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Multi Control/Full auto UAV

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large_ghostman

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So this is it!! There is a website in the making for this as well, but that will be more about the actual bits that get built, this is more a brain storm and a place to kick ideas around as well as document the entire process.
Pics galore I promise.

First the boring bits and some background information.

RULES
Many of you are old enough to remember the old startrek series where they had communicator's, I remember watching a couple with my dad and him telling me when he was young and watched it he thought it would be so cool to invent a communicator, a device you flipped up and could talk to people on!! Obviously science fiction, and yet a decade or two after that mobile phones appeared! At first a little like the star trek communicator and then much later the mobile phone of today, able to pay bills and buy things in a shop with just a simple swipe.

I watched the old James Bond films with him and especially Gold Finger, in that they had a laser that could cut through things!! He said at the time it seemed like something that would never happen and even if one day it was possible it would be the size of an industrial estate! 30-40 years on you can buy laser that cut pretty thick ply etc off ebay cheap.

He told me about wondering when he was my age if in 100 years or so we could get a space ship on mars and see if anything lived there, since then we have sent a space ship past Pluto and landed on Mars!

As a boy he wondered if one day maybe we could build a place in space where people could live............ok we only have the international space station but its getting there.

My point?

None of the above broke any laws of physics, they were simply science fiction because no one had done it yet. People hadnt got together and thought the problems through and come up with solutions.

He was 14 ish when he got a commodore PET 80 computer, but it didnt do much, there wasnt the world wide web although there was apparently a kind on internet.
In the 21st century we have access the most information man has ever been able to reach at a press of a button, a forum is a place where people come together, so to me if you combine both of them things and have a positive attitude I am sure what hasnt been done before is simply something waiting to be done. The project i am doing has already kind of been done, there are a few big differences and mine is very ambitious. WHEN I make it work there are more applications than first seems likely, I know the last bit because of conversations with people (companies) who would be very interested in a simple solution.

So the rule is NO saying it CANT be done UNLESS you can prove beyond doubt it violates a law of physics! By all means point out possible problems and things I may have missed, and your welcome to express doubts, but be prepared to offer some backing for your doubts, a simple it cant be done and no proof = YOU CANT DO IT, dosnt mean WE CANT!

Equally I am prepared to offer papers to prove aspects that seems difficult, if they are paid for stuff I cant post online I will try and get a link or at least the paper identifier, if there isnt a paper but a way to do an experiment to see if something can or cant be done then we do the experiment before declaring its impossible. In short this is to be a positive thread that brings out the best of ETO, kind of like back when we all had alot of fun making mad stuff.


The thread will jump around a bit, this is a bit beyond my control and rather than stop and wait for something I will switch to another aspect of the project. There is so much to do I see no reason why (apart from exams etc) that there is dead time.

There will also be a fuel thread because its a large topic on its own and it will just confuse things all in one thread.

I guess next step is to explain as much as I can exactly what this is for and what it is intended to do, the final aspect as to the what exactly its getting and how that is done isnt important and isnt something I can go into. But honestly the little bit I cant tell you isnt important and dosnt really affect anything with the project, it does place a couple of special conditions we need to meet but the reasons behind the why are not important to get this done.

So next post I will outline as much as I know at this point, the one thing we dont yet know is what its going to look like, except a fixed wing plane and I dont know how big it will be yet, this cant be done until alot of the systems have been worked out and I have a good idea of total weight for the wing loading etc. So there is some ground work and experimenting to be done before the final plane can be designed. Because of parts etc the first thing I am going to do some work on is the ground station control unit, i am waiting for some parts and information before I can do much on the system side for the actual plane, so rather than wait around I will get on with parts I can now.

The case size has been narrowed to one of two cases, I would like to use the smaller case but lets see how it goes. The layout of things will be done mounted on cardboard or whatever I can get hold of, once the final layout is done and I am happy it will be machined from Aluminum and covered with perspex and vinyl lettering etc.
Tomorrow I will post ics of some of the DEV kits I am using, once something is working on the dev board I can move too doing a pcb for it. This is not an exercise in getting a single chip to do everything!! and squishing as much code in as small a space as I can, I intend to break the sections into parts and have the micros talk to each other, I prefer on the ground station side to break it down into small chunks. On the actual plane is a bit different as we have weight to consider.

The radio comms side between ground and plane is more than one system, but to get the ground controller moving I dont need to add the radio side for a while, in the end the chips will just pass messages to the radio board and these are sent to the plane, so in parts we can use hard wire for now and later on add in the radio side as I intend to use a bus system.

Currently inter chip is likely to be SPI and RS232 and sensors are likely to be mainly on a I2C bus, I would rather keep it separate like that than do something like a complicated can system. No actual computer involved, but there will be the odd R PI or 2 as I need a screen to connect to the ground box to display telemetry and other things, but I dont intend to use laptop or computer as such.

the only other point to add is, alot of the parts of this have already been done on the hex's and quads i have built, so the vision system when I get to it has been tried and tested, I do want to improve on it and where I can I will use existing video, you tube also has videos that will demonstrate some of the techniques its based on. Next post will be pics of the kits and starting materials and hopefully I am going to answer cowboy's question on how I intend to measure the amount of fuel ;). I want to alter something I have already tried but this time take some pics, I need to double check something but will explain that by picture as try both ways out.
I know the technique I want to use but I thought of something that might negate the inherent problem of fuel moving moving about in a tank :D. No idea if it will work until I try it at the weekend, I wont be trying it with fuel but with IPA, if it works with that it will work with fuel but the calibration will be different.

While I dont know the actual size yet of the plane, I do know the wing span is likely to be over 62"

When I explain the time and distance this thing needs to obtain keep one thing in mind.........a 30cc 2 stroke weedwacker runs a pretty long time off a ltr of fuel, we will be using something like a .79cc engine and two .45 -.65 engines
 
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Just some engine porn! most of these are going to be sold on, I am keeping a couple to use for experiments etc but most have served there purpose and time to sell on. The two glass things are for testing glow fuel and being able to actually seen the burn, the one with the coil is platinum coated like a glow plug and the other is two platinum wires with a tiny gap in case I go the spark route, they are deside for this kind of thing and can take combustion inside.
combustion.PNG
mass engines.PNG
combustion.JPG
 
The radio comms side between ground and plane is more than one system, but to get the ground controller moving I dont need to add the radio side for a while, in the end the chips will just pass messages to the radio board and these are sent to the plane, so in parts we can use hard wire for now and later on add in the radio side as I intend to use a bus system.

Hold on there a minute tiger.

While I agree that testing your control and telemetry systems can be done by wire without involving the radio systems, do not forget that the data rate which you can pass via the radio link will be a lot slower than that which you can pass via a hard wired link.

JimB
 
Hold on there a minute tiger.

While I agree that testing your control and telemetry systems can be done by wire without involving the radio systems, do not forget that the data rate which you can pass via the radio link will be a lot slower than that which you can pass via a hard wired link.

JimB
Jim I am off to bed soon, but before I go the frequency is 868MHz and the chip is the one in the pic with the red arrow pointing to it, in the morning I will post the datasheet. Trust me this chip your gonna love :D. I will be using two of them.
zerog.JPG
radio 3.JPG


I am genuinely hoping the specs are gonna make you feel all warm and fuzzy inside :D, Also the UAV is actually intended to fly 99.9% of time automatically, the ground station is mainly for monitoring and will have the ability to 'interfere' if needed. But once in the ait I am hoping the ground station wont need to do much other than read the telemetry stuff being sent back, the chips are micros with built in transceivers, I cant remember the specs off hand but used them on the quad. They are really great chips
 
I got a slightly different version this one https://www.silabs.com/products/wireless/EZRadioPRO/Pages/Si446x.aspx it goes upto around 1mbps, but on the dev kit I have I have had it faster than that, there site isnt great for getting datasheets from, normally you use the IDE called simplicity studio, when you choose the chip in the IDE the datasheet pops up, when on the other computer in the morning I will fire it up and grab the datasheet. But the link gives you a rough idea about it
 
I have the updated chip with +20dbm but the pic is of the older board, I will take pics of the newer one at the weekend when I do the pics for specs. This is the datasheet for the one in the current pic (I think??) But will plug the board in tomorrow for the newer dev kit and grab the other sheet, let me know what you think of it please. I am hoping its as good as it seems to of been so far
 

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I wasnt going to do anything about the radio side yet, but since its been mentioned I have the EZ Radio Pro set in the link as well as some dev kits that were designed for smart metering, The only difference between the two types is the one connects to dedicated dev board and the other is designed to connect there higher end 32 bit micro dev kits. on this project while messing with the radio i will be using both to get the radio side set up, I will drop a pic of the EZRP dev kit the other type of board is shown above connected to one of there micro dev kits. For the actual project I intend to just use two of the plug in boards in the photo with the antenna, they are small and light and have all you need on board.

radio 1.JPG


I will get some better pics over the weekend
 
Right back to fuel level and engine control, the level will use the same kind of system as a real plane. But I have had an idea I want to try over the weekend before saying anything, I feel really rough today and not sure why!! So might not mess with IPA until tomorrow. The gauge with be analogue on the ground station, while the whole thing is designed to fly completely on its own it will also to be able to be semi auto, full auto or almost manual control. The other issue is it needs to be able to have control surfaces and engines calibrated and trimmed. I have thought alot about this aspect and later will do some pics and show you what I have in mind for control and calibration stuff.

The ground station will have a small lcd screen plugged into it with 4 terminal windows open and I might use Nigels software he found to do some simple graphics to show various telemetry. But rather than have to try and read screens of data I am going to use leds and switches as well to make things instantly obvious. The terminal screens etc are more of a way of giving a greater depth of information if needed and will also allow direct access to calibration FRAM etc.

Probably going to make more sense as we go along. Anyone got comments on the radio stuff? if anyone thinks its not upto the job speak up!! I would rather look around for something better now rather than later! I have used these chips in all my drones and I did a telemetry system with a set for a wind turbine at 6Km. All performed well but this is alot more data going back and forth, the quad was mainly sending data back as both are just about completely self flying with little ability to be user controlled. I figure with two transceiver chips on board 1Mbps should be plenty, if video (not like normal video BTW) is a problem then there is a dedicated module for FPV video in drones etc, but I would prefer not to use it as I still need the other system for crash avoidance and landing control etc.
 
Ok a little on fuel level detection. i had hoped to try a few things out today and post the pics but the day didnt go to plan and nothing got done! I am looking into a form of cap sensing which apparently is used in some real planes, I have a couple of what I hope are unique ideas but before anyone says anything on it I ask that you wait until I try something out tomorrow, it wont take long to test what i have in mind and if it works then I will be pretty chuffed.
The other option is a slightly complicated optical system, if the cap sense dosnt work then I will try the other.
I hope to post a couple of pics and drawings tomorrow of what i have in mind, I will also take pics of the test and if both dont work the way i think they will then I have a couple of other ideas. I noticed lazerus runs on the R PI so i might try that for the graphical interface,

probably going to use this as the light sensor, i have dev kits for this one a couple of there other ones. Two stroke engines have a coloured oil in, also i have what i hope is a neat way to get around the sloshing around of the fuel.
 

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Turns out Cap sensing for fuel is very common, and pretty awful! At the moment I am 70% sure alot of the fuel will be in the wings as the plane is likely to be a upper wing design and maybe based around an ugly stick or something like that. The common methods looks like using splash baffles and a tube with a rod inside and holes in the tube, then there is the multi sensor approach. I am going to be dead arrogant and bold and declare i think there is a better way! most the designs for small planes are based on very old designs from more than 10 years ago, I cant help but think even if cap sensing hasnt basically changed then the knowledge on the actual sensor design has a little.

Cap sensing has increased a great deal in every day life and the type of sensor used has changed as the uses have grown, Once we know more on the size of plane a fuel quantity then I am going to look at how and where placing a paired sensor can be used to give a more accurate reading, so a tick in the box for using cap sensing and a cross at the moment in exactly how its going to be used. I need to build a couple of mock wings (maybe ply wood or other cheapo method) so I can work out how best to make custom fuel tanks and how I am going to mount stress gauges on the wing and actually mount the wings!.

I did test out cap sensing with a small plastic parts box and some pcb strips with IPA and oil mixed, there is zero problem using cap sense apart from problem with slosh. Most the designs I have seen are based around the tube with a rod inside, I am thinking an inclined plate with separating tracks on X 2 and at 45 degrees to each other (would look like wings with a 40 degree dihedral ) then take readings from both and cancel out the difference, I am hoping that would give you the straight level even when the wing is inclined.

Most of the time flight is going to be straight but there are points of slow climbs and turns so periods where fuel level indication could be out for a while if not right. Still need splash plates as i dont fancy the weight of fuel shifting about in the wings.
I should have mock wings in a week, these are not full scale as I still dont know exactly what the plane will look like yet. Next easy to do job is the battery sled, strictly speaking this isnt just for the battery, its a small stepper moved sled that will have the heavy things like some of the electronics and the battery stuff sitting on it. The Idea being the center of the sled will be the center of gravity, its likely despite having fuel in the wings some fuel will need to be at the back. What ever happens the COG is likely to change a bit on a long flight, normally this is just trimmed out with the flight control surfaces (so i am told), I wanted a way to alter the COG of the heavier things by a few cm front and back, this might be a useful way of trimming out.

