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MATRICE 100
University of California, Berkeley
ME 102B, Spring 2016
Design Review 2
Professor Liwei Lin
Contents
Executive Summary........................................................................................................................................ i
1. Introduction .............................................................................................................................................. 1
2. Customer Specifications............................................................................................................................ 1
2.1 Mechanical Specifications ............................................................................................................... 3
2.2 Electrical Specifications ................................................................................................................... 3
2.3 Economic Specifications .................................................................................................................. 3
3. Concept Generation .................................................................................................................................. 3
3.1 Tensioning System .......................................................................................................................... 4
3.2 Power Transmission System ........................................................................................................... 4
3.3 Landing Scheme .............................................................................................................................. 4
4. Concept Selection ..................................................................................................................................... 4
4.1 Tensioning System .......................................................................................................................... 4
4.2 Power Transmission System ........................................................................................................... 4
4.3 Landing Scheme .............................................................................................................................. 5
5. Concept Description.................................................................................................................................. 7
5.1 Tensioning System .......................................................................................................................... 7
5.2 Power Transmission System ........................................................................................................... 7
5.3 Landing Scheme .............................................................................................................................. 9
5.4 DJI Software Development Kit (SDK)............................................................................................... 9
6. Parameter Analysis ................................................................................................................................... 9
6.1 Tensioning System .......................................................................................................................... 9
6.2 Power Transmission System ......................................................................................................... 10
6.3 Landing Scheme ............................................................................................................................ 10
7. Final Design ............................................................................................................................................. 10
7.1 Tensioning System ........................................................................................................................ 10
7.2 Power Transmission System ......................................................................................................... 11
7.3 Landing Scheme ............................................................................................................................ 11
8. Problem Analysis ..................................................................................................................................... 11
8.1 Tensioning System ........................................................................................................................ 11
8.2 Power Transmission System ......................................................................................................... 12
8.3 Landing Scheme ............................................................................................................................ 12
9. Action Plan .............................................................................................................................................. 12
Executive Summary
Small, unmanned quadcopters have been quickly gaining popularity over the last few years because of a
wide range of recreational and research-related applications, such as aerial photography, navigation, and
surveillance. Many companies, such as DJI, Parrot, and 3D Robotics, have developed easy-to-use,
inexpensive flight platforms and controllers, allowing a variety of users to own and operate their own
quadcopters. Because of their increasing robustness and decreasing cost, quadcopters have also generated
interest in commercial and industrial realms. However, the full adoption of quadcopters in industrial
applications has been severely limited due to the short battery lives, and therefore flight times, of currently
available quadcopters. If a quadcopter were to be developed that had significantly longer, or even indefinite,
flight times, many industrial applications would become much more viable. For example, there is much
interest in the use of quadcopters as temporary communications towers, where a quadcopter with additional
communications equipment would hover above any obstructions for as long as necessary. A temporary
communications tower such as this could find use at sporting events, sites of natural disaster, or other
humanitarian aid projects, where enhanced communications are often required at a moments notice.
However, there are currently no market-ready quadcopters with the necessary capability of long-term hover,
so temporary communication towers have not been realized.
For this project, DJI is sponsoring The Hot Quads to design the mechanical and electrical accessories and
interface needed to achieve unlimited hover in a DJI Matrice 100 quadcopter. After providing us with an
M100 and the necessary funds for accessories, DJI expects that the quadcopter will be capable of at least
100 foot above ground level (AGL) hover. In addition, tether tension should be autonomously managed
from takeoff through landing, the power system should have at least 50W of free capacity for additional
communication systems, and the standard 22V battery should be absent from the system while it is tethered.
It is expected that a working demonstration of the tethered quadcopter will be given at the beginning of
May, including the tensioning system, electronics, and all other necessary interfaces. DJI has also provided
us with access to their DJI Developer software, which will allow us to program our own flight paths and
alter the quadcopter in ways that some standard users cannotwe have made it a stretch goal to create a
fully autonomous system using custom flight paths and hