|Oct 03, 2012, 09:55 PM|
CURRENT PROJECT: Surveillance Drone Quadframe Hexacopter Build
This copter build & blog was created for a request on how to build a reliable and affordable surveillance drone with normal off the shelf equipment for use by small budget PD's and FD's. The copter is designed for really one major function, a high hovering platform for the systematic observation of a particular designated area of interest by visual, electronic, photographic, or other means. The platform may also be used as a communications relay system for short range point to point communications in perching mode.
I have decided to name this copter : "Tarantula"
We begin by listing the equipment which will comprise the drone's hardware portion of the build.
Type: IPower 2212Q - 22*12mm
135W, 400mm long wires with soldered 3.5mm male bullet connectors,
Shaft: short shaft, 3.17 x 41mm
Weight: 65g x 6 = 390gr
Max Current: 12.2A
Good quality motor - perfect for 10x4.5
With a 3s battery we are looking at 460 x 6 = 2760gr of thrust a max (6540rpm) which is equivalent to 6 lbs of thrust. If we go to a 4s battery we can boost our thrust to 8.5 lbs. On this build we will concentrate on the 3S battery for power knowing we have the 4s available for extra power if needed.
Shaft Diameter 4mm
Motor Diameter 42x24mm
Weight 70grx 6 = 420gr
Idle Current@10v(A) 0.2
Max Cont. Current 14.5A
Max Cont. Power(W) 200W
Internal Resistance .143 ohms
Standard Motor Props:
Gemfan: carbon reinforced propellers 10 x 4.5 ABS
APC11038SF APC PROP 11X3.8 slow flyer
Optional Motor Prop:
APC13047SF APC 14X4.7 electric slow fly prop
Hobby-Lobby 35A Product#: ERCE035RD (6) Compact (28x38x8mm) and light (35g) this "Rapid Drive" ESC is designed for use on multi rotor aircraft only. Suitable for use with 2-4 Lipo cells, eRC's "Rapid Drive" speed controllers have a blazing fast response rate to the motor. 210gr total
Quadframe.us medium weight SixCopter with 16mm aluminum arms. 680mm motor to motor which includes motor mounts. 720gr
Quadframe.us Gimbal 2 axis LL4 roll and pitch control using 2 EMAX ES08MD servos. 95gr
CNCHelicopter.com power convert cable T plug male to JST male x 6
Landing legs of my own design which will comprise of 3 sets of CF legs connected 1/3 way out from hub on arms.
Flight Control Unit:
For flight testing will start with the V1 FC-1212-S complete with Compass and GPS but will not be offered on PD and FD units. 120gr
Offered on PD and FD units:
Standard Unit: Naza-M-GPS 66.3gr
Upgrade Unit: WK-M full 50 waypt system 150gr
Onboard Video System:
Standard System: GoPro with GoPro Micro Video/Contol Board for realtime viewing. So you will have realtime view and use SD to record flight. Adapter from ReadyMadeRC.com 99gr
Upgrade system: FPV fever HP520 CCD 10x optical zoom from CNCHelicopter.com 88.5gr piggybacked with Contour 1080p Video Camera with SD to record flight. 125gr eBay or Amazon
Both on board Video systems will have an OSD setup which is undetermined as this time.
Quick Calculations of average flight times. Mins are averaged down to whole min.
Standard 2212Q Motor:
5400mah battery at 2086gr on 10x4.5 = 67% throttle with 10 mins of flight time.
11000mah battery at 2256gr on 10x4.5 = 73% thottle with 19 mins of flight time.
5400mah battery at 2086gr on 11x3.8 = 57% throttle with 11 mins of flight time.
11000mah battery at 2256gr on 11x3.8 = 62% thottle with 21 mins of flight time.
Optional T-Motor MT3506-25 Kv 650 Motor:
5400mah battery at 2086gr on 14x4.7 = 38% throttle with 16 mins of flight time.
11000mah battery at 2256gr on 14x4.7 = 42% throttle with 29mins of flight time.
5400mah battery at 2600gr on 14x4.7 = 50% throttle with 11mins of flight time.
11000mah battery at 2600gr on 14x4.7 = 50% throttle with 24 mins of flight time.
|Oct 12, 2012, 10:31 PM|
The Build is Now ON
Finally the build is on after completion of a very busy travel schedule. I was able to complete the arms with motor mounts and 2212Q motors installed. I also started on the center section of Hexacopter installing the esc's. The upper center plate shown below with copper foil installed to cut down on the EMF produced by the esc's and current that runs through the wiring.
I mounted the distribution panel but have decided to use a 6 to 1 connector to deans for power cable. I may set up the distribution panel for secondary power to different electronics I may carry on board. I ordered a few things from CNCHelicopters.com such as the power cable and extra copper foil.
I will be using the Devo 10 Radio system on this copter with the long range Rx1002 receiver. For the Surveillance side of the copter I will carry slide in and out video units and I will carry a special microphone system onboard for directed listening.
I put a few pictures of the build below starting with the inside view of the bottom hub plate showing the distribution panel and esc wiring which will use JST female connectors to the power cable.
The next picture shows the bottom of the center hub where the escs are mounted followed by the underside of the top hub plate with the copper foil installed. If I had thought of it earlier I would have copper foiled the bottom of the bottom plate before installing the escs. I may go back and do this before continuing assembly.
