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Materials Today: Proceedings 00 (2015) 000–000 www.materialstoday.com/proceedings

ICAAMM-2016

In-flight Re-Configurable Systems

Arvind Kumar Yadava,Kamlesh Kuamrb,Richard Beckerc
a
Student,8970201660,arvind6020@hotmail.com
b
Assistant Professor,MIT Manipal, 9901249743,kamlesh.kumar@manipal.edu;kamlesh.iisc@yahoo.com; Corresponding Author
c
IAESTE Intern,richard.becker@tu-ilmenau.de

Abstract

Multirotors are providing ease for various applications like, environmental monitoring, surveillance, spying, radiation data collection, indoor 3-D
mapping and navigation etc. This paper introduces a design of multirotor which can reconfigure its size in-flight i.e. inflight re-configurable
system (IRCS).The size can be changed by decreasing or increasing its arm length, using Rack and Pinion Type Mechanism (RPTM). In this a
quadcopter multirotor has considered, its all four arm which have RPTM, are connected to a single high torque stepper motor which can control
the length of arm based on vision decision. Camera connected to each arm will provide visual decision to reconfigure its shape and avoid
collision or make accessible to constraint environment. The stability will be maintained by Adaptive PID Controllers (A-PID) and changes
simultaneously based on its arm length. Feedback from stepper motor is linked to Autopilot Flight Control Board of System (AFCBS) which has
ability to decide and give correct PID values to system to maintain level flight.

© 2015 Elsevier Ltd. All rights reserved.

Selection and Peer-review under responsibility of the Committee Members of International Conference on Advancements in
Aeromechanical Materials for Manufacturing (ICAAMM-2016).

Keywords:Re-configurable;In-flight; Image Processing;Autopilot;Rack and Pinion ;UAV;PID

1. Introduction:

The concepts of multirotor have been in the aerospace industries since many years. When we see the advancement
of this technology it was very slow till mid’s 90’s. But the recent developments of better electronics and battery
technology have given boost to develop the concept of multirotor. At present the global market is flooded with
various designs of multirotor. Companies like DJI, Parrot drone, Horizon hobby, Hobby king are some of the
biggest players in this field. Everyday new innovations are popping up to solve common problems using this
technology.
A quadcopter is a popular form of UAV (Unmanned aerial vehicle). It is operated by varying the RPM of its four
rotors to control lift and torque. The thrust from the rotors plays a key role in manoeuvring and keeping the copter
airborne [1]. UAV market is expected to be worth 14.9 billion USD by 2020. The U.S. accounts for nearly 65.53%
of the global UAV market, in 2015.The U.S., Israel, China, the U.K., Australia, Canada, France and India are some

2214-7853 © 2015 Elsevier Ltd. All rights reserved.

Selection and Peer-review under responsibility of the Committee Members of International Conference on Advancements in Aeromechanical
Materials for Manufacturing (ICAAMM-2016).
2 Arvind Kumar Yadav and KamleshK et al./ Materials Today: Proceedings 00 (2015) 000–000

geographies contributing to the high demand for UAVs [2]. Some of the few remarkable contribution done in these
areas are following: - swarm and cooperative control of multirotor, development of fully autonomous system which
can follow path planning, vision sensory based indoor navigation, creating real-time 3D map of its surroundings etc.

Recently, DJI launched S800 Retractable Landing Skid for better perspective in aerial photography work [3]. In
flight reconfiguration system provide an added advantage to UAV. The variable size helps the system to avoid from
collision easily. It also accounts for the agility of the system because as the size decreases the agility of the
quadrotor increases and it can perform difficult maneuvers easily, like going through narrow space, moving at some
orientation for certain period of time etc. From design and development point of view IRCS is a new innovation
being developed and tested in lab and real world. In order to avoid complex operation, IRCS is designed to give
simplified setup and operation. Considering the stability of system at different size, it is very much stable platform
as the PID gains changes simultaneously with change in size.

2. Design, development and working principle of the Reconfigurable system:-

Fig.1. Isometric View Fig.2. Rack and Pinion Fig.3. Stepper Motor

Multicopter: In this a quadcopter design has been considered. The design explains the following features:-
i. Reconfigurable system
ii. Rack and pinion system to reconfigure its arm
iii. Stepper motor to support the motion of rack and pinion
iv. Camera system integrated to each arm to detect the collison cause or constraint of place while fly. It will
provide the visual guidance to take decision to reconfigure.
v. Embedded board will be used to get signal from camera and make decision to reconfigure.
Other supported hardwares are as follows:
 Arvind Kumar Yadav and KamleshK et al./ Materials Today: Proceedings 00 (2015) 000–000 3

Fig.5. Fully retracted arm Fig.6. Fully actuated arm

2.1. Stepper Motor

The sole function of stepper motor (Fig.3.) is to change the arm length of the IRCS based on its number of rotation.
Stepper motor’s each rotation can be controlled by micro controller. Each rotation determines the increase or
decrease of the arm length. Different model of stepper motor and gear pitch determine that how many rotations
should be given to get required length. The spur gear of the stepper is connected to each arm of the multi-copter in
such a way that each arm actuates at the time.

2.2. ESC

Electronic speed controller is used in the system to control the speed of the motor which will provide thrust
requirements. Each motor is connected to its own ESC. Signal from FCS is given to ESC to rotate the propeller at
required rpm.

2.3. Modified Arm

Arm of the copter has linear gear on face of the arm. When the arms come in contact with spur gear of stepper motor
then it forms rack and pinion type mechanism.

2.4. RPTM

Rack and pinion type mechanism (RPTM) helps in linear actuation of the arm to and fro motion to adjust its arm
length based on constraint.

