TeslaQuad - self made / designed mini Quadcopter

[teslahed]

About time i posted up some details of my current project - my first attempt at a CAD mini quadcopter.

My idea was to produce a mini quadcopter design based around hobbykings cheap carbon fibre square tube sections using nylon bolts to clamp plywood (or G10 fibreglass, eventually) together. In a hard crash the nylon should break saving everything else. I am hoping to produce a stiff and strong frame that isn';t too heavy for throwing around in small spaces and general fun flying without worrying about destroying anything more expensive. It';s sized for 5 inch props but you can cut the arms to different lengths if you want. I made the arms on mine slightly longer than the arms on the X250 mini quadcopter i had previously, just to make it a little bit more stable.

I used Inkscape which is a free 2d CAD program to design the first prototype which i got cut on a friends laser cutter from cheap 3mm plywood;



I was quite surprised to find it all went together on the first attempt;



I shifted over all the gear from a previous mini quad i had crashed a few times too many (frame was mostly hot glue and badly overweight);


http://www.multi-rotor.co.uk/index.php?topic=540.0

The maiden testflights went well, both indoors and out;

http://youtu.be/Zh_IpEORl3I

http://youtu.be/wdqmwpSnBoc

And once i had it PID tuned it flew acrobatically too;

http://youtu.be/O4FB6csr6z4


(Current PID settings).

I';ve also attached my home made multiwii controller, partly so i can show off by claiming i made it all myself ::) And partly because it';s lighter than the flyduino multiwii controller i replaced;

http://www.multi-rotor.co.uk/index.php?topic=806.0

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Total flying weight is 360 grams including a 3 cell 960mAh battery. The frame is 74 grams on it';s own;






(scales turned off just as i took the last pic  )

The hardware i have mounted is as follows;

Some 12 amp hobbyking blue series ESCs (flashed with the simonK firmware);
( http://www.hobbyking.com/hobbyking/store/__11429__HobbyKing_12A_BlueSeries_Brushless_Speed_Controller.html )

AX 1806N 2100kv Brushless Micro Motor (19g) recommended by Marty (Neagron);
http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=5431

Giant shark Prop adapter 3mm shaft (Grub Screw Type);
http://www.giantshark.co.uk/product/169654/prop-adapter-3mm-shaft-grub-screw-type

Flyduino 5 inch props;
http://flyduino.net/5030-2-bladed-Propeller-Set-Green-8-pcs-4-CW-and-4-CCW
http://flyduino.net/5030-2-bladed-Propeller-Set-Orange-8-pcs-4-CW-and-4-CCW

Homemade multiwii flight controller with MPU6050 sensor chip;
http://www.multi-rotor.co.uk/index.php?topic=806.0

ZIPPY Flightmax 1500mAh 3S1P 25C (UK Warehouse)
http://www.hobbyking.com/hobbyking/store/__34631__ZIPPY_Compact_1500mAh_3S_35C_Lipo_Pack_UK_Warehouse_.html

Hobbyking Extruded (cheap) carbon fibre square tube section;
http://www.hobbyking.com/hobbyking/store/__9012__Carbon_Fiber_Square_Tube_750x10_5mm.html (never in stock)
http://www.easycomposites.co.uk/products/carbon-fiber-section/carbon-fibre-box-section-10mm-8mm.aspx (not quite a cheap)
http://www.multi-rotor.co.uk/index.php?topic=231.0

The next stage is to redesign the motors mounts to make them slightly stronger and provide a couple of MM more clearance for the motors, then to try and get it cut out from fibreglass G10 instead of plywood. And after that, go into mass production, make my fortune and take over the world with an army of flying drones

Probably not really - but once i have the design finished i may see if i can get them cut cheaply somewhere to sell a few if anyone is interested, and if anyone does have a cheap laser cutter they would like to use to churn a few out with, give me a shout!

Cutting services provided by Ian (Smeagol) - message him via the forum if you have a project you want to get cut and he might be able to help!

[teslahed]

Added a few improvements as well as lightening holes on the latest version. I got some G10 fibreglass in the post today so hopefully i will get to test this at some point soon now.

[Flyinegypt]

Very nice. Obviously scaelable if you wanted to build a bigger quad.
Will your friends laser cutter handle the fibreglass ok?

[teslahed]

Will your friends laser cutter handle the fibreglass ok?

Good question - i';ve booked some time on the laser cutter for this saturday so i will get to find out then. It';s 1.6mm think G10 if that helps at all?

It cut through 3mm plywood fine. If you have any advice on the settings relative to that I';m all ears!

http://www.ebay.co.uk/itm/290857710019?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

[teslahed]

Anyone wondering about further progress with the quadcopter - things have stalled on the laser cutter unfortunately. It wont cut fibreglass and there was a problem with the last batch of plywood so i haven';t been able to test my latest design in wood either.

More positively i';ve made progress with FPV. I';ve attached a small screen to my transmitter;



Along with some cheap video radio gear;
http://www.hobbyking.com/hobbyking/store/__15295__5_8g_200mw_FPV_Wireless_AV_Tx_Rx_Set.html

and some 5.8GHz Circular Polarized spiroNet Antenna;
http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=31647

And a small 808 #16 ';spy'; camera that comes with a video out;
http://www.multi-rotor.co.uk/index.php?topic=1056.0

which seems to work well enough to fly;



I';ve only managed two short test flights so far but they went well in the sense that i went around in a few circles, didn';t crash, and managed to land when i wanted to without taking my eyes of the screen.

