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Task: Propeller Design Report

Introduction

Propellers are essential components in drones, converting rotational motion into thrust to enable flight. For this task, the objective was to design a toroidal propeller capable of generating a lift of approximately 9 Newtons. Both clockwise (CW) and counterclockwise (CCW) propellers were designed to ensure stability and functionality. The propellers were modeled using the Autodesk Fusion 360 .

Drone Propellers

Function and Working

• Purpose: Propellers generate thrust by creating a pressure differential between the top and bottom surfaces of the blade. This allows drones to ascend, descend, and maneuver.
• Mechanics: The rotation of the propeller blades causes airflow. The angle of attack and blade shape dictate how much thrust is produced.
• CW and CCW Propellers: To counteract torque (rotational force), drones use pairs of propellers rotating in opposite directions.

Reading Propellers

• Labeling: Propellers are often marked with dimensions like 5045 (5-inch diameter, 4.5-inch pitch). The pitch refers to how far the propeller would travel in one rotation if it were moving through a solid medium.
• Orientation: CW propellers are mounted on motors rotating clockwise, while CCW propellers are for counterclockwise rotation.

Step-by-Step Process in Fusion 360

Design Workflow

1.Create the Base Profile:

• Open Fusion 360 and start a new design.
• Use the Sketch Tool to draw a 2D profile of the blade’s leading and trailing edges on the X-Y plane.
• Ensure the blade's shape accounts for aerodynamic principles (e.g., a slight camber for lift generation).

2.Generate the Blade Shape:

• Use the Loft Tool to create a 3D blade by connecting the root and tip profiles of the blade.
• Apply a slight twist using the Form Tool to simulate the pitch angle, enhancing airflow efficiency.

3.Design the Hub:

• Create a cylindrical hub using the Revolve Tool. Ensure internal threading matches the motor shaft specifications.
• Include keyholes or flat sections to secure the propeller on the BLDC motor shaft.

4.Replicate for Multiple Blades:

• Use the Circular Pattern Tool to replicate the blade design around the hub, creating a toroidal configuration.

5.Final Adjustments:

• Smooth edges and surfaces using the Fillet Tool to reduce turbulence.
• Check dimensions against required specifications (e.g., Marvel’s dimensions).

Features Used in Fusion 360

• Sketch Tool: For creating 2D profiles.
• Loft Tool: For transforming 2D sketches into 3D geometries.
• Revolve Tool: For creating symmetrical hub components.
• Circular Pattern Tool: For arranging multiple blades around a central axis.
• Fillet Tool: For smoothing sharp edges.
• Parameter Tool: To input and adjust specific dimensions dynamically.

Conclusion

This task provided valuable insights into the design and function of drone propellers. Using Fusion 360, the process of designing CW and CCW toroidal propellers was streamlined, emphasizing both aerodynamic efficiency and practical fit with BLDC motors.

“Aviation is the branch of engineering that is least forgiving of mistakes.” – Freeman Dyson

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Task: Assembling a Drone using eCalc

Introduction

This report documents the design process of a drone with an empty weight of 800 grams using data obtained from eCalc. The aim is to optimize payload capacity, thrust-to-weight ratio, endurance, and overall performance while justifying the selection of materials and components.

Material Selection

For the drone frame, carbon fiber was selected due to its exceptional strength-to-weight ratio, rigidity, and resistance to deformation. It ensures the drone remains lightweight (frame weight: 200 grams) while being capable of withstanding mechanical stress during flight. Its non-corrosive properties make it ideal for long-term use in various environments.

Component Selection

1.Motor:

• Model: T-Motor MN3110-700 (700KV)
• Justification: This motor provides a balance between efficiency and power, ensuring sufficient RPMs for stable hover and maneuverability.

2.Propellers:

• Type: Generic 10-inch with a 4.7-inch pitch
• Justification: Optimized for high efficiency and compatibility with the motor, ensuring adequate thrust.

3.Battery:

• Type: LiPo 2500mAh, 4S, 35/50C
• Justification: This battery offers adequate capacity to sustain a hover flight time of 9.5 minutes while maintaining a manageable weight of 260 grams.

4.ESC (Electronic Speed Controller):

• Type: 20A max ESC
• Justification: Matches the current and voltage demands of the selected motor, providing reliable control without overheating.

5.Frame:

• Material: Carbon fiber (weight: 200 grams)
• Justification: Lightweight and durable, enhancing stability and endurance.

Results from eCalc

Key Performance Metrics

1.Thrust-to-Weight Ratio:

• Achieved: 2:1
• Implication: This ensures stable flight with room for payloads of up to 1153 grams.

2.Hover Flight Time:

• Achieved: 9.5 minutes

3.Mixed Flight Time:

• Achieved: 6.8 minutes

4.Total Weight:

• Frame Weight: 200 grams
• All-Up Weight (including payload): 1548 grams

5.Max Speed:

• Achieved: 59 km/h

6.Efficiency at Hover:

• Achieved: 88.7%

7.Estimated Temperature of Motor:

• At Hover: 27°C

Analysis

Payload and Endurance

The thrust-to-weight ratio of 2:1 provides ample room for payloads while maintaining stable flight. The hover time of 9.5 minutes is ideal for most mid-range applications, ensuring efficient energy use from the battery.

