Project Report

“Design Considerations & Product Development

of a Fixed-Wing VTOL Drone"

[ANE 2810]

Apurva Sharma - A717104917001

Amandeep Singh - A719104917002
Prathamesh Mahadik - A719104917007
Rahul Lohar - A719104917010
Sambhaji Morajkar - A719104917011

B.Tech ANE
Semester - VIII
Amity Institute of Technology
Amity University Mumbai
Amity Institute of Technology (AIT)
Bhatan, Panvel – 410 206

Bachelors of Technology – (Aeronautical Engineering)

Semester – (VIII)

This is to certify that Apurva Sharma, Prathamesh Mahadik, Rahul Lohar,

Amandeep Singh and Sambhaji Morajkar of B. Tech Aeronautical have successfully
completed their PROJECT under the guidance of Mr. Jyothi Kumar Mandava as per the
Syllabus for the Academic Year 2017- 2021.

Signature of faculty – In charge Signature of Head of the Dept.

Signature of External Examiner Date:

ABSTRACT

The objective of this report is to explore and create the design process while
developing a fixed-wing VTOL drone used in surveillance and tracking for military
purposes. The report contains all the theoretical calculations in the aerodynamics
regime, along with structural design features and analysis, desired performance
parameters, weight estimation and power, propulsion system used, a thorough
description of the avionics and the detailed sizing of all the parts of the drone.
All practical applications and availability of components is considered while
developing the design and selecting the parts of this drone. Cost reduction and
environmental factors are also given prime importance.

ACKNOWLEDGEMENT

We would like to thank our professor Mr. Jyothi Kumar Mandava Sir, for helping and
guiding us in the completion of our project, by reviewing our ideas and formulating a
path for the successful development of a design for our drone.

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 CONTENTS

I. INTRODUCTION 1

II. LITERATURE SURVEY 2

A. FIXED – WING DRONE 2
B. HYBRID VTOL FIXED WING DRONE 2

III. MARKET SURVEY 3

IV. OBJECTIVE OF THIS REPORT / PROBLEM DEFINITION 3

V. DESIGN METHODOLOGY & DEVELOPMENT

3
(Along with component selection)
A. DESIGN 3
B. BATTERY 19
C. ESC 21
D. CAMERA SELECTION 22
E. MOTOR SELECTION 24
F. TECHNICAL SPECS 28
G. VIDEO TRANSMISSION 29
H. DRONE BENCHMARKING DATA 29
I. MATERIAL RESEARCH 30
J. OUR HYBRID DRONE (Part by Part Breakdown) 39
K. CAMERA HOUSING & GIMBAL 47
L. CFD ANALYSIS 51

CONCLUSION 61

REFERENCES 61
I. INTRODUCTION

Drone technology is replacing many hazardous and high-end jobs to provide cost-effective and
harmless solutions to everyday issues- ranging from military applications to commercial usage.

For businesses using drones, the developing global market is estimated to be about $127 billion. The
investment in the drone technology has increased manifold with more capitalization in the area. More
advanced drones enter into the market every month as new innovations arise.

Unmanned Aerial Vehicle Technology comprises –

→ Aerodynamics of the drone
→ Material selection
→ Structural design feature and analysis
→ Circuit Boards
→ Chipset
→ Software
→ Overall avionics system design

The various applications of drones include –

→ Healthcare
→ Agriculture
→ Waste management
→ Weather forecast
→ Construction planning
→ Mining
→ Surveillance
→ Urban Planning
→ Defense
→ Telecommunications and so on.

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II. LITERATURE SURVEY

A. FIXED – WING DRONE

Fixed-wing drones are airplane-like; an unyielding structure that generates lift under the wing due to
forward airspeed. They are of three types- Straight, Swept and Delta. The propulsion is carried out by
electric motor-controlled propellers or an internal engine. Fixed wing drones involve either a handheld
or runway take-off and can fly endlessly over long distances instead of prolonged hovering.

These drones have a simplistic design, and a growing interest. These drones are usually custom-built,
so that they meet their respective operational requirements.

Uses
Government militaries use fixed-wing drones to monitor war-torn areas. Agricultural, construction,
and mining industries also use these drones due to their superior versatility and versatility in severe
weather conditions.

The major advantage of a fixed-wing UAV is its simple construction that ensures far less maintenance
and repair work, therefore lowering the cost. These drones also have the capability to carry greater
payloads for longer distances on less power, which allows you to carry bigger sensors, as well as twin
sensor configurations.

Types of Fixed – Wing Drones

Straight Wing
▪ Rectangular Straight Wing
▪ Tapered Straight Wing
▪ Rounded or elliptical straight wing

Swept Wing
▪ Slightly swept wing
▪ Moderately swept wing
▪ Highly swept wing

Delta Wing
▪ Simple delta wing
▪ Complex delta wing

B. HYBRID VTOL FIXED-WING DRONES

Hybrid VTOL fixed-wing drones incorporate the functions of both, a vertical take-off and landing
drone, as well as a fixed-wing drone; a multi-rotor platform along with fixed-wing can be used along
with transition between these two modes during flight.
These drones can be operated in any location due to their ability to vertically take-off and land without
the need of a runway or launcher. Hybrid drones of these kind provide greater endurance, the ability
to cover longer distances, faster and longer flying operations, and a greater land coverage in
comparison to multi-rotor UAVs. In a nutshell, VTOL fixed-wing drones combine the vertical landing
of multi-rotors along with the cruising flight efficiency of the latter.

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Hybrid VTOL fixed-wing drones find a wider area of applications in military and commercial aerial
applications.
VTOL fixed-wing drones can offer real-time intelligence to decision-makers, permitting better pre-
planning, better control and more resourceful resolution of emergency situations without putting
human operators in harm’s way.

III. MARKET SURVEY

Till 2020, a 100-billion-dollar market has been forecast for drones. This is facilitated by he growing
demand from the commercial and civil government sectors.
Drones got their start as safer, inexpensive and often more accomplished alternatives to manned
military aircraft. Defense will remain the largest market for the probable future as global competition
heats up and technology continues to advance.
The consumer drone market was the first to develop outside the military. Demand has taken off in the
last two years and hobbyist drones have become a familiar sight, but there is plenty of room for growth.
The fastest growth opportunity comes from businesses and civil governments. They're just beginning
to explore the possibilities, but we expect they'll spend $13 billion on drones between now and 2020,
putting thousands of them in the sky.

IV. OBJECTIVE OF THIS PROJECT / PROBLEM DEFINITION

The need for drones in extreme temperature conditions of the country is necessary for military uses
such as tracking and surveillance. The following report suggests a design for a hybrid drone with both
VTOL as wells as fixed-wing (Cruise) capabilities that can function in cold climate areas like the
northern parts of India where slight snows and sub-zero temperatures are observed. A simplistic, crash-
proof, cost-efficient design is considered, with all the aerodynamic calculations and analysis, structural
design features, detailed sizing and weight estimations. Avionics system design including command
and control scheme, flight controllers, battery selection, video transmission and camera selection are
discussed in detail. A special emphasis is given on the design configuration and motor location.

V. DESIGN METHODOLOGY & DEVELOPMENT

(Along with component selection)

A. DESIGN

The drone is designed for vertical take-off and landing. The drone will have an X motor configuration
for vertical take-off. It will also have a separate motor at the rear end to provide force for cruising. The
drone will have a lift generating wing.
The flight profile will consist of a vertical take-off, then acceleration to the stall velocity followed by
cruise and finally vertical landing.