The sled will be like the part in a CD drive that moves the laser, imagine that with small top plate on, if I go this route i take pics and post. The other thing I can get on with and need to think about carefully is the lighting, Might not seem like much but the lights could be a problem, I will get the mock wings done and then post what I have in mind. I am also working on the ground station engine control side. last few days of exams so once thats out the way i will post alot more.
 
Havnt decided if I am going to bother posting about the idea of making a new fuel, i have some things brewing (literally) to try out but its way more chemistry than electronics so not sure how much interest there would be in it.

Other things that have happened is i have obtained a load (9) old RC transmitters, they are all old and most are past being useful as transmitters. They were very cheap :D, i got them because all of them except one have decent working Joysticks ;) and switches etc, so £10 well spent seeing as these type of joysticks are around £35 each sometimes more. There is also a nice selection and range of switches.

I have two decent JR transmitters one is old frequency and the other 2.4GHz, but the moduels on each can be swapped over, so i can use 2.4GHz on either transmitter same as the old frequency.
One is a 6 channel transmitter and the other 9 channel, they will be handy when I build the new test plane (1/4 size) to try parts out on, saves me having to have all flight control electronics done before I can test something out.

The idea is simple, i build the modules like say the camera system and stick it in the test plane, i can fly it with the transmitters like a normal RC plane and try out the camera electronics and systems. this will be handy when doing the actual flight system.

I did have a test plane..............it worked well, one day i was trying out the first board for crash prevention, the idea being if signal is lost what will the plane do? In this case it was to try other means of connecting and keep on the flight path for X amount of time. I have since changed the way all of this will work, but no point explaining what will happen now until we get that far.

Anyway the original small test plane used alot of the quad system stuff in it, except the part that turned the plane around to abort and come home, the night before i was going to test i changed the code on the dev kit I was going to use. I worked late into the night and got it done. come the morning I tried the plane out, it was flying unassisted with the quad system (this is a commercial type flight system I had), it got to the point of trying out the new board and I flicked the switch that made the system switch to the new test board..............Except the test board was still sitting on my bench!!

At 250 feet the plane turned and switched over to a system that didnt exist! all controls went to home position (down), without the board I had no way to switch it back to the quad system.

i wont be making those mistakes again.
 
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Next easy to do job is the battery sled
That may not be as easy as you'd like :D. The sled with that considerable mass on it is going to have to sustain large forces with the inevitable heavy landings, so will need to be very sturdy. That implies additional weight and a mechanical-shock-proof powerful drive mechanism. A nice challenge for you, though :).
 
That may not be as easy as you'd like :D. The sled with that considerable mass on it is going to have to sustain large forces with the inevitable heavy landings, so will need to be very sturdy. That implies additional weight and a mechanical-shock-proof powerful drive mechanism. A nice challenge for you, though :).
I dont understand this? we are talking about the part that normally just has the battery sitting on it, instead of being fixed it will be able to move is all. Mass wise it should be under 780g (ish) Maybe I need to find a pic on the web to show you what I have in mind, i dont think i have explained well, this is one reason i want to sort taking pictures out and getting them posted, so much easier to explain with a picture!
 
Ok not a great pic and not the battery! but gives you an idea, if you look at the receiver arr-owed and imagine the battery will also be in the same segment, I will mount them on a sled so they can be moved a little forward or backward to alter the planes COG
reciver.JPG
 
we are talking about the part that normally just has the battery sitting on it
I understand that. Normally the part would be firmly anchored to the airframe and so decelerate at the same rate as the airframe when landing. The airframe would absorb the inertial energy arising from a hard landing. However, if the part is on a slide, deceleration forces acting on the slide will be transmitted through the slide driver to the airframe and that inertial energy will be absorbed partly by the mechanism that moves the slide. 780gm decelerating at several g might strip the teeth of the gears in a standard servo if used as the slide driver. Just saying.
 
I understand that. Normally the part would be firmly anchored to the airframe and so decelerate at the same rate as the airframe when landing. The airframe would absorb the inertial energy arising from a hard landing. However, if the part is on a slide, deceleration forces acting on the slide will be transmitted through the slide driver to the airframe and that inertial energy will be absorbed partly by the mechanism that moves the slide. 780gm decelerating at several g might strip the teeth of the gears in a standard servo if used as the slide driver. Just saying.
Now I get what your saying!! Its a screw thread type drive and the stepper is a longer shaft version of a CD stepper with no gears, the gearings is worm like screw on the shaft of the motor if that makes sense?

A motor like this https://i.ytimg.com/vi/Tbz8J-WO2tU/maxresdefault.jpg
The other point is the ugly stick type design is being used because the plane needs to fly super slow past the pick up point when its grabbing data from the turbines, so landing should be slow and controlled any way, lucky enough the sled is one of the mods I can test early on a hand flown test set up. If it survives my hand landing then it will survive a system landing no problem :D.

