7.

0 Design for Assembly and Maintainance

For our department, which is department 2, the main material of our group that needed to
be focus are the propellers, motor, electronic speed control (ESC), and battery. All of the
components mention had their own ways of assembly and further ways of maintainance.

PROPELLER

Assembly of Propellers on Quadcopter

Propeller Rotation Direction

Props are designed to produce maximum thrust when turning in only a single direction.
Quadcopters are equipped with two sets of two different props: one set of “clockwise” (CW)
props which rotate like a clock, and another set of “counter-clockwise” (CCW) props.

One can determine the direction of a prop in one of several ways. Most props have labels
on them that look something like “5045” and “5045R”. When labeled like so, the “R” stands for
CCW while the lack of an R means the prop is a CW prop.

The better way to determine the intended direction of a prop is to find its leading edge.
The leading edge of a propeller blade is the side of the blade that is raised above the other side
with a slight concave curve underneath it. All props have this, whether or not they are labeled, so
learning to recognize it pays off.
Installing the Propellers

Once the direction of rotation had been determined, it can be installs on the quadcopter.
Pretty much every quadcopter these days uses the Multiwii prop configuration. This looks like
this:

In the diagram, the red arrow points to the front of the quadcopter. The blue circular
arrows represent the rotation direction of the props. One just need to install the props so that they
are oriented to rotate as show on the diagrammed direction.

Propeller Safety

When assembly of the drone propeller is ongoing, one should be careful of the propeller
as the propellers can seriously cause injuries. While they are only plastic, the centrifugal force of
the prop tips at 27,000 RPM causes the plastic to take on near-metal hardness and turns even a
dull leading edge into a potential knife. Think about what the much lower RPM of the string
trimmers used by gardeners can due to weeds and multiply both the RPM and plastic hardness by
several factors.

When handling, point the quadcopter away from the face at all times and try to keep body
parts and clothing out of the prop arc. Remember that if it does arm, it will very likely spin about
in a rapid, uncontrolled fashion — be prepared to drop it and run.

Maintainance
First things first, from a safety standpoint, one should inspect the props after/before each
flight for any hairline fractures, chips, dents, or scratches. Also, one should also be cleaning off
any bug juice that has been deposited on the props (this often happens when flying in the evening
when the mosquitoes, dragonflies, and gnats start to swarm

Next, look for any discoloration in the plastic, and other visible changes in the properties
of the plastic (texture, shape, sheen,etc.). If notice anything that makes the integrity of the blade
reduce-simply replace or toss it. It is not worth the consequences. Therefore, always have 2
spare sets of props.

Store the drone in its case, in a shady place if bringing it on a hot day. A black box will
get extremely hot inside (that kind of heat is terrible for batteries) if it is left sitting in the sun!
Never do that! Be mindful of the boxes placement in the car as well - if it is in the truck in full
view of the sun for an extended period of time, one could be literally cooking the batteries and
sensitive plastics inside the box.

MOTOR

For the motor assembly, the motors will have a huge impact on the payload (or maximum
load) which UAV can support, as well as the flight time. Note that even if a pair of motors are
the same brand and model, and from the same production run, their speeds may vary slightly,
which is something the flight controller will take care of.

Brushed vs Brushless

Brushed motors spin the coil inside a case with fixed magnets mounted around the
outside of the casing. Brushless motors do the opposite; the coils are fixed either to the outer
casing or inside the casing while the magnets are spun. In most situations, you will be
considering only brushless DC motors. Brushless DC motors are used extensively in the hobby
RC industry for products ranging from helicopters and airplanes to the drive system in RC cars
and boats. "Pancake" brushless motors have a larger diameter and are essentially flatter and often
allow for higher torque and lower KV (details below). Smaller UAVs (usually the size of the
palm of your hand) tend to use small brushed motors because of the lower price and simpler two-
wire controller. Although brushless motors come in a variety of different sizes and specs,
selecting a smaller brushless motor rarely means it will be less expensive

Inrunner vs Outrunner

There are a few types of brushless DC motors:

 Inrunner - these have the fixed coils mounted to the outer casing and the magnets
are mounted to the armature shaft which spins inside the casing (tend to be used
on RC cars because of the high Kv)
 Outrunner - these have the magnets mounted on the outer casing which is spun
around the fixed coils in the center of the motor casing (the bottom mounting of
the motor is fixed).
 Hybrid outrunner - technically outrunners but have a static outer shell around
them to make them look like they're inrunners

Inrunner brushless DC motors tend to be used in RC cars, airplanes and helicopters

because of their high KV. They may also be geared down to increase the torque. Outrunners tend
to have more torque.