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Working
The X copter configuration will take the drone to the appropriate height. Then the fifth thrust providing
motor will start and accelerate the drone in the forward direction. The wings will generate the lift
(equal to weight) at the velocity greater than the stall velocity. After the latter condition is achieved,
the X configuration motors will turn off. Then the cruise will be carried out by the fifth thrust providing
motor giving appropriate thrust. For landing, the drone will decelerate closer to stall velocity and the
X configuration motors will start to balance the weight. This thrust producing motor will then be turned
off.
Landing will be carried by gradually decreasing the thrust of the X configuration motor.

Flight Mission Profile

Airfoil selection
Airfoil will be selected for maximum lift generation at smallest possible stall velocity and minimum
negative coefficient of moment. Conventional cambered airfoil generates the larger negative moment
which is balanced by a tail structure. The design is small and will not have a large tail, hence for
stability a reflex profile airfoil will be used. Reflex airfoil doesn’t generate the negative moment
hence single wing configuration is possible with reflex airfoil.

Selected Airfoils

Centre airfoil NACA 34118

Design CL 0,5
Camber position & 20% reflex
Reflex
Thickness (%) 15%

Wing airfoil NACA 34112

Design CL 0,5
Camber position & 20% reflex
Reflex
Thickness (%) 12%

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Lift calculations

Velocity Density Surface Area Lift Lift Force

Cl
(m/s) (kg/m3) (m2) (N) (Kg)
15 1.2 0.439 0.5 29.6325 3.023724
16 1.2 0.439 0.5 33.7152 3.440327
17 1.2 0.439 0.5 38.0613 3.883806
18 1.2 0.439 0.5 42.6708 4.354163
19 1.2 0.439 0.5 47.5437 4.851398
20 1.2 0.439 0.5 52.68 5.37551
21 1.2 0.439 0.5 58.0797 5.9265
22 1.2 0.439 0.5 63.7428 6.504367
23 1.2 0.439 0.5 69.6693 7.109112
24 1.2 0.439 0.5 75.8592 7.740735
25 1.2 0.439 0.5 82.3125 8.399235
26 1.2 0.439 0.5 89.0292 9.084612
27 1.2 0.439 0.5 96.0093 9.796867
28 1.2 0.439 0.5 103.2528 10.536
29 1.2 0.439 0.5 110.7597 11.30201
30 1.2 0.439 0.5 118.53 12.0949

Drag calculations

Surface Drag
Velocity Density
Area CD0 CL req k CDi CD CD0×q×s CDi×q×s
(m/s) (kg/m3) Total
(m2) Parasite Induced
15 1.2 0.439 0.015 0.6749 0.082 0.0375 0.0525 0.889 2.2217 3.1107
16 1.2 0.439 0.015 0.5932 0.082 0.029 0.044 1.0115 1.9526 2.9641
17 1.2 0.439 0.015 0.5255 0.082 0.0227 0.0377 1.1418 1.7297 2.8715
18 1.2 0.439 0.015 0.4687 0.082 0.0181 0.0331 1.2801 1.5428 2.823
19 1.2 0.439 0.015 0.4207 0.082 0.0146 0.0296 1.4263 1.3847 2.811
20 1.2 0.439 0.015 0.3797 0.082 0.0119 0.0269 1.5804 1.2497 2.8301
21 1.2 0.439 0.015 0.3444 0.082 0.0098 0.0248 1.7424 1.1335 2.8759
22 1.2 0.439 0.015 0.3138 0.082 0.0081 0.0231 1.9123 1.0328 2.9451
23 1.2 0.439 0.015 0.2871 0.082 0.0068 0.0218 2.0901 0.9449 3.035
24 1.2 0.439 0.015 0.2636 0.082 0.0057 0.0207 2.2758 0.8678 3.1436
25 1.2 0.439 0.015 0.243 0.082 0.0049 0.0199 2.4694 0.7998 3.2692
26 1.2 0.439 0.015 0.2246 0.082 0.0042 0.0192 2.6709 0.7395 3.4103
27 1.2 0.439 0.015 0.2083 0.082 0.0036 0.0186 2.8803 0.6857 3.566
28 1.2 0.439 0.015 0.1937 0.082 0.0031 0.0181 3.0976 0.6376 3.7352
29 1.2 0.439 0.015 0.1806 0.082 0.0027 0.0177 3.3228 0.5944 3.9172
30 1.2 0.439 0.015 0.1687 0.082 0.0023 0.0173 3.5559 0.5554 4.1113

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Power calculations

√2 (𝑊 )
𝑆
𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 min 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑(𝑉𝑚𝑖𝑛) =
𝜌𝐶𝑙

= 20.24 𝑚/𝑠

𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 (𝑃) = 𝐷 × 𝑉𝑚𝑖𝑛

= 2.62083 × 20.24 = 53.04 𝑤𝑎𝑡𝑡.

Considering cruise time of 30 min

𝑒𝑛𝑒𝑟𝑔𝑦 = 53.04 × 1800 = 95472 𝐽

= 26.54 𝑤𝑎𝑡𝑡 ℎ𝑟

Considering other power losses, we can consider energy requirement of cruise as 30 Watt-Hr.

1000
𝑚𝐴ℎ = 𝑊𝑎𝑡𝑡 ℎ𝑟 ×
𝑉

= 30 × 1000/6

= 5000 𝑚𝐴ℎ

Velocity Power
Total Drag
(m/s) (Watt)
15 3.1107 46.6598
16 2.9641 47.4256
17 2.8715 48.8158
18 2.823 50.8132
19 2.811 53.4093
20 2.8301 56.6019
21 2.8759 60.3939
22 2.9451 64.7920
23 3.035 69.8056
24 3.1436 75.4469
25 3.2692 81.7295
26 3.4103 88.6688
27 3.566 96.2815
28 3.7352 104.5851
29 3.9172 113.5981
30 4.1113 123.3396

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 Velocity v/s Drag
4.5000

4.0000

3.5000

3.0000
Velocity v/s Parasite Drag
2.5000
DRAG

Velocity v/s Induced Drag

2.0000
Velocity v/s Total Drag

1.5000

1.0000

0.5000

0.0000
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
VELOCITY

Velocity v/s Power

130.0000

120.0000

110.0000

100.0000

90.0000

80.0000
Power (W)

70.0000

60.0000

50.0000

40.0000

30.0000

20.0000
12 14 16 18 20 22 24 26 28 30 32

Velocity (m/s)

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CAD, Drawings & Renderings
Software used: CREO Parametric 6.0

Version 1.0 – This was the initial model, which determined the changes to be implemented. Hence,
this design was rejected.

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Version 2.0 – This is the updated model, keeping in mind the required changes. This design was
accepted and from this point on the changes made were mostly associated with requirements of tails,
winglets, manufacturing perspective i.e., 3D Printing, etc.

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Version 3.0 – This is the updated model, with the changes like eliminating the tail and addition of
winglets. Also, the design was made modular with regards to manufacturing perspective and the ease
to problem solving.

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Version 3.1 – This is an update to the previous model, with an accepted Gimbal imitation and
eliminating the propellor guards, as some flaws had been established in regards to feasibility.

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Version 4.0 – This model has been updated largely in terms of modularity. This model is closely related
to the final model.

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(Colors distinguish modularity)

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B. BATTERY

A Drone Battery is the foundational component of a quadcopter and must be considerately selected to
achieve an ideal balance between performance and flight time. Lithium batteries are the most common
battery chemistry used to power quadcopters due to their high energy densities and high discharge
capabilities.

