predator, first and Advanced Technology Demonstration Project, demonstrated its worth in the
skies over the Balkans .Some of the current versions of the Predator is loaded with Hellfire missiles
for attack purposes.
Another popular UAV is the Global Hawk. This is a jet powered UAV that was used
effectively in Afghanistan. It operates at around 60,000 feet, and carries a wide range of sensors.
UAVs that are in use and under development are both long-range and high-endurance
vehicles. The Predator, for instance, can stay in the air for around 40 hours. The Global Hawk can
stay in the air for 24 hours.

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2.0 HOW TO DESIGN UAV AND WHAT ESSENTIALS?

Design UAV is not so easy, according to need of consumers means payload, wing area and
UAV going to do means stunts, how much fast.

I decided to what my UAV gonging to do is

Slow runner

Only day time operations( 9 am to 4pm)

No stunts

Can be use surveillance

UAV total weight not more than 1000 grams

Electric propulsion

Table2.1: Design Specification from Graphs

DESIGN PARAMETERS

SPECIFICATIONS

Cursing speed

14-15 m/s

Weight

800 1000 grams

Wing span

700 1200 cm

Range

3 5 km

Endurance

20 30 min

Pay load

300 400 grams

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3.0

DESIGN CALCULATIONS
AerotriX is the brainchild of IIT Kanpur alumni formed with the intention of improving the

skills and employability of engineering students through hands-on activity based training programs.
We use aero modelling workshops, wherever possible, as a means to deliver exciting and fun based
training to the students of various Engineering disciplines.
3.1 AerotriX Design Algorithms

Conditions and constants values for design Mini UAV

Wing loading = 0.46

gm
cm 2

Aspect Ratio = 6 to 7

4 to 5 degree to keep the aircraft away from the stall angle providing a safer

side.(chosen = 4 degree)
Taper ratio of tail, T 0.45
Tail setting angle, it must be l to 2.5 degree less than alpha ( I t 2.4)
Consider weight of Mini UAV about 650 grams
Wing area calculation
S wing m

w s

= 650/0.46
Wing Area = 1413.05 2
Wing Span
Wing Span = 100 cm

bw AR * S wing

Wing Chord

Cw

S wing

bw
Wing Chord = 14.14 cm
Co-efficient of lift
mg
0.5 * *V 2 * S wing
V=14 m/s from literature survey
CL = 0.3759
CL

Tail Design
Tail Area = 211.96

S t 0.15 * S wing
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Form no. Tech/R&D/04 Rev: 00/00000000

 Tail span (tail aspect ratio 4 to 5) chosen value - 4.5

=30.8cm

bt ARt * St

Tail root chord

2S t
C roott
b (1 t )
Tail tip chord t

Tail root chord = 9.5 cm

C tip t t C roott

Tail Tip chord = 4.3 cm

Tail momentum
C L 3 D * S wing * x
Lt
C Lt ( I t ) S t

= 42.732

Volume Ratio
Lt * S t
Vh
S wing * C w
=0.454
Longitudinal stability check
The value of pitching moment at 0 degree angle of attack should be positive i.e. nose up.

C mo C L * it * Vh
=0.079
The slope value of the Cm vs. , Cm should he negative for stability.

Cm ((CL 3D * X ) / Cw ) (Vh * CL * (1 d / d ))
= -1.406
X is distance of your centre of gravity from the aero dynamic centre of your wing.
Aerodynamic centre is at 25 % of the chord length of wing from loading edge.

X cg X X ac
X 3
X ac =3.535
X cg 6.535

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3.2 DESIGN SPECIFICATION UAV

Weight

650 grams

Speed

14 m/s

Aspect ratio

Wing area

2
1413.05 cm

Wing span

1 meter

Wing chord

14.14 cm

Tail wing aspect ratio

4.5

Coefficient lift

0.3759

Tail wing area

2
211.96 cm

Tail wing span

30.8 cm

Tail root chord

9.5 cm

Tail tip chord

4.3 cm

Tail momentum

42.732

Co-efficient lift at zero AOA

2 for flat plate

Volume ratio

0.454

Co-efficient moment at zero angle attack

-1.2

Aerodynamic centre

3.535

Centre of gravity

6.353

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4.0

MATERIAL SELECTION

4.1

Wood

Paper/Boxboard

Balsa wood

Light plywood

4.2

Carbon Fibre

4.3

Plastic / Foam

4.4

Corrugated plastic (such as Coroplast)

Extruded polystyrene (such as Depron )

DEPRON
Depron is a foam sheet material that has become popular in building model airplanes
and for use in constructing architectural models. It is constructed from individual closed
cells of polystyrene plastic and comes in either white or gray sheets. Depron is a fully
recycled material, and doesn't contain potentially harmful chemicals like Freon and halogen.
Due to its unique cell structure, Depron is lightweight, strong and reliable, able to maintain
its physical and mechanical characteristics no matter its use. It also does not age, giving
Depron remarkable durability.

FIGURE DEPRON
Depron foam consists of polystyrene processed into foam. This foam comes in EPS and XPS
varieties and possesses durability and low cost of manufacture.