The last picture shows the aluminum arms with the motor mounts and motors mounted. Since all this assembly is common sense building I didn’t include any actual construction sequences. I think everyone can figure it out.
|Oct 15, 2012, 08:59 PM|
The parts arrived from CNCHelicopter today and started work once more on the Hexacopter. I soldered all jst’s to the esc’s. I then started laying out and installing electronics on top hub. I used old spare parts and build a mount for the battery and 2 axis mount under bottom hub and will install camera mount when it arrives. I am not sure it will all fit inside the bottom dome, we shall see. On the upper hub I installed another layer of copper foil. I will start installing the arms tomorrow. Just a couple of pics below.
|Oct 16, 2012, 08:57 PM|
Parts arrived from Quad frames today which included the extra dome for bottom of main hub, 2 axis camera mount with servos and shock mounts. I changed out wire from USB input device to the FC unit since I found a bad wire yesterday. I repaired the wire but since I had a spare wire I replaced it.
I completed power cable wiring and ran cables below to battery area. Test fitted the arms and motors on board and checked the wiring to make sure I had correct length. I will have to wait until Rx1002 replacement comes in so I can bind the Rx and then start setting esc high and low throttle settings. I can then check motor direction is correct and start closing up the hub compartment. If I get time I will build the new 2 axis camera mount and install the new servos that came in today. The mounting of the electronics for the V1 control system went very well. I installed shock mounts on FC and will install the other set on the camera mount. I also built a tower for the gps head which mounts on one of the motor arms. While I was at it I powered up electronics and did a GPS pacc check on head and inside I was getting 6 sats with 200 pacc so I would say it is working fine. Just a few pictures below showing progress.
|Nov 06, 2012, 06:42 PM|
I was able today to get a little work done on Hexacopter but another big storm moving in so had to stop work and get ready for the snow and 60mph winds, again
Here is the progress today. I finally got all wiring completed, esc's programmed and motor direction set for each. I have now closed up the hub section and you can see by pictures the esc's plugs coming up on top hub for install to output side of FC. The bottom of hub shows battery side wiring from esc's ready to plug into 6-1 power plug to deans.
I provided a picture of the 2 axis camera mount installed but picture did not come out as well as I would like. I had to remove while reassembling the hub frame but once I reinstall I will try to get some good shots of the mounts shock system. I am finding it harder now to do what I wanted with dome on top and bottom but will continue to try to resolve the space issue allowing bottom dome to be installed.
|Nov 12, 2012, 07:32 PM|
I finally gave up on locating ready-made landing legs for a fair price and built my own from spare parts. I will have to get some rubber boot connectors to install compression struts on these legs to complete build.
I installed all the basic FC electronics and will start a new user profile for the FC and PID setting as I get time. I will then install all connectors after completing twist and EMI/RFI prevention work.
It is finally coming together and I hope to be testing Hex before spring depending on weather. This flight control is rock solid with over 50+hours of testing on quads letís see how well it is going to do on Hexacopters. It should be an interesting testing period.
Below are some pictures.
|Dec 03, 2012, 06:41 PM|
Slow going but consistently so! I had a few setbacks in this build mostly finding after a complete system is tested and installed that there are wiring issues or I was not happy with the way I constructed it. I have now completed the building stage for testing the unit. The final assembly will be concluded after the test flights. I will be testing the Hexacopter with the XAircraft FC-1212-S series full flight control system including compass and gps along with XA firmware FC1212-S V1.33 AHRS-S V1.23 and GPS-S V 1.01.
I will initially be testing with XA firmware but after initial test flights completed will swap with another S-series controller system acquired recently which I have striped clean and loaded my own firmware. This is also the reason things have been a little slow. I have had to rework the firmware for a Hexacopter since I originally wrote the firmware for a quadcopter. This took a little time and then a lot of simulator work to verify set up correct, I hope? This is the reason for using the XA firmware first to make sure the copter flies as it should. Once working correctly then will install the one with my firmware. I want to test both and see whose firmware is better suited overall. This firmware will be used on my own designed and constructed flight control system later. (More on that at a later date)
Ok just a few pictures below and yes I moved the gps to center of copter for testing.
|Jan 02, 2013, 05:48 PM|
Sorry for no updates lately but weather here in Connecticut Sucks big time
If we aren't buried in snow then its too wet to fly. When the snow is hard and things dry out then the winds are 25mph. Does not make for good testing weather so I will hold off flight testing until the weather is more favorable in the spring.
|Feb 07, 2013, 11:16 PM|
Hi everyone just a quick update.
The copter is built and ready for flight test but it looks as though it is going to be a while with all the bad weather we have been getting over the last month or so. Now a major blizzard incoming so we are on to another project for the time being. The new project is listed on my blog. The time duration X-Sspider design. See you in the spring on both copters.
|Apr 03, 2013, 08:02 PM|
Still waiting for nice weather to finally arrive. We have had a terrible winter here for flying and the opening spring has included more snow and windy conditions. The ground is finally free of snow but wind has been a real issue. The average day brings 20mph winds gusting to 30mph. Hope to be up soon and testing the new Hexacopter. Believe I am going to switch out the FC from the XAircraft V1 to the Naza before the first flight.
|May 01, 2013, 08:12 AM|
United States, TN, Fayetteville
Joined Mar 2013
Have enjoyed your blog and interested in how the results of your first flight. I've been getting a lot of time on the X-830D. Came to the quad from helis and getting the bugs out for FPV. I am a full time narcotics officer for the county here and hope to be able to use the 830 for the department. I would like to move up to a hex and was looking at the S-800, but apparently they have problems with the arms flexing and warping.
Good luck with the project.!
|Nov 18, 2013, 09:09 PM|
South Korea, Busan
Joined Nov 2012
Some good months later, someone is curious about how it flies?
I want to build a 650 hexa myself and not sure about the motors / prop combo?
Could I use my existing 980 kv/1045 props I already have on my quad?
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