LiPo and LiHV Drone Battery

The lithium battery packs used to power quadcopters have two common chemistries: Lithium polymer
(LiPO) and lithium polymer high voltage (LiHV). In regards to the performance of the two packs, a
LiHV battery will initially provide more power but abruptly drops in voltage when discharged whereas
a LiPO has a more linear discharge making it easier to qualitatively gauge the remaining flight time.
LiPO packs are the most commonly used across all sizes of quadcopters however LiHV packs are quite
popular for use on “Tiny Whoop” micro drones because the extra voltage moderately improves the
quadcopters performance.

Drone Battery Cells and Voltages

Battery voltage is the potential energy difference between the positive and negative terminals. A higher
FPV Drone Battery voltage allows the pack to provide more power to the quadcopter without
increasing the current or amp draw. A standard lithium polymer cell has a nominal (storage) voltage
of 3.7V hence to increase the power that a single LiPO pack can deliver, these cells are grouped
together in series to increase the overall battery pack voltage. LiPO packs are commonly sold in 1S,
2S, 3S, 4S, 5S or 6S configurations where the digit followed by the ‘S’ stands for number of cells in
that specific pack. The more cells that are grouped together, the more voltage the overall battery pack
will have. The battery pack voltage is important as it impacts the maximum motor speed of a
quadcopter.

Number of LiPO Cells Nominal Battery Voltage

1S 3.7V
2S 7.4V
3S 11.1V
4S 14.8V
5S 18.5V
6S 22.2V

FPV Drone Battery C-Rating

Battery capacity is measured in milliamp hours (mAh) which is a unit describing the current a battery
can supply for a unit of time. As an example, a 1500mAh battery would be able to supply: 1500
milliamps (1.5A) of current for an hour, 3000mA (3A) of current for a total of 30 minutes, 6000 Ma
(6A) for 15 minutes and so on. A higher milliamp rating on a battery essentially means that it will
provide more flight time per charge. When choosing a battery, a sacrifice must be made between the
battery size and the weight. A larger capacity battery will provide longer flight times however the
added weight will restrict the performance of the quadcopter by increasing the craft’s momentum
thereby making it respond in a more sluggish manner.

C-Rating Formula
Maximum Safe Current Draw (Ma) = Battery Capacity (mAh) × C-Rating

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Drone Battery Capacity
The battery capacity represents how much power the battery can hold. You can think of this as being
the size of your fuel tank. The higher the capacity, the longer you can fly your quadcopter. Battery
capacity is measured in units of milliamp hours mAh. If you have a battery with a capacity of X mAh,
and you drain X Ma, then it will take one hour to drain the battery.

Power estimation needed to hover a drone

Rotors take stationary air above the vehicle and push this air down. By increasing the momentum of
the air, the rotor exerts a force on the air and the air pushes back on the rotor. If this air force is equal
to the weight of the vehicle, the drone will hover. This leads to the following expression for the air
speed of a hovering drone;

In this expression ρ is the density of the air, m is the mass of the drone, and g is the gravitational
Constant and A is the area of the rotors.

This is important for the power, which can be written as;

Power is the rate at which something uses energy. This can be described with the following equation;

AIRSPEED(m/s) POWER(W) ENERGY(Wh)

DRONE PROPELLER
WEIGHT DIAMETER

8” 22.22 870.84 500

4 kg 10” 17.77 695.97 388.88
12” 14.81 580.37 333.33
8” 23.57 1039.41 583.33
4.5 kg 10” 18.85 830.74 472.22
12” 15.71 692.74 388.88

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Battery Selected
For our drone we will require a 10000 mAh 4s battery. Since it’s not easy to get a battery with this
specs so we will get 2 batteries 10000 mAh 2s each. This will give us the same output whatever is
required.

Component Specifications Price

C Rate 35 C
Volts 7.4
Capacity 10000 mAh
Venom 35C Cell Count 2S
2S 7.4V 10000mAh Continuous Discharge 35 C (350 A) 8308 (× 2) = Rs.16316
LiPo Battery (x 2) Max Burst Rate 50 C (500 A)
Max Volts per Cell 4.2 V
Dimensions (127 × 43 × 39) mm
Weight 462 g (× 2) = 924 g
Reference: https://www.amazon.com/Venom-10000mAh-Battery-Universal-Traxxas/dp/B00E94LNIG

C. ESC

VTOL Drone Electronic Speed Controller

The Electronic Speed Controller (ESC) on a drone is a hard-working, powerful component. The ESC
connects the flight controller and the motor. The ESC takes the signal from the flight controller and
power from the battery and makes the brushless motor spin.
Our drone will be using a 4-in-1 ESC in which all 4 ESCs are combined into one circuit board and
mounted in the main stack under the flight controller. For lighter builds, or for a cleaner look, many
pilots choose to purchase the 4-in-1 ESCs. Often, they come with built-in voltage regulators and can
act as a power distribution board (PDB) as well.

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 Component Specifications Price
Brand name HAKRC
Item name E50AX4 BLHeli_32 ESC
Size (36 × 36 × 6) mm
Package size (62 × 58 × 17) mm
HAKRC E50AX4 Fixed hole distance (30.5 × 30.5) mm / Φ3 mm
Rs. 5439
50A 4 IN 1 ESC 3-6S Weight 16 g
Package weight 40 g
Continuous current 50 A
Maximum current 65 A (sustainable 10s)
Input voltage 3 – 6s
Reference: https://www.banggood.in/HAKRC-E50AX4-50A-4-IN-1-ESC-3-6S-BLHeli_32-5V- 3A-BEC-
Dshot1200-For-RC-Drone-FPV-Racing-Multi-Rotor-p-1331996.html?p=63061312105582015022&utm_
source=sns&utm_medium=rcgroups&utm_campaign=albert&utm_content=tanghao&cur_warehouse=CN

D. CAMERA SELECTION

Camera Specifications Price

FPV FOV 4:3@140°, 16:9@170°/HD
Field of View (FOV)
Recording 170°
Lens Thread Size M12*0.5
1080@60fps/1080@50fps
Video Resolution
/1080@30fps/720@60fps
Video File Format MOV
Image Resolution 2 Megapixels
TV Mode NTSC (720×480)/PAL (720×576) Switchable
RunCam Split 2S Rs 7574
Interface Micro USB / UART
Max Micro SD Card 64G (need Class 6 or above, recommend Class
Supported 10/UHS-I/UHS-II/UHS-III)
WIFI Module Support (Removable)
Dimensions PCB 38×38mm/Lens Module 19×19mm
Power Input DC 5-15V / DC 5V(USB)
Working Current 650Ma @5V / 270Ma @12V
Net Weight 19 g
References: https://www.banggood.in/RunCam-Split-2S-FOV-170-Degree-Super-WDR-Mini-FPV-Camera-
1080P-60fps-DVR-HD-Recording-OSD-for-RC-Drone-p-1365856.html?rmmds=search&cur_warehou se=CN

Features
− 1080P@60fps HD recording & WDR 16:9 / 4:3 FPV camera
− 38x38mm@30.5x30.5 M4 holes, Standard size for a better experience
− Removable Wi-Fi module for APP
This particular camera is chosen due to its compact size, and better compatibility with the digital
transmission system.

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Dimensions

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E. MOTOR SELECTION

Thermoplastics and Aluminium alloys are used.

To cool the motor, materials with HIGH THERMAL CONDUCTIVITY like Aluminium is used.
Brushed motors and brushless motors are two common types of motors used in quadcopters, or drones
in general.

Construction Differences of Brushed and Brushless Motors

A “brushed” motor has a rotating stator (wire coils) which acts as an electromagnet with two poles.
The shell is stationary (not moving) therefore brushed motors can often be mounted without using any
screws.