"KV"

The KV rating / value of a motor relates to how fast it will rotate for a given voltage. For
most multirotor aircraft, a low KV is desired (between 500 to 1000 for example) since this helps
with stability. For acrobatic flight however, you might consider a KV between 1000 and 1500
and also consider using smaller diameter propellers. If the KV rating for a particular motor is
650rpm/V, then at 11.1V, the motor will be rotating at 11.1V x 650 = 7215rpm. If you operate
the motor at a lower voltage (say, 7.4V), the rpm will be 7.4V x 650rpm/V = 4810rpm. It is
important to note that using a lower voltage tends to mean that the current draw will be higher
(power = current x voltage).

Thrust

Some brushless motor manufacturers give an indication of a motor's thrust corresponding

to several propeller options (often presented in a table). The unit of thrust is often Kg, Lbs or N.
For example, if you are building a quadcopter and find that a specific motor can provide up to
0.5Kg of thrust with an 11 inch propeller, that means that four of these motors (with that given
prop) can lift 0.5Kg*4=2Kg at maximum thrust. Therefore if your quadcopter weighs just less
than 2Kg, it will only take off at maximum thrust. You need to either choose a motor + propeller
combination which can provide more thrust, or reduce the weight of the aircraft. If the
propulsion system (all motors and props) can provide 2Kg of thrust (max) then your entire copter
should be at most about half this weight (1Kg, including the weight of the motors themselves).
The same calculation can be done for any given configuration. Let's assume a hexacopter's
weight (including frame, motors, electronics, battery, accessories etc) to be 2.5Kg. Each motor
should therefore be capable of providing (2.5Kg/6 motors) x 2:1 = 0.83kg of thrust (or more).
You can now calculate the specs of your motor(s) but suggest reading through the sections below
before making a decision.

Additional Considerations

Connectors: Brushed DC motors have two connectors: one for positive, the other for
negative. Reversing the wires reverses the rotation of the motor.

Connectors: Brushless DC motors have three connectors. Refer to the ESC section below
to know how to wire them and reverse direction of rotation.

Windings: The windings impact the KV of a motor. When you want a lower KV but
maintain the torque, you may need to consider a larger pancake-style brushless DC motor.

Mounting: Most manufacturers have a general mounting pattern for brushless DC motors
which has allowed companies which produce frames to not have to design adapters. The pattern
is normally metric, with two holes spaced 16mm apart, and another two holes spaced 19mm
apart (at 90 degrees to the first).

Thread: The mounting thread used to secure a brushless motor to a frame can vary.
Common metric screw sizes include M1, M2 and M3 and imperial might be 2-56 and 4-40.

Maintainance

Bearings

It seems today that most people are so concerned with looptimes, gyro sync, airmode,
betaflight, the latest trending gear, the newest tech, that they are overlooking one of the most
basic and important parts of a quadcopter- the motor bearings.

The Motor Bearings.

All motors have bearings, and most of the time the thing that separates the mediocre
motor from the top performing one is the bearings. If you don’t properly take care of your
bearings in any motor, you will destroy them, and without proper maintenance, you might not be
getting the top performance out of your motor

Ball bearings are high precision devices compared to many mechanical parts. Good
performance will therefore require treatment that takes into account their characteristics and
operating environment. A high percentage of bearing problems, including failures, are the result
of improper handling procedures.
The Function of Ball Bearings

From small and large motors to car axles to electric fans, Quadcopters and hard disc
drives (HDDs), ball bearings are used in a wide array of machines for rotary motion. Ball
bearings support rotary parts and reduce friction to facilitate the smooth operation of machines.
The size of ball bearings can range from smaller than a grain of rice — small enough to fit inside
a wristwatch—to over one meter in diameter for factory and power plant applications.

Most often you will find that quadcopter motors specify NMB bearings- this is good
because the NMB company specializes in the manufacture of miniature and small-sized ball
bearings with an outer diameter of 30mm or less. These bearings are typically found in
Quadcopter motors- We recommend purchasing motors with NMB bearings in them for the best
performance.

Ball Bearing Components

Ball bearings are comprised of four major parts: a large ring (outer ring), a small ring
(inner ring), balls between the rings (steel balls), and a cage to prevent the balls from hitting each
other. The modern structure dates back to around 1500, when Leonardo da Vinci invented ball
bearings to reduce friction against the axles of horsedrawn carts. For more than 500 years, the
ball bearing has been defined by this simple structure.