Component Compatibility

The motor, ESC, and propellers are well-matched, as evidenced by the efficiency and stable RPM performance. The selected battery complements the overall design, allowing sustained operation without overheating.

Takeaways

1. The importance of thrust-to-weight ratio in drone design.
2. Understanding the balance between weight, power, and endurance.
3. Learning to interpret motor and battery datasheets for optimal selection.
4. Familiarization with tools like eCalc to simulate performance metrics.

Conclusion

By carefully selecting lightweight yet durable materials and compatible components, the designed drone achieves optimal performance metrics. The process highlights the importance of balancing payload capacity with endurance and efficiency.

“Aviation is poetry. It’s the finest kind of moving around, you know, just as poetry is the finest way of using words” – Jessie Redmon Fauset

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Task :DGCA, ICAO, SARPs, QCI, BIS, and Stakeholders Regulations.

Introduction

The Directorate General of Civil Aviation (DGCA) and other legal frameworks such as ICAO, SARPs, QCI, BIS, and stakeholders play a crucial role in ensuring the safety, efficiency, and regulation of aviation practices in India and globally. This report outlines their establishment, key treaties, and operational protocols, with a particular focus on laws and regulations related to unmanned aerial vehicles (UAVs) or drones.

DGCA (Directorate General of Civil Aviation)

• Establishment: DGCA was established in 1927 under the Aircraft Act of 1934.
• Founding Treaty: Aircraft Act, 1934, and subsequent rules.
• Purpose: It regulates civil aviation in India, ensures airworthiness, and oversees air transport services.
• Scope: Applicable in India.
• Key Areas: Aircraft registration, certification, licensing of pilots, safety inspections, and implementation of ICAO standards in India.

ICAO (International Civil Aviation Organization)

• Establishment: 1944 under the Chicago Convention.
• Founding Treaty: Chicago Convention (Annexes 1-19).
• Purpose: It promotes the safe, orderly development of international civil aviation globally.
• Scope: Global.
• Key Areas: Standardizes aviation laws, including air navigation, airport design, and border-crossing procedures.

SARPs (Standards and Recommended Practices)

• Annexation: SARPs are documented under the 19 Annexes of the Chicago Convention.
• Purpose: Provides the framework for uniform aviation safety standards globally.
• Scope: Global.
• Key Areas: Establishes operational protocols for air traffic management, aircraft operations, and safety measures.

QCI (Quality Council of India)

• Establishment: 1997.
• Founding Treaty: Joint initiative by the Government of India and industry associations (CII, FICCI, ASSOCHAM).
• Purpose: Promotes quality standards across industries, including aviation.
• Scope: India.
• Key Areas: Certification of processes, ensuring quality and safety compliance.

BIS (Bureau of Indian Standards)

• Establishment: 1986 under the BIS Act.
• Purpose: Develops and implements standards for various sectors, including aviation.
• Scope: India.
• Key Areas: Certification of aviation equipment, including drones.

Stakeholders

• Stakeholders in aviation include airlines, airport operators, air navigation service providers, and manufacturers of aviation equipment. Each plays a role in maintaining safety and adhering to DGCA and ICAO standards.

AIP (Aeronautical Information Publication) Review

The AIP provides essential information about airspace use, including drone operations. Key points include:

Drone Size Classifications

• Nano Drones: Up to 250 grams.
• Micro Drones: 250 grams to 2 kilograms.
• Small Drones: 2 to 25 kilograms.
• Medium Drones: 25 to 150 kilograms.
• Large Drones: Above 150 kilograms.

Airspace Zones for Drones

• Red Zones: No-fly zones. Permission from the DGCA is mandatory to operate in these areas.
• Yellow Zones: Controlled airspace. Permissions are required from the Air Traffic Control (ATC) and DGCA.
• Green Zones: Uncontrolled airspace where drones can fly without prior permission, up to the prescribed height limit.

Requirements for Flying in Each Zone

• Red Zone:
  • DGCA approval.
  • Specific operational and safety protocols.
• Yellow Zone:
  • ATC and DGCA permissions.
  • Compliance with traffic management regulations.
• Green Zone:
  • Adherence to altitude limits and privacy laws.

Relevant Articles and Sections

• Aircraft Act, 1934:
  • Section 5: DGCA's authority to issue rules.
  • Section 8: Licensing of personnel.
• Drone Rules, 2021:
  • Section 8: Classification of drones.
  • Section 12: Registration requirements.
  • Section 21: Remote pilot licensing.

Conclusion

Understanding the laws and regulations established by DGCA, ICAO, SARPs, QCI, BIS, and other frameworks is essential for ensuring safe and lawful aviation practices. The review of the AIP highlights the importance of adhering to airspace zones and drone-specific rules.

By adhering to these regulations, aviation operators and drone pilots can contribute to a safer and more efficient airspace, ensuring that technological advancements in aviation are used responsibly and sustainably.

“Both optimists and pessimists contribute to our society. The optimist invents the airplane and the pessimist the parachute”-Gil Stern