A “brushless” motor uses a permanent magnet and accomplishes the switching by electronically
switching the polarity, instead of brushes, hence the name “brushless”. Because of the moving motor
bell, the motor is usually mounted by the base using screws.

Advantages of Brushless Motors

→ No brushes – lower maintenance and longer durability
→ Better speed and torque due to the absence of brushes, because brush friction increases with speed
→ Wider speed range
→ Better heat dissipation due to the construction compared to brushed motors
→ More cost effective for high speed/power operations

Popular applications: radio-controlled model airplanes and drones, electric vehicles and industrial
machinery that requires high rotation speed and power

How to Choose Motor:

Knowing the Total Weight and Frame Size
The total weight of the drone should include all the components: frame, FC, ESC, motors, propellers,
RX, VTX, antenna, ESC’s, battery, and payload.
It doesn’t have to be 100% accurate, an estimation would be fine. It’s better to overestimate the weight
and have extra power than underestimate, and struggle to take off.

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Calculating Thrust Required:
A general rule is that the maximum thrust produced by all motors is at least double of the total weight
of the drone. If the thrust is too little, the copter will not respond well to your control, it might even
struggle to lift off.

For our design we will have thrust to power ratio to be 2.3. This does not only give you better control,
but also provides room for extra payload in the future.

Total drone weight = 4 Kg

Thrust to weight ratio = 2.3:1
Number of motors used to lift drone = 4

𝑇𝑜𝑡𝑎𝑙 𝑡ℎ𝑟𝑢𝑠𝑡 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 𝑑𝑟𝑜𝑛𝑒 𝑤𝑒𝑖𝑔ℎ𝑡 × 𝑇ℎ𝑟𝑢𝑠𝑡 𝑡𝑜 𝑤𝑒𝑖𝑔ℎ𝑡 𝑟𝑎𝑡𝑖𝑜

= 4 × 2.3 = 9.2 𝑘𝑔
Now,
𝑡ℎ𝑟𝑢𝑠𝑡 𝑜𝑛 𝑒𝑎𝑐ℎ 𝑚𝑜𝑡𝑜𝑟 = 9.2 ÷ 4 = 2.3 𝑘𝑔

So, we need to choose a motor that is capable of producing thrust of 2.3 kg.

Motor Size Explained

The Size of brushless motors in RC is normally indicated by a 4-digit number – AABB. “AA” is the
stator width (or stator diameter) while “BB” is the stator height, both are measured in mm (millimeter).
A stator is the stationary part of the motor, this has ‘poles’, which are wrapped around by copper wires
(windings). The ‘poles’ are made of many layers of thin metal plate that are laminated together with a
very thin insulation layer in between.

According to the general consensus:

▪ Taller stator = more power at higher RPM
▪ Wider stator = more torque at lower RPM

The main difference is, when increasing the stator height, it increases the permanent magnet size more
than the coil size, and when increasing the stator width, it increases the electromagnetic coil size more
than the permanent magnet.

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KV
“KV” is a guideline of how many RPM a motor gives up per volt. It’s an important parameter of
brushless motors, which indicates the theoretical increase of RPM (rotation per minute) when voltage
goes up (without load, i.e., propeller).
Once you mount a propeller on the motor, the RPM decreases drastically due to air resistance. Higher
KV motors would attempt to spin the propeller faster, and it can draw more current. That’s why we
tend to see larger props paired with low KV motors, while smaller and lighter props are better suited
to high KV motors.
Heavier drones usually pair with medium to low KV motors, lighter quad usually uses high KV motors.
Since our drone is a heavier drone, we will require lower KV.

Motor Torque
Torque is mainly defined by:
→ stator size: the bigger the more torque
→ Mate: the type of magnets, quality of the copper windings
→ Motor construction: things like air gap, number of poles etc.

Motor KV doesn’t necessarily affect torque. One reason that people assume lower KV motors have
more torque is the worse voltage sag they witness with high KV motors, and the voltage drop kills the
torque. In theory they’d have the same amount of torque, but they can’t in reality.

Voltage and Current Draw

It’s important to understand that voltage has a large impact on your motor and propeller choice. Your
motor will try to spin faster with a higher voltage, thus draw a higher current. Ensure you are aware of
how much thrust your motors produce and how much current they will draw.
When you know the current draw of the motor and prop combination, you are now ready to choose
ESC for your drone.

How to Choose Propeller

Propeller Size – Propellers exist in different length and pitch:
→ The length of a propeller is the diameter of a disc the prop makes when it’s spinning
→ Pitch can be defined as the travel distance of one single prop rotation

The Effects of Propeller Length and Pitch

Propellers generate thrust by spinning and moving air. When the propeller is spun faster, the more air
it can move, and thus the more thrust it generates.
In a nutshell, larger propeller or higher pitch length will increase your aircraft’s speed but also use
more power.

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Reading Propeller Specification
There are 2 types of format that manufacturers use.
L × P × B or LLPP × B
Where;
L – Length, P – Pitch, B – No. of Blades.

For example, 6×4.5 (also known as 6045) propellers are 6 inch long and has a pitch of 4.5 inch. Another
example, 5x4x3 (sometimes 5040×3) is a 3-blade 5″ propeller that has a pitch of 4 inch.
“BN” indicates Bullnose props.
Sometimes you might see “R” or “C” after the size numbers, such as 5x3R. R indicates the rotation of
the propeller, which stands for “reversed”. It should be mounted on a motor that spins clockwise. C is
the opposite, should be used with motors that spins counter-clockwise.

For our drone:

Motor chosen : EMAX GT2826/04 No. of cell: 4s
RPM / V : 1090
Prop: 10x5 RPM : 13200
Max current : 47A
Weight : 175g

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F. TECHNICAL SPECS

▪ FMU Processor: STM32F765

− 32 Bit Arm® Cortex®-M7, 216MHZ, 2MB memory, 512KB RAM
▪ On-board sensors
− Accel/Gyro : ICM-20689
− Accel/Gyro : BMI055
− Mag : IST8310
− Barometer : MS5611
▪ GPS: ublox Neo-M8N GPS/GLONASS receiver; integrated magnetometer IST8310

Electrical Data – Voltage Ratings

▪ Power Brick Input : 4.75 ~ 5.5V
▪ USB Power Input : 4.75 – 5.25V
▪ Servo Rail Input : 0 ~ 24V
▪ Max current sensing : 120A

Absolute Maximum Ratings

Under these conditions the system will remain intact.
▪ POWER input (0V to 6V undamaged)
▪ USB input (0V to 6V undamaged)
▪ Servo input: VDD_SERVO pin of MAIN OUT (0V to 24V undamaged)

Mechanical Data
▪ Dimensions : 38×55×15.5 mm
▪ Weight : 37.2 g

Environmental Data, Quality & Reliability

▪ Operating temp. : -40 – 85°C
▪ Storage temp. : -40 – 85°C
▪ CE
▪ FCC
▪ RoHS compliant (lead-free)

Interfaces
▪ 8 PWM servo outputs
▪ 4 dedicated PWM/Capture outputs
▪ Dedicated R/C input for CPPM
▪ Dedicated R/C input for Spektrum / DSM and S. Bus with analog / PWM RSSI input
▪ 3 general purpose serial ports
− 1 with full flow control
− 1 with a separate 1A current limit
▪ 2 12C ports
▪ 3 SPI buses
− 1 internal high-speed SPI sensor bus with 4 chip selects and 6 DRDYS
− 1 internal low noise SPI bus dedicated for Barometer with 2 chip selects, no DRDYS
− 1 internal SPI bus dedicated for FRAM
− Supports dedicated SPI calibration FLASH located on sensor module

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▪ 1 CANBUSes for CAN ESC
− CANBUS has individual silent controls or ESC RX-MUX control
− Analog inputs for voltage / current of battery
▪ 1 additional Analog inputs

G. VIDEO TRANSMISSION

→ First Person View is what the drone transmits and the video is as if the person is onboard.
→ FPV technology uses radio signals to transmit and receive the live video.
→ Parts in FPV System: Camera, Transmitter, Receiver and Power Supply
→ 3 possible ways to do Wireless Video Transmission:
1. Wi-Fi: This is usually used for short distances. The range of the Wi-Fi signal depends on the power
of the transmitter, the frequency used and the antenna used.
2. 3G/4G: 3G/4G dongles can be attached to the drone. This solution is feasible depending on the
availability of the 3G/4G network in the operating region.
3. RF transceivers: These Radio Frequency Transceivers are used usually for drones made with the
purpose of industrial, commercial and military use.