Good comment though and something I will keep in mind.

I will make a note of it, if it is a problem on the small test plane (same weight ) then as its designed to trim in flight, for landing I see no reason it cant return to original position and be locked in with a solenoid pin (current to pull in, no current pin is engaged)
 
Ah, a screw thread drive sounds promising. Good luck with the build.
 
Ah, a screw thread drive sounds promising. Good luck with the build.
Thanks, comments are useful especially pointing out things I havnt explained well or need to check, so I appreciate all comments and concerns otherwise i will end up with all the problems at the end of the build and not mostly at the design stage where I can do something about them alot easier. Now you have mentioned the inertia I will try it on the small scale one I build/rebuild, better to double check now and the reason for doing a test model is so I can solve problems that crop up.
Not making much progress at the moment but nearly through the exams and hopefully alot more free time coming up
 
Bumped into a wall (metaphorical), I am designing the engine control side for the ground station. Keep in mind there are several modes from almost manual to complete self control. Even modern transmitters for RC have fairly complex systems for doing things like having an ofset for twin engines, so when you increase power one engine is slightly offset throttle wise. I can go further than this, if a encoder or even small pot is added to the throttle linkage then you can offset by throttle amount or because of the way I want to measure RPM it could be done via RPM.

The problem is I am using 3 engines, the control side isnt the problem, the problem is how best to implement the system on the control station.
Some information and thoughts and choices.............

I could use a normal throttle joystick, these stay put in the up/down position as you move the stick, if you let go at say 70% forward the stick stays there. Now in 3 engines this could be useful.
For example the same joystick is able to move left and right as well, but that movement always returns to center. So in theory you could push the stick to the left and hold for X amount of time and that would engage control for left engine, then adjust speed and press button to send new signal. Same for right side.

But you still need to trim and have offset switches, so in reality you might as well use a fixed one way joystick, these tend to be alot cheaper and nastier looking though. Its trying to work out the most efficient way of doing it while making sure there is enough options and control for each mode.

Simple solution would be to simply input offsets and trim onto the screen/terminal page and have it sent that way, but in almost manual mode I can see that being a problem, its more natural to want to adjust via a switch or joystick, plus I dont want to force the use of the terminal side, its there to duplicate alot of functions and give deeper amounts of information, the control box itself is more for instant attention grabbing if things are right or wrong, the terminal screen or program screen is more for providing more information and setting up things like calibration information.

Its a small issue but one I need to think about carefully, while thats going around in my head I will look at the actual modes and the key switches I am going to use. Also start to map out where I want each section on the actual control box. Its tiny steps and stop! but each step is a win, and once one is done it opens the way to another.

I know its completely non linear way to do things, but my other choice is too simply wait until I have all the jigsaw bits then start! That could take a long time and likely kill off the project, so I have chosen to do what I can when I can and just take small steps.
 
Right exams out the way! Back at the job in hand :D.

First off is a question, I am having trouble deciding something so consider this a kind of vote.

Background bit
There will be/is a R PI on the ground unit, the main purpose is so commands etc can be given over a program (lazerus if I get it working) or terminal, it also serves a few other functions like displaying data you are not going to need all the time but useful to log.

With three engines there is a good chance that one maybe 2 will be slightly offset power wise, especially the two wing ones, while they are same make and model they are not equal power wise, so for example lets say the left engine is turning at 6,000 RPM and the right engine is slightly more powerful and needs to run at 5,200 RPM so they balanced and not torque turning.

on the engine control part of the panel I had intended 3 separate 4 digit seven segment displays for the RPM's. Mostly the UAV flys itself but there might be times the person using it needs to alter engine speed for example manually.
There will be an offset pot for each engine and the amount of offset will be on the terminal window, there will be one power joystick but 3 switches (one for each engine), so flick a switch and move the joystick to increase or decrease power. OR do it via the terminal.

there is also a send switch, so adjust the joystick and press send and the command goes to the UAV, what I can decide is if there is any advantage in having 2 sets of Segment display for each engine? One displaying what your about to set the engine too (just before pressing send) and one showing the actual RPM.

I am leaning more and more to one for each engine, but does anyone else think two per engine has any merit? Typing this has strengthened my belief in just one set for each but I wanted opinions. The fuel gauge should be done by Tuesday unless my bodged DAC works ok! Thanks to those that replied on the DAC, next time I wont try and do this stuff while revising at the same time!
 
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