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4.5 CORRUGATED SHEET

FIGURE CORRUGATED SHEETS

Acrylic corrugated sheets and board offered by us find extensive usage in the signage and
advertising industry. Some of the work areas these find application in include displays, danglers,
light diffusers, folio cases, packaging, printing and natural cushioning. Further, we can deliver these
in both standard and customized specifications.

4.6

ACRYLATE GLUE

FIGURE CYANO ACRYLATE

Acrylate glue is actually an acrylic resin, not a traditional adhesive in the mold of water
based school glue. Some crafters or automotive repairmen may be familiar with other acrylic resins
such as bonded, the clear liquid used to embed small objects.
Usually an acrylic resin consists of two separate liquids, one for pouring into the mold and
another used sparingly as a hardener. In case of cyano acrylate glue, the hardener is water.
The main ingredient in super glue is called cyano acrylate. If cyano acrylate glue is placed
on a perfectly dry surface or certain plastics, the cyano acrylate cannot form a bond with the
surface.
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5.0

POWER ESTIMATION
Electrical Propulsion system
According to model weight we have to select the motor can pull the model weight. So,
Model weight = 500 grams (fabricated)
Need pulling capacity Motor = 1000 grams

MOTOR SELECTION - OUT RUNNER

The term out runner refers to a type of brushless motor primarily used in electrically
propelled, radio-controlled model aircraft. Out runners spin much slower than their in runner
counterparts with their more traditional layout (though still considerably faster than brushed motors)
while producing far more torque.
This makes an out runner an excellent choice for directly driving electric aircraft propellers
since they eliminate the extra weight, complexity, inefficiency and noise of a gearbox.

FIGURE BRUSHLESS OUT RUNNER MOTOR

BRUSHLESS MOTOR SPECIFICATIONS
Motor used: dys Brushless motor

Kv: 14000 RPM/V

15,540 RPM

Voltage Input: 5.6 V 11.1V

Max watts:180W

Max Efficiency:75%

Max Efficiency current:14 -20A

Resistance:0.065 ohms

Weight:50 grams

Size:27.88 mm x 31 mm

Shaft Diameter:3.2 mm

Pulling capacity:1000 grams

No of motor: 1
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 ELECTRICAL COMPONENTS
To run the motor we need 20Amps, 11V battery to supply power to motor as well other
electrical system servo, electronic speed controller.
SERVO
We are using plastic gears. It has maximum load bearing capacity. Control surface and tiling
mechanism is using this concept. Two plastic servos can be used as control surface and tilting
mechanism also two plastic servos can be used.

FIGURE SERVOS
By using this plastic servo weight as 9 gram. Control surface and tilting mechanism can be
used as same servo. It servo working level 0 to 90 degree only.
SPECIFICATION

Weight: 9 gram

Speed: 0.3sec/60degree

Stall torque: 1.5kg/cm

Voltage: 4.2V-5V

Temperature: 0oC -55oC

Body size: 23*12.2*29mm/0.9*0.5*1.1inch (L*W*H)

Type: Plastic servo

LI-PO BATTERY
Lithiumion polymer batteries, polymer lithium ion, or more commonly lithium polymer
batteries (abbreviated Li-Po) are rechargeable batteries (secondary cell batteries). Normally
batteries are composed of several identical secondary cells in parallel addition to increase the
discharge current capability. This type has technologically evolved from lithiumion batteries.
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FIGURE 3.5 Li-Po BATTERY

The advantage of Li-ion polymer over the lithiumion design includes potentially lower cost
of manufacture, adaptability to a wide variety of packaging shapes, and ruggedness.
Lithium-ion polymer batteries started appearing in consumer electronics around 1996. Li-Po
batteries are also gaining favor in the world of radio-controlled aircraft as well as radio-controlled
cars, where the advantage of both lower weight and greatly increased run times can be sufficient
justification for the price.
SPECIFICATIONS
11.1V
20C continuous discharge
1300 mAh
3 cells
ELECTRONIC SPEED CONTROLLER

FIGURE ELECTRONIC SPEED CONTROLLER

SPECIFICATIONS
Continuous: 25A
Burst: 30A (up to10secs)
BEC (BATTERY ELIMINATION CURCUIT): 5V 2amp
Batteries: 2-4s Li-Po
Input voltage: DC 6-20V
Dimensions: 26*26*7 (mm)

Weight: 24gram

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 PROPELLER
The propeller's job is to accelerate air to keep the plane flying.

FIGURE 3.4 GWS PROPELLER 9x5

SPECIFICATIONS
Speed =(8000rpmx5/1056)=16m/s
Thrust available = ((5 * 93 *108002 * (1.0)) =23.34o.z = 0.000164(kilonewton
meter)=16.4 N

PITCH - A propeller's pitch is the theoretical distance it will travel along the axis of
rotation for one complete revolution - the more pitch, the more the prop will travel, and
consequently the faster the plane will travel - i.e. more speed.