H. DRONE BENCHMARKING DATA

Aircraft Wt. Aircraft Wt.

Payload
Name of Drone With Without MTOW Range Endurance
Weight
Battery Battery
X2Q 1.5 kg 250 g 25 min
C-2
4.5 kg 500g 7 kg 80 km 80 min
Hummingbird

Eagle eye Mini UAV 400 g 3.5 kg 10 km 120 min

ALTI Ascend 8.5 kg 600 g 9 kg 10 km 360 min

Skywalker Drone 4 kg 500 g 15 km 40 min

x2 Geo 1.27 kg 3 km 45 min
SkyProwler 2 600 g 2.3 kg 60 min
Wingtra One 3.7 kg 800 g 4.5 kg 10 km 60 min

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I. MATERIAL RESEARCH

Top materials used in drones:

− Carbon fiber-reinforced composites (CFRCs)
− Thermoplastics such as polyester, nylon, polystyrene, etc.
− Aluminium
− Lithium-ion batteries

For material consideration,

Properties:
1. 3-D print available
2. Good Strength
3. Low Density
4. Increased cargo capacity
5. Extended flying time
6. Reduced Inertia
7. Improved maneuverability

The drone will be manufactured using 3D printing technology. The first prototype will be all made
using 3D printing materials. Below is the in-depth study of 3D printing materials that can be used for
manufacturing of the drone.

3D Printing Materials
3D printing Materials Material science is as important as the 3D printer technology to the success of
the 3D printing world. It’s been a long time since 3D printing has
graduated from its focal point of plastics only and are expanding to
other materials like ceramic, titanium, and even chocolate. In some
areas 3D printing has made tremendous leaps to create new materials
that are created exclusively for 3D printing.

Types of 3D printing materials:

→ Plastic Filament
→ Powder
→ Resin

▪ Plastic Filament based 3D printing – 3D Filament

3D filaments are special types of plastics called thermoplastics. Once heated to the right temperature,
thermoplastics become flexible. It’s this pliability that allows the printer to sculpt the filament to create
your shapes before it cools down.
The two common types of 3D filaments are:
− ABS (Acrylonitrile Butadiene Styrene)
− PLA (Polylactic Acid)

1. ABS 3D Filament
Price starting from: $20 for 1.75 mm, 1kg spool
ABS print temperature range: 210°C – 250°C (high)

ABS is popular for good reasons. It’s tough, and has impact-resistant properties. It’s this strength and
moderate flexibility that makes it such a great choice for printing in 3D. It’s also easy to extrude from
the printer’s nozzles, which makes it an easy material to work with.

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Applications
ABS is a great choice for printing plastic automotive parts, moving parts, musical instruments, kitchen
appliances, electronic housings, and various toys, like LEGO. It has other applications too, aside from
3D printing. For example, traditional manufacturers use ABS to make plastic wrap, water bottles, and
cups, to name a few uses. Despite its popularity for 3D printing, ABS is not the best filament for most
home users. This is because it has a high melting point that needs to print on a heated surface, or bed.
A heated printer bed is not something a lot of budget-range 3D printers come equipped with. Printing
with ABS also produces unpleasant fumes that can irritate some people. Needless to say, good
ventilation is essential. These things combined make ABS a material favored more by professionals
than amateur users.

Pros
→ A durable, strong 3D filament
→ Quite flexible and lightweight
→ Cheapest thermoplastic available at the time of writing
→ Most favored material among professional 3D printers and keen armatures

Cons
→ ABS is petroleum-based, making it a non-biodegradable material
→ Needs a high temperature to reach its melting point
→ Creates unpleasant fumes, most notable in poorly ventilated space

2. PLA 3D Filament
Price starting from: $20 for 1.75 mm, 1kg spool
PLA print temperature range: 180°C – 230°C (low)

PLA (Poly Lactic Acid) is popular for

amateurs and professionals alike. It’s a
special type of thermoplastic made from
organic materials, namely cornstarch and
sugarcane. The main benefits of PLA are that
it’s safer and easier to use, and with no toxic
fumes to worry about. Some users even find
the sweet smell of the sugar-based filament
pleasant. Compared to ABS, PLA produces
3D parts which are more aesthetically pleasing. This finish is thanks to its unique sheen and smooth
appearance.

You might think it sounds like the perfect solution, but there are some drawbacks. For one, the melting
point of PLA is much lower than ABS, and that makes it weaker. This matters if you’re printing moving
parts or exposing the parts to high temperatures. Both of these things can result in the 3D objects,
cracking, warping or even melting. If none of the above applies to you and your 3D projects, then PLA
should be your filament of choice. It will award you with superior print details and is also less prone
to printing errors during the build process.

Applications
PLA has wide-ranging uses. At the professional level, PLA filament uses include medical suturing
(stitching). We can also see PLA used for various surgical implants, including surgically implanted
pins, rods, screws, and mesh. The applications work thanks to the material’s degradable properties. All

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the aforementioned 3D printed parts break down in the human body. They can take anywhere between
six months to two years, depending on the part and its purpose. At the amateur level, PLA filament is
great for producing a whole range of consumer items. Other benefits of PLA are that it prints faster
than ABS, and there’s no need for a heated printer bed. The end products are a decent strength, durable,
and offer some degree of impact resistance. Aside from 3D printing, other products that use PLA
include food packaging, disposable tableware, and diapers, as a few examples

Pros
→ No harmful fumes, produces a sweet aroma when heated
→ Easier to work with compared to ABS (great material for beginners)
→ Compared to ABS, PLA is less prone to warping
→ Available in special effects like glow-in-the-dark colors and translucency

Cons
→ Susceptible to clogging the printer nozzle
→ Can attract moisture that makes it potentially brittle and more difficult to print
→ Less sturdy overall than ABS
3. PET 3D Filament
Price starting from: $24.99 for 1.75 mm, 1kg spool
PETG print temperature range: 210°C – 230°C

Today, Polyethylene Terephthalate (PET) is a popular 3D material. Another common use for PET is
in everyday plastic bottles. This plastic is both stable and harmless, emits no unpleasant or harmful
odors, and is 100% recyclable. In its raw state, the filament has no color and is crystal clear. Once
exposed to cold or heat the material quickly changes to a non-transparent state. A more advanced
version if PET is a filament called PETG, also marketed as Amphora AM1800.

Applications
PETT is on a list of FDA approved polymers. This makes it completely food safe, meaning it’s safe
for products like cups, and plates, etc. Needless to say, common applications for PETT filament include
food containers and various kitchen utensils.