2.5. FCS

Flight control system controls the flight dynamics of the entire system. It controls the thrust demand by controlling
the signal. The microcontroller of the stepper motor is connected to FCS. No. of rotation of stepper motor as
feedback will be available from microcontroller to help the FCS to adapt the PID values or load the autopilot
algorithm in real time as the copter changes its arm length.

2.6. Camera

High resolution camera is used for visual imaging as well as to determine the obstacle if any. The function of
4 Arvind Kumar Yadav and KamleshK et al./ Materials Today: Proceedings 00 (2015) 000–000

camera has been explained in above statement i.e. point (iv).

Fig.1. Shows the isometric view of the IRCS. The design has been developed in X-configuration of quadrotor.
Stepper motor is placed at the centre of the quadrotor with its gear connected to shaft in perpendicular direction to
the base of copter. Guide is provided for the free movement of all the arm, supporting with two free rotary parts. It
will avoid the cantilever problem. Motor is placed at the end of arm on the motor mount. Landing gear is fixed to the
base plate of the quadrotor. Camera is connected at each end of the arm.

Fig.2. shows the rack and pinion mechanism. If the shaft of stepper motor rotates in anti-clockwise direction then
the arms will actuate in outward direction resulting in fully actuated system as shown in Fig.6. Also fully actuated
system shows the largest size possible. If the stepper motor rotates in clock wise direction then the arm will actuates
in inward direction resulting in fully retracted system as shown in Fig.5. It also shows the smallest size of the
system.

3. Why Inflight reconfiguration system?

The benefits of having an inflight re-configurable system (IRCS) in air are as follow:

 Can increase or decrease its size and maintain stability while hovering.
 Ability to avoid collision with other UAV by changing its size.
 Transverse through narrow space providing better access.
 Become more or less agile as situation demands.
 Comparatively more effective will rescuing people from fire hazardous building.
 Landing in any type of terrain become more feasible.

4. Fabrication process

4.1. Manufacturing and assembly

Aluminium booms are used for making arms. Linear gear is machined on the arm using CNC. Spur gear is also
designed using CNC, which is to be fitted on the shaft of the stepper motor. Base plate is designed from 3mm-5mm
sheet of aluminium. Guide is made from the extruded C section of aluminium. Solid aluminium square rod is
designed to fit into required dimension and welded together to form landing gear. Assembly is quick and easy as
booms can directly align with stepper gear. Almost all the component are made from aluminium , so fabricating the
model becomes very easy as any operation can be easily done on this material. In the future metal matrix composite
will be used to designed the system to improve its capability.

4.2. Selection of Material

Entire system body is made from Aluminum as it is easily available in market and provides ease of manufacturing.

5. Selection of electronics:

 High torque stepper motor

 Flight control board
 Motors
 Electronic Speed controller
 Battery
 Microcontroller
 Arvind Kumar Yadav and KamleshK et al./ Materials Today: Proceedings 00 (2015) 000–000 5

 Transmitter and receiver

 Camera etc

6. Maintenance of Multirotor:

As we are dealing with the electro mechanical system, utmost care needs to be taken of the system as follow:
 Lubrication of the rack and pinion mechanism.
 Proper cooling of ESC and Motor.
 Calibration of the system to make it stable.
 Pre check of loose connection if any before every flight.
 Low voltage alarm is mandatory.

7. Application Area

 Environmental monitoring
 Military and Defense.
 Indoor mapping
 Monitoring of crop health
 Spraying in Agricultural Field.

7.1. Real time testing in kind of spray application:-

Fig.7. Quadrotor fitted with spray gun Fig.8 Hovering and Spraying

The above system used in testing has length of 60cm from Centre of one motor to other diagonally. It weighs 2.8kg
including the spray mechanism. It has flight duration of approx. 30min with 8000mAH LiPo battery in the real
world. The demonstration shows that a quadcopter attain required altitude (Fig.8.), then it hover there and spray the
fruits. Continuous fluid is supplied from the ground using pneumatic pipe. Flow of spray can be controlled by
controlling the volume of fluid going out though the nozzle of approx. 0.8mm. Once the work is done it lands safely.
Initial testing has been done with manually pumped fluid (water) from ground. The copter has been controlled by
human pilot.
6 Arvind Kumar Yadav and KamleshK et al./ Materials Today: Proceedings 00 (2015) 000–000

8. Modelling and Simulation

Fig.9.

Fig.9. Shows the CAD Model of quadrotor which can vary its size. The modelling simulation of the above system is
under progress. MATLAB and SIMULINK used to Model the system and simulate it[4]. Ansys is being used to
determine the various load factors acting on it. Proper analysis of the copter is required for better functionality of the
system.

9. Future work
 Fully Autonomous System which will able spray automatically.
 System can determine its surrounding by creating 3 D map.
 Control via Cloud.
 Collision avoidance using camera.
 Path planning.

Conclusion

Development of UAV is helping in every sector for solving various problems. It is extensively being used for
educational and research purpose. The entire world is behind UAV technology. As stated above it’s going to be
14.9billion USD industry by year 2020. So innovation is very necessary in this emerging technology. Developing
efficient and effective design for the upcoming market will give a boost to the product. The above IRCS has
potential to become one of the major product in future, incorporating future technology and various applications.

Acknowledgements

We would like to acknowledge the Mr. Avinash Rao who has supported financially and various technical inputs.
We also thank to our head of the department, Aeronautical Engineering, MIT Manipal, prof. (Dr.) Satish Shenoy B
who has given research environment and laboratory facility to continue this research work.
 Arvind Kumar Yadav and KamleshK et al./ Materials Today: Proceedings 00 (2015) 000–000 7

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