Unfortunately i ran out of power in the camera';s battery half way through the second flight. Fortunately i was able to power up and see it to start flying line of sight withing a second or two so no damage was done but that was the end of flying for the day.

First flight;
http://youtu.be/XTzA_HEiam0

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http://youtu.be/SKlktt3mJfk

http://youtu.be/CLpBtj3_A5M

http://youtu.be/5cyme1JrdEs

Starting to get the hang of basic flying around now.

[teslahed]

I really need to get some cheap video goggles...

[Gaza07]

I really cant think of a comment       
I hope it works well 

[mickyt]

Yeah i think goggles would be a little less weighty

[teslahed]

Yeah i think goggles would be a little less weighty

It';s ok - the lipo on the back counterbalances the screen at the front.

It does seem to work pretty well though - better than my previous setup with the screen on the transmitter anyway;

http://youtu.be/BwB1J-9_Akg

[teslahed]

I really cant think of a comment       
I hope it works well 

So far so good; I';ve been practicing buzzing the back of my own head;

http://youtu.be/6CiX7h1OHNQ

In other news it has been pointed out to me that the design may not be as original as i first thought;

[Gaza07]

Very good flight Chris it works very well  I wonder if he went to the same camp to get his helmet 

[teslahed]

http://youtu.be/nu-6GdD-Sfw

I managed one more flight

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FPV mini quadcopter and helmet as they are currently setup.

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http://youtu.be/rtyvl6yIdKc

Practice flying around the tree.

[Gaza07]

Very good Chris 

[Gav]

I really need to get some cheap video goggles...

Haha that fpv helmet is something else. Nice one.

[teslahed]

http://youtu.be/-2fFxE1x35c

I';ve got some new zippy flightmax 1300mah 3 cell batteries and despite being a bit heavier they seem to provide more power than the 950mah 3cell nanotech i was using before. The quadcopter seems faster and climbs better as well - i';m quite pleased

http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=31947

They were just under £5 each so i got 4.

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http://youtu.be/hMTTGV4KM3Q

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http://youtu.be/V7TpR9qJx8s

Another one - taken from a slightly different location.

I went too high at the beginning and lost my video feed for about 5 seconds between 55 and 60 seconds into the flight. I cut power until it fell back down into range and then carried on :-)

[Gaza07]

Nice flight Chris 

[teslahed]

I';m hoping the weather will be good tomorrow as I';ve just discovered my mini quadcopter is capable of carrying my gopro. It';s not exactly sporty but it does fly!

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[teslahed]

I';ve just fitted a new sony WDR camera;

http://www.ebay.co.uk/itm/600TVL-SONY-Super-HAD-CCD-II-D-WDR-Mini-FPV-Camera-2-8mm-Wide-Angle-Lens-/200788570395?_trksid=p5197.m1992&_trkparms=aid%3D111000%26algo%3DREC.CURRENT%26ao%3D1%26asc%3D14%26meid%3D5916384903782500516%26pid%3D100015%26prg%3D1006%26rk%3D1%26sd%3D200788570395%26

And rearranged the camera and GoPro 3 layout a bit.

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http://youtu.be/fwhcR7FHF68

[teslahed]

I';m just back from getting the Mark 2 laser cut on my mates laser cutter. It';s fitting together better than my first attempt - i just need to order some more plastic bolts before i can finish putting it together now.

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[teslahed]

Well the Mark 1 teslaquad is no more - i crashed into a tree branch whilst flying FPV and bounced of some tarmac

I';ve started putting the Mark 2 together - so far just the frame but it';s all fitting together ok which is nice;

[Gaza07]

Looks very good Chris 

[teslahed]

Everything is back together now with the new frame;

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Not test flown yet but the FPV gear still works

Test flown over my bed - it flies!

Flown outside - slightly more stable than the Mark 1, probably just because the arms are fractionally longer.

https://vimeo.com/61119989

[rundtmeg]

probably just because the arms are fractionally longer.

How long are they now? (motor to motor)

[teslahed]

How long are they now? (motor to motor)

My current one measure 275mm from motor axle to motor axle - so bigger than the old X250 i started with (and noticeably more stable). I could rebuild it at pretty much any size though - just replace the square section carbon fibre arms with longer or shorter pieces.

[teslahed]

Not the most exciting of photos but i thought i would do a quick update on the progress of my attempts to get these frames cut from fibreglass with a view to selling at least a few in a limited test production run.

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Now the only part left to sort out is getting the fibreglass G10 itself cut. As i am relying on the help of friends who also have to work for a living rather than a commercial company that will charge me through the nose for this i may have to be patient on getting the cut completed (and I';m certainly not complaining - it';s very much appreciated!). So hopefully in the next couple of weeks.

Here';s the latest FPV video recorded on a gopro 3 silver, uploaded to vimeo for a change where the quality is better than youtube;

Lancaster sunset flight - FPV quadcopter with GoPro 3 silver on Vimeo