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Pros
→ Strong, flexible, and with biocompatibility
→ Does not warp
→ Does not shrink
→ Does not absorb moisture from the air
→ Does not degrade in water
→ FDA approved; food safe
→ Prices for PETT are falling

Cons
→ Not an easy material for beginners to work with
→ Nozzle and printer bed temperatures needs fine-tuning for best results

4. Nylon 3D Filament
Price starting from: $39.99 for 1.75 mm, 1kg spool
Nylon print temperature range: 210°C – 250°C (high)

Nylon filament, also called polyamide, is

another popular choice. This is a synthetic
polymer that’s stronger and more durable
than ABS and PLA—and cost-effective. It’s
also flexible, light, wear-resistant, and less
brittle than both ABS and PLA. There are
different kinds of nylon filament available,
and what you choose will depend on which
one suits your budget and needs. The
difference between them is in the filament’s
layer bonding abilities, tensile strength, and
water absorption. You can also choose nylon
filament that has a translucent or opaque
finish and reduced shrinkage.

Applications
Nylon filament is great to use in a whole variety of applications thanks to its strength, flexible
properties, and durability. It’s particularly suited for various consumer products, tools, mechanical
components, machine parts, structural parts, containers, and a much more.

Pros
→ Strong, durable and flexible
→ Less brittle than ABS and PLA
→ 100% thermoplastic material
→ Filament can be re-melted and used again without any loss of bonding

Cons
→ Needs a high melting temperature
→ Breaks down and emits toxic fumes when heated
→ Absorbs moisture easily—proper storage is essential

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5. Flexible, TPE 3D Filament
Price starting from: $31.99 for 1.75 mm, 1kg spool
TPE print temperature range: 225°C – 235°C

TPE 3D printer filament is easily the most

flexible of all the printer materials. It is
super stretchy because of the thermoplastic
elastomers, or TPE for short. It has such
high elasticity properties that it feels like
real rubber, easily springing back into
shape like an elastic band. TPE is great to
use with most FDM 3D printers. If you
need to fabricate stretchable 3D parts that
can endure more punishment than any
regular ABS or PLA, this is your material.
Applications
There are wide ranging applications and industries which benefit from TPE filament. We can see it
used in household appliances and the automotive sector. It’s also a popular for kid's toys, wearables,
and smartphone cases, etc. For commercial use, TPE is found in medical supplies, weather seals for
windows and doors, electrical insulation, and the soles of footwear, to name a few.

Pros
→ High elasticity properties and exceptional abrasion-resistance
→ Smooth consistent diameter
→ Bonds well between layers (vital for high-quality objects)
→ Durable material with little shrinkage during the cooling process
→ No heated bed needed

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Cons
→ 3D printing with TPE is difficult for the inexperienced
→ Print nozzle needs fine-tuning for optimal performance
→ Can extrude from nozzle inconsistently

6. Amphora 3D Filament
Price starting from: $00 for 1.75 mm, 1kg spool
Amphora print temperature range: 220°C – 250°C

Amphora is a great filament for anyone who

wants to produce objects which are lustrous,
bright, and opaque. The Eastman Chemical
Company created this fancy material
specifically for 3D printing. Most common
thermoplastics have uses other than 3D printing
technologies, but not this one.

Applications
Amphora is more of a specialist type of lightweight, impact-resistant, 3D printer filament. Common
applications include mechanical parts and other objects that need a material that is of excellent strength,
highly flexible, and durable.

Pros
→ No notable odors during the printing process
→ Strong material with a high melting point (higher than regular PLA)
→ Better layer adhesion resulting in an improved finish
→ Impressive performance for bridging gaps
→ Little to no warping, cleaner overhangs overall
→ FDA-approved, making Amphora food safe

Cons
→ Not an easy material to print with
→ Printer nozzle and bed need fine tuning for best results

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▪ Powder based 3D printing
Powder-based 3D printing is an additive manufacturing method that uses raw material in powder form.
This is in contrast to the filament materials used in other, more common 3D printing techniques. The
powder material, in this case, can be either metal or plastic.
The basic principle of powder-based 3D printing is to promote the ―binding of the individual powder
particles via the controlled emission of energy. This energy source can be either a laser, a narrow beam
of UV light, or an electron beam. The specific method used for 3D printing, hardware parameters and
the size of the powder particles all play a role in determining the characteristics of the finished print.
In all other aspects, powder-based 3D printing is similar to other 3D printing techniques. The process
also starts with a 3D model of the desired design which then has to be processed by slicer software.
This software generates very thin slices of the model which will correspond
to layers that the 3D printer will build one by one.
With each successive layer of the powder raw material that the 3D printer binds together, the printer
introduces a fresh layer of unprocessed raw powder. This process repeats until the whole model has
been generated. In some cases, post-printing treatment will be needed to
achieve the material’s optimal physical and chemical properties.
To better understand the technology and working principle of powder-based 3D printing, we’ll take a
look at its two major categories: metal-based and plastic-based powder printing. Even for each
category, several methods are available.

1. Metal-based powder printing

In metal-based powder printing, metal powder is
fused together through the introduction of a high-
energy beam or an agent that promotes binding.
Just about all industrially significant metals can be
processed via powder-based 3D printing
including stainless steel, aluminum, titanium,
copper, cobalt, nickel alloy, and chrome.
However, energy requirements and appropriate
techniques may vary from one metal to another.

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For this reason, it’s rare to see a metal-based 3D printer that works well with such an expansive suite
of powder metal types.
There are four major technologies used for metal powder 3D printing;
→ Selective laser melting (SLM)
→ Direct metal laser sintering (DMLS)
→ Electron beam melting (EBM)
→ Multi-jet Fusion (MJF)

2. Plastic-based powder printing

Compared to other 3D printing methods for plastics, a
powder-based method is easily one of the most versatile.
There is a wide variety of plastic materials that can be made
into powder including silicates or polystyrene, which are
generally not available in filament form. Since plastic does
not require a lot of energy to melt, the 3D printing technology
for plastic powder does not need as much diversity, hence the
major technology used for plastic-based 3D printing is
Selective Laser Sintering (SLS).
Despite powder-based 3D printing techniques being around
for quite some time, they haven’t quite caught on at the same
level as 3D printers that use plastic filaments or resin. Right now, even SLS printers for plastic are not
available at the consumer level. The technology remains industrially relevant, however, which is
indicative of its strengths in additive manufacturing.

Pros
→ Isotropic mechanical properties
→ Complex geometries
→ Economical for small volumes

Cons
→ More expensive than other 3D printing methods

▪ Resin based 3D printing

− Stereolithography
The machines for resin-based 3D printing use neither powder nor filament; they use liquid resin.
The stereolithography process takes place in a large tank and begins with a layer of liquid polymer
spread over a platform. Since this piqued polymer is UV-sensitive, a UV laser hardens the area that

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will become one layer of your 3D print. The rest of the layer stays liquid. The platform is then lowered
and the next layer is drawn directly on top of the previous one.

When the object is complete, it is raised out of the tank via the supporting platform – much like a
submarine rising to the surface of the water – with the excess liquid flowing away.
Because a liquid material is used (and not powder), we need to add support material for overhanging
parts and parts that stick out. The supports will then be removed manually after the model is taken
from the machine. This means that the design freedom of this technology is somewhat limited. The
main advantages of materials printed with Stereolithography are smooth surfaces and a lot of finishing
and post-processing possibilities.

Materials used in this printing process include standard resin, mammoth resin, transparent resin, and
gray resin. They all feature smooth, high-quality surfaces.

− PolyJet Printing

Another technology that is based on resin is PolyJet Technology. It works by jetting resin in ultra-thin
layers onto a build tray until the model is completed. Each layer is cured by UV light immediately
after being jetted, producing fully cured models that can be handled and used immediately. This
technology produces a high level of detail.