Particle Contamination

The performance of miniature precision ball bearings is critically affected by minute

particle contamination. Avoiding exposing the bearing to any environment where particles may
be present is highly recommended.

Shields and seals are used to prevent contaminants from reaching the inside of the
bearing. However, after assembly, there is still a small gap between the shield and the inner ring.
This gap may permit particle entry.

Please observe the following procedures carefully:

 Keep your bearings handling room as clean as possible.

 Do not remove the bearings from their packaging until just before use.
 If you move the bearings to a container, be sure the container is clean. The lid should be
kept close, and it should be cleaned every day to prevent particle accumulation.
 Never use a bearing that has been dropped. It may be brinelled (race track dented). In use,
a brinelled bearing will generate a high level of acoustic noise.
 Before applying adhesive to a bearing, use a clean cloth dampened with an alcohol agent
to clean oily materials such as anticorrosion oil from the inner and outer rings. Do not
saturate the cloth excessively with the cleaning agent. The liquid agent itself could leak
into the bearing, carrying particles with it.
  When applying a lubricant to the outer circumference of a bearing, take care to make sure
the lubricant is not contaminated. You might inadvertently transfer the contamination into
the bearing.
 Never use an applicator that will leave contaminants on or near the bearings. A cotton
swab, for instance, may leave small fibrous particles behind. We recommend a
mechanical dispenser, many are available, or a clean room type of applicator.
 Do not handle bearings in a place where they could be directly exposed to outside air.
Airborne contaminants include dust, dirt, and humidity.

Rust Contamination

Since bearings are metallic products, they rust easily. Their treatment requires certain
precautions:

 When handling bearings, use finger caps, tweezers or gloves that do not generate cotton
fibers.
 When using unprotected fingers to handle a bearing, first make sure they are clean and
free from perspiration and dust. Apply a quality mineral oil to the fingertips before
touching the bearing. Do not use hand cream, as it may induce rust.
 If a shaft is dirty on the surface, rust may gather between the shaft and the bearing after
they are fitted.
 It is important to make sure that the shaft is free from finger prints, perspiration, dust and
dirt.
 Avoid storing bearings near air conditioners and direct sunlight.
 Bearings may rust when placed near an air conditioner outlet, or any place where wind or
sunlight can enter directly.
 A great temperature difference may cause condensation to form on the bearings. In colder
climates, allow the bearings to reach room temperature before unpacking them.
 Store bearings in centrally heated and properly ventilated environments.

Shock Forces

Bearings are easily affected by shock forces. Depending on the size of the bearing, a
shock force from a 100 gram weight at 4mm away could cause brinelling. Brinelling could also
occur when bearings are automatically press-fitted to a rotor shaft, if the shaft and bearing bore
are not kept accurately in line.

A typical example of shock causing brinelling is when motors are placed on a conveyor
belt. As the motors moved through the conveyor, the movement causes the motors to hit the iron
plate underneath the conveyor, resulting in shock which causes brinelling to the bearing. Holes
made to the iron plate prevent this type of shock force to be generated.
Another obvious example of shock causing brinelling is when a quadcopter is crashed and a
motor experiences direct impact.

Lubrication

Synthetic Lubricants are recommended for brushless motor bearings.

The esters, diesters and poly-a-olefins are probably the most common synthetic lubricants. They
do not have the film strength capacity of a petroleum product, but do have a wide temperature
range (-65º to 350 ºF) and are oxidation resistant.

Synthetic hydrocarbons are finding a greater use in the miniature and instrument ball bearing
industry because they have proved to be a superior general purpose lubricant for a variety of
speeds, temperatures and environments.

ELECTRONIC SPEED CONTROL (ESC) ASSEMBLY

1. Connect motor PWM signal outputs

Connect the power (+), ground (-), and signal (s) wires for each ESC to the flight
controller’s main output pins by motor number.
2. Using a Power Distribution Board (PDB)
 There are two methods of connecting the motor outputs. Either connect the electronic
speed controllers (ESCs) directly to the flight controller OR use a power distribution
board (PDB).