6.0

7.0

WEIGHT ESTIMATION
COMPONETS

WEIGHT(grams)

Model

500

Motor

50

Propeller

ESC

24

Servo

Battery

100

Total

690

REQUIRED CURRENT TO OPERATE UAV (70% THROTTLE)

MOTOR
Required voltage = 6v
Required current =10.5 Amps
SERVO
Required current = 3v
Required current = 0.4 Amps

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 Total current consumption

Vt 9V
I t 11Amps
POWER AVILABLE FROM BATTERY
11.1V
20Amps
RANGE AND ENDURANCE CALCULATIONS
a) ENDURANCE
= ((mAh/ I b )/1000) x60
= (1300/11/1000) x60
Or E b =7 minutes
b) RANGE
D =VT
=14x426
=5964 m
Rb = 5km (approximate)

8.0

POWER OBTAINED SOLAR PANEL

Vs 5V
I s .6 Amps
RANGE AND ENDURACE increases by using solar panel

ENDURANCE
I Ib Is
= ((mAh/I)/1000) x60
= (1300/10.4/1000)x60
Or Eb s =7.5 minutes
RANGE
D =VT
=14x450
=6300 m
Rb s = 5.5km (approximate)

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Form no. Tech/R&D/04 Rev: 00/00000000

SOLAR PANEL PROCURED (2 Nos)

specifications
No Load
Output Voltage 7.2V
Output Current 0.3Amps
With Load
Output Voltage- 5V
Output Current 0.2Amps

Page 19 of 22
Form no. Tech/R&D/04 Rev: 00/00000000

FINAL FABRICATED DESIGN:

CONCLUSION

It has been found that the endurance of UAV increases from 7 minutes to 8.6 minutes and
range of UAV increases from 5km to 7 km.

This may be the first Mini UAV model in 2013that has been constructed with a wing span
0f 1 meter equipped with solar panel of weight 700 grams and 200 grams of payload.

FUTURE PROSPECT
This model will be developed by using upcoming technologies and can be used for 24 hours
surveillance in borders, monitoring Warfield, emergency check on high way roads for accidents.

Page 20 of 22
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Details of Financial Expenditure (in Rs.)

Fund to be
arranged by
Students
Instt. /
other sources*

Sl.

Details of expenditure

Type
Amount
(Recurring
Spent
/ NonIn Rs.
recurring)

Fabrication of aircraft structures

Rec.

15,000

RC Transmitter and receiver

non-rec.

12,000

DC Brushless motor

non-rec.

4,000

Electronic Speed controller

non-rec.

Students
5,000Institute

11.1V 3400mah LIPO BatteryRec.

Charger
Microcontroller & programming non-rec.
kit
Solar Panels
non-rec.

7,000

30,000

6
7

TOTAL

Fund
Received
from IEI
Rs.

20,000IEI

20,000

93,000

20,000

[Fund provided by IEI has been used for non-recurring expenditure only i.e. for special equipment,
Solar panel]

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Form no. Tech/R&D/04 Rev: 00/00000000

REFERENCES
http://www.microuav.com/airvehicles2.html
http://defense-update.com/products/w/wasp3.htm
http://defense-update.com/features/du-2-04/mav-design.htm
http://www.avinc.com/uas/small_uas/wasp/
http://blogs.ottawacitizen.com/2013/04/06/chiles-army-orders-spylite-mini-uav-system/
http://www.rand.org/content/dam/rand/pubs/monograph_reports/MR1187/MR1187.appb.pdf
http://en.wikipedia.org/wiki/Lehmann_Aviation_LM450
http://www.rcgroups.com/forums/showthread.php?t=288091
http://www.lcrcc.net/thrust_calc.htm
http://www.rctech.net/forum/electric-off-road/355777-1-8-brushless-motor-rpm-chart.html
http://www.nbcnews.com/id/48311607/ns/technology_and_science-innovation/t/solarpowered-plane-comes-home-after--mile-odyssey/#.UWrrg6LDD74
http://www.dw.de/solar-powered-plane-lands-in-morocco/a-16000892
http://www.flyelectric.com/products.html
http://scriptasylum.com/rc_speed/top_speed.html
http://www.multircshop.com/site/index.php?route=common/home
http://eastbay-rc.blogspot.in/2011/02/let-there-be-light-emitting-diodes.html
http://www.rcgroups.com/forums/showthread.php?t=768115
http://mvvs.nl/utilities.htm
http://www.adamone.rchomepage.com/calc_motor.htm
http://mattsrc.rchomepage.com/ssir/allinone.shtml
http://flbeagle.rchomepage.com/
http://adamone.rchomepage.com/guide.htm
http://www.airfieldmodels.com/information_source/math_and_science_of_model_aircraft/fo
rmulas/engine_offset.htm
http://www.mat.uc.pt/~pedro/ncientificos/artigos/techbal.html
http://legacy.amaglider.com/assets/general-technical-documents/balsa-wood-properties.html
http://en.wikipedia.org/wiki/Ochroma_pyramidale
http://www.rcscalebuilder.com/tutorials/Balsa/balsa_1.htm
http://www.small-generator.com/
http://www.rchelicopterfun.com/rc-lipo-batteries.html
http://www.4-max.co.uk/usefulinfo.html

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