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J. OUR HYBRID DRONE (Part by Part Breakdown)

Prototype
The Hybrid UAV drone conceptualized earlier is added with design of internal structures, Control
surfaces and Electronic equipment space. 3D PRINTING is used to produce the model of UAV.

Modular Design
The whole structure is divided into modules. Modular design is good from maintenance and repair
point of view. This modularity in the design has helped in creating, replacing and modifying the design
independently. In case of any crashes a single module can be changed making the UAV airworthy in
minimum time.

BOM
Part / Component Type Quantity
F1 – Left half
Fuselage Modular 1 (F1 + F2)
F2 – Right half
Components’ Cavity Cover (Fuselage) Modular 1
Inboard Wing Modular 2
Components’ Cavity Cover (Inboard Wing) Modular 2
Rotor Boom Attachment 2
Outboard Wing Modular 2
Flaperon Control Surface 2
Fuselage 1
Spar Inboard Structural Member 2 5
Outboard 2
Winglet Attachment 2

EXPLODED VIEW

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Joints
Interlocking joints are designed to assemble each module i.e., the wing-to-fuselage, wing-to-wing and
wing-to-winglet connections. Interlocking structures are further tightened by screws to get a fixed and
solid joint. Such joints will make the UAV easy to assemble and dismantle.

Front exploded view showing the splitting of Fuselage (F1 & F2)

Section showing the Outboard wing-to-Winglet connection

Appearance highlighting the joints

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Components’ Cavities
Space has been created for allocation of the various components responsible for achieving the flight.
The space created in both Inboard wing sections is intended for flight controller and other electronics;
perhaps responsible for flaperon movement. A larger space is created at the bottom of the fuselage,
dedicated for a battery pack and other components that may link the gimbal or others.
The image below shows the intended honeycomb structure (which will be created as an infill while 3D
printing) and the void is for allocation of components.
Section of Fuselage

Section of Drone showing the voids

Section of Inboard wing showing the components’ cavity

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Control Surfaces & Gimbal Integration
Control surfaces are required for this fixed wing type drone for faster reaction to rolling and pitching.
But, at the same time, the space available to the wing is limited. Hence, instead of having separate
elevators or flaps or ailerons, we decided to incorporate “flaperons” in the design, which satisfy the
needs of both – flaps and ailerons.

Section of Inboard wing highlighting the Flaperon

A gimbal is integrated with the fuselage near the leading edge

Side view highlighting the Gimble

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Drawings & Renderings

Fuselage

Page | 43
 Inboard Wing

Outboard Wing

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Center of Gravity

Page | 45
Parameters
General Sizing Length 505 mm
With Winglets 1870 mm
Wing Span
Without Winglets 1750 mm
Height 102.86 mm
With Winglets 676835 mm2
Wing Area
Without Winglets 650214 mm2
Empty Weight 1200 g
Weight with components & Payload 3600 g
With Winglets 5.1665
Aspect Ratio
Without Winglets 4.71
Mean Chord 353.5 mm
Propeller Diameter 14”
Center of Gravity (from LE) 271.24 mm
Fuselage Center Airfoil NACA 34118
Tip Airfoil NACA 34118
Fuselage Length 505 mm
Fuselage Span 350 mm
Center Chord 555.5 mm
Tip Chord 404 mm
Taper Ratio 0.7273
Inboard Wing Root Airfoil NACA 34118
Tip Airfoil NACA 34112
Root Chord 404 mm
Tip Chord 353.5 mm
Taper Ratio 0.875
Span 200 mm
Swept (LE) 14.4o
Outboard Wing Root Airfoil NACA 34112
Tip Airfoil NACA 34112
Root Chord 353.5 mm
Tip Chord 202 mm
Taper Ratio 0.5714
Span 500 mm
Swept (LE) 18o
Flaperon Length 60 mm
Flaperon Width 300 mm
Winglet Airfoil NACA 34112
Length (Curve) 87.6298 mm
Area 13310.6 mm2
Swept (LE) 20.2455o
Root Chord 202 mm
Tip Chord 121.2 mm
Aspect Ratio 0.5769
Taper Ratio 0.6

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K. CAMERA HOUSING & GIMBAL

The principal focus would be to design the gimbal such that it fits comfortably into the mainframe of
the drone without compromising the aerodynamics of the aircraft. The Camera housing will safeguard
the camera; mount it, and provide crash-protection. Aluminium casings, or neoprene gaskets will be
used to construct the camera housing. The housing will be a second skin to the gimbal to ensure
compactness and reduction in drag. Transmission compatibility will be checked thereafter.

Damping Vibration Absorber

Gimbal with in-built cameras is sensitive to vibrations. High
vibration levels can cause a range of problems, including
increased wear-and-tear of a gimbal, sultry images, or videos.
In extreme cases vibration may lead to sensor
clipping/failures, possibly resulting in estimation failures and
fly- away. Well-designed airframes damp/reduce the
amplitude of specific structural resonances at the autopilot
mounting location. Further isolation may be needed in order
to reduce vibration to the level that sensitive components can
handle.
These units have the very important function of reducing or
damping the medium to high vibration frequencies from the
drone reaching the camera while still allowing low-frequency actual board movement to take place in
conjunction with the drone frame.
Some DIY anti-vibration dampers are made from foam, rubber balls, and even earplugs. However,
these are a very vital piece of equipment and don’t cost a lot of money so it is probably a good idea to
have the best dampers you can afford.
A professionally made gimbal damper will be made with carbon fiber with an anti-vibration plate with
4 rubber balls specifically designed for the gimbal.

Thermal Camera
Thermal Imaging sensors are commonly referred to terminology such as thermal camera, temperature
camera, heat vision camera, infrared camera, thermal imaging sensor, heat signature camera, and even
thermal heat vision sensor. In this post we will refer to this type of imaging as infrared or thermal
imaging. All objects (above absolute zero) emit infrared energy as a function of its temperature.
Infrared energy is generated by the vibration of atoms and molecules. The higher the temperature of
an object, the faster its molecules and atoms move. This movement is emitted as infrared radiation
which our eyes cannot see but our skin can feel. Thermal imaging is the use of a special infrared camera
sensors to illuminate a spectrum of light invisible to the naked eye. Thermal energy is invisible to the
naked eye and works in different ways; it can be emitted, absorbed, or reflected. Infrared cannot see
through objects but can detect differences in radiated thermal energy between materials. This is known
as thermal bridging or heat transfer. To sum it all up thermal imaging cameras are precise non-contact
temperature measurement devices.

The amount of thermal energy in a scene has a direct impact on the infrared image. Typically, the
amount of infrared energy is attributed to the diurnal cycle, solar loading, and thermal crossover. The
diurnal cycle is the daily heating and cooling of the Earth’s surface from the sun. Solar loading is when
a scene absorbs more radiation from the sun’s rays the temperature differences between objects
decrease. When two different objects in a scene are indistinguishable this is known as thermal
crossover.

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With these factors in mind, early morning or late-night conditions are ideal. Thermal cameras are also
known by various names including;
▪ Thermal Camera Heat
▪ Vision Camera Thermal
▪ Imaging Sensor Thermal
▪ Imaging Camera
▪ Temperature Sensor Camera
▪ Thermal Heat Vision Sensor
▪ Heat Signature Camera
▪ Heat Sensor Camera
Thermal vision cameras make pictures or video from heat, not visible light. Heat (infrared thermal
radiation) and light are both parts of the electromagnetic spectrum.