When using a PDB, connect the power (+), ground (-), and signal (s) wires for each ESC
to the PDB according to motor number. Find your frame type below to determine the
assigned order of the motors. Then connect the signal wires from the PDB to the main
output signal pins on the flight controller (ensuring that the motor order numbers match
the main output pin numbers on the controller). If you are using a power module, it is
optional to connect the power and ground wires from the PDB to the flight controller
board. If you would like to use these cables in addition to or instead of the power module
or as a common point for low current servos, connect the ground (-) wire to a main output
ground (-) pin and the power (+) wire to a main output power (+) pin.
3. Motor order diagrams
The sections below show motor order for each frame type (the numbers indicates the
connected autopilot output pin) and the propeller direction (clockwise (CW) motors are
shown in green and take pusher propellers,counterclockwise motors (CCW) are shown in
blue and take puller propellers.

We use the diagram by referring frame type, and wire the motors as shown.
 4. Attach propellers
Clockwise motors are shown in green, marked CW, and take pusher propellers.
Counterclockwise motors are shown in blue, marked CCW, and take puller propellers.
Use the diagram for your frame type, and attach propellers to your vehicle as shown. For
copters, attach propellers with the writing facing towards the sky. For more information
on recognizing the different types of propellers, see the next section.

5. Recognizing clockwise and counterclockwise propellers

The diagrams above show two types of propellers: clockwise (called pushers) and
counterclockwise (called pullers). Pusher propellers are often marked with a P. However not all
propellers are marked and both types are often available in either rotational direction. Therefore,
it is most reliable to recognize the correct propeller type by its shape as shown below. Note that
the propellers below have the edge with the shallow consistent curve at the leading edge in
direction of rotation and the more radical scalloped (and usually thinner edge) as the trailing
edge. You can use these features to recognize propellers of the correct direction of rotation.
6. Testing motor spin directions
If you have completed the Radio and ESC calibration, you can check that your motors are
spinning in the correction direction:

 Make sure there are no propellers on your copter!

 Turn transmitter on and ensure the flight mode switch is set to Stabilize.

 Connect battery.

 Arm copter by holding the throttle down and rudder right for five seconds.

 If it fails to Arm with the throttle down and to the right and the motors will not spin, it has
probably failed the Pre-Arm Safety Check.

 Pre-Arm safety check failure is also indicated by the red arming light double flashing and then
repeating.
 If the Pre-Arm check fails go to the Prearm Safety Check Page and correct the problem or disable
the check before continuing.
 When you can Arm successfully, apply a small amount of throttle, and observe and note spin
direction of each motor. They should match directions shown in the images above for the frame
you’ve chosen.

 Reverse any motor spinning in the wrong direction.

Maintainance of Electronic Speed Control (ESC).

PREVENTATIVE DRONE MAINTENANCE
Significantly reduce mechanical issues with these preventative drone maintenance tips:
 Keep and document a routine pre-flight inspection list, to prevent any errors or missed
steps before operation
 Visually inspect the condition of all propellers, motors and ESCs - any signs of fatigue,
cracks, loose hardware, or failing bearing need to be immediatley corrected before flight
 Check for any motor interference or lodged debris - all motors should move freely when
spun by hand before arming the system
 Closely inspect the condition of all battery connectors and control lines
 Check the state of all wiring and solder-joints monthly, as cyclic fatigue is the reality of
physics and will eventually creep up
ROUTINE DRONE MAINTENANCE
One of the most important factors in regular drone maintenance is keeping electronics up-
to-date via software and firmware updates. By upgrading to the latest version of firmware
for your drone, you’ll be able to get the latest features and upgrades - including bug fixes,
which could have an impact on flight time and efficiency.

Propellers are often the first components to be damaged in the event of a crash.
Additionally, they are crucial when it comes to keeping your drone in the air. In order to
avoid extended downtime, it’s smart to keep an additional set of propellers and propeller
adapters on-hand in order to get flying again immediately.

When it comes to routine drone maintenance, it helps to have shaft and bearing
replacement kits available for optimal brushless motor performance. In addition to shafts
and bearings, routine maintenance also includes the occasional replacement of bullet
connectors and new-solder joints. By replacing shafts, bearings and bullet connectors as
part of your routine drone maintenance, the life of your UAS and equipment and enhance
performance is greatly extended throughout its lifetime.

Remember to perform regular preventative maintenance checks on your drone in order to

prevent unexpected physical damage and unsafe operation conditions. While
electromechanical systems always have the chance of failure, performing routine drone
maintenance you can give your UAV the best chance of survival.

KDE Direct offers multirotor replacement kits - including bearings, shafts, bullet
connectors, and lead extensions - in addition to replacement motors, propellers and ESCs.
When it comes to routine drone maintenance, KDE Direct is your resource for new and
replacement components.