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3-Axis Gimbals
A gimbal whether handheld or mounted on a drone is designed to give the camera operator the
independence of photographing or filming without camera vibration or shake. Generally powered by
three brushless motors (3-axis), the gimbal has the ability to keep the camera level on all axes (pan,
roll, tilt) as the operator moves the camera. An inertial measurement unit (IMU) responds to movement
and utilizes its three separate motors to stabilize the camera.

With the guidance of algorithms, the stabilizer is able to notice the difference between deliberate
movement such as pans and tracking shots from unwanted shake. This allows the camera to seem as if
it is floating through the air. Having a top-quality drone gimbal is essential to capturing great aerial
film, photography, 3D mapping, lidar, photogrammetry, and other sensor driven imagery.

For drones to be widely used across different sectors, it is essential that UAV gimbal stabilization
technology keeps in line with drone innovation. This is very much the case so far. Here is a quick
overview of the design and workings of a drone gimbal, including the gimbal components. With this
knowledge, you will be able to choose the best drone gimbal for your aerial cinematography. Knowing
the aerial gimbal components will help you if you need to troubleshoot any gimbal issues.

From 3 axis brushless motors, Gimbal Control Units (GCU), IMU, and anti- vibration systems 3-axis
gimbals provide better video stability than 2-axis gimbals. This is because 3-axis gimbals stabilize
your video on all 3 axes (yaw, pitch, and roll) while a 2-axis gimbal will stabilize only on the pitch
and roll axis. Jittery horizontal, jello, or rolling shutter movement, is more obvious in videos taken
using a 2-axis gimbal due to the lack of stabilization in the yaw axis.

3-axis gimbals are able to greatly reduce and sometimes completely eliminate jello due to the third
motor, which helps absorb unwanted movement in the yaw axis. However, 3-axis gimbals are heavier
and more expensive than their 2-axis counterparts. They also draw more battery power due to having
more motors.

Gimbal Brushless Motors and Angles

3 × Servo Driver Modules (Pan, Roll, Tilt) to power the gimbal. Most drones’ gimbals components
including the motors are designed for a particular camera or sensor.
This design method achieves almost perfect filming because the gimbal has been fine-tuned to the
weight and balance of the individual camera.
Almost all drone gimbals today are powered today by brushless motors. At the very basics of motor
design, the difference between a brushed and brushless is a dead giveaway.

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Drone Gimbal Axis Movements
Pan (Yaw): A yaw motion is a lateral side to side movement of the gimbal/camera to the left or right.
Most drone gimbals have 360-degree movement.

If you have a drone with retractable arms, then you have a full 360 degree of unobstructed views. The
DJI Inspire 1 and Walkera Voyager 3 drones have retractable arms.

Roll: A positive roll angle lifts the gimbal/camera to the left or right. The above has a +45 /-45 degrees
of roll movement.

Tilt (Pitch): An up and down movement of the gimbal and camera. In the above gimbal diagram, we
can see this has a -90 to +15 degree of movement.

3D CAD Model

Motors used in Gimbal

Quanum 2208 is the perfect size for a
GoPRO class camera (100-200g). It has a
superb Fit and Finnish and is engineered
to have a lean profile for easy integration
into your set-up. Quanum 2208 has
preloaded bearings for slop free precision
mount and 14 poles (one of the highest for
a motor this size) for ultra-smooth motion.
If it needs to be stabilized Quanum Brushless Gimbal Motors are up to the task.

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 Details
KV (RPM/V) 114.00
Resistance (mH) 23.00
Shaft A (mm) 3.17
Length B (mm) 24.00
Can Diameter C (mm) 28.00
Can Length D (mm) 12.00
Total Length E (mm) 26.00

Specifications
Camera Range 100 – 200 grams
(GoPro Size) Poles 14P12SKV: 114
Idle current amps 0.03A
Resistance 23 mH ohm
Weight 39 g
Voltage 6 – 14 V
Lower back mounting 16 × 19 mm
Upper top mounting 12 mm (hole to hole)
Connection 3 wire servo style connection; 190 mm long leads
Mounting Thread M3

L. CFD ANALYSIS

Geometry

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Mesh

Setup

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Page | 53
Calculations

Test AOA Velocity CL/CD FL FD

1 0 20 6.604256261 10.057026 1.5228097
2 0 21 6.659452423 11.087443 1.6649181
3 0 22 6.709738432 12.169741 1.8137429
4 0 23 6.761470758 13.301899 1.9673086
5 0 24 6.805349694 14.484305 2.1283704
6 0 25 6.851253723 15.719966 2.2944656
7 2 20 12.80610294 21.975061 1.7159835
8 2 21 12.90730244 24.236378 1.8777261
9 2 22 13.00205751 26.608673 2.0464971
10 2 23 13.09341616 29.090425 2.2217598
11 2 24 13.14712579 31.529825 2.3982295
12 2 25 13.22812204 34.221911 2.5870574
13 5 20 15.49280299 39.714215 2.5633976
14 5 21 15.57229914 43.801696 2.8127957
15 5 22 15.6483448 48.090542 3.0732031
16 5 23 15.7206524 52.582455 3.3448011
17 5 24 15.78801932 57.274719 3.627733
18 5 25 15.85273681 62.165698 3.921449

Results

Figure 1: Pressure contour on wing at AOA 2

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Figure 2: Pressure contour on wing at AOA 2

Figure 3: Pressure contour on wing at AOA 2

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Figure 4: Velocity contour on wing at AOA 2

Figure 5: Pressure contour on wing at AOA 2

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Figure 6: Pressure contour on full body at AOA 2

Figure 7: Velocity streamline on wing

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Figure 8: Velocity streamline on airfoil NACA 34112

Figure 9: Velocity streamline on wing

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Figure 10: Velocity vector on wing

Page | 59
Page | 60
CONCLUSION

Thus, the idea generated for a drone is further developed with a design in mind. All
the theoretical surveys, mathematical calculations are calculated in accordance with
the technical specifications given in the proposal keeping the needs and requirements
in mind.
Prototype is produced successfully and further refinement and tuning can be done as
per requirement.
There is an ultimate need to make cost-efficient, inexpensive, multi-functional and
environment friendly drones that adhere to all the purposes of the military due to its
high demand, increased endurance necessities, and high crash occurrences.

REFERENCES

o https://www.cbinsights.com/research/drone-impact-society-uav/
o https://www.coptrz.com/a-guide-to-fixed-wing-drones/
o https://www.unmannedsystemstechnology.com/category/supplierdirectory/platform
s/hybrid- vtol-uav-manufacturers/
o https://oscarliang.com/brushed-vs-brushless-motor/
o https://oscarliang.com/quadcopter-motor-propeller/
o https://oscarliang.com/choose-propellers-mini-quad/
o https://emaxmodel.com/catalog/product/view/id/429/s/gt2826/category/1921/
o https://www.datarespons.com/drones-wireless-video/
o https://www.instructables.com/id/FPV-System-for-Drones/
o http://www.codeplayon.com/2019/01/drone-wireless-video-transmission-
technologies- challenges-and-probable-solutions/
o https://www.dronezon.com/learn-about-drones-quadcopters/what-is-drone-
technology-or- how-does-drone-technology-work/
o https://www.goldmansachs.com/insights/technology-driving-innovation/drones/
o https://3dinsider.com/3d-printing-materials/
o https://3dinsider.com/powder-based-3d-
printing/#:~:text=Powder%2Dbased%203D%20printing%20is,raw%20material%2
0in
o %20powder%20form.&text=With%20each%20successive%20layer%20of,whole%
20 model%20has%20been%20generated.
o https://imaterialise.helpjuice.com/design-printing/resin-based-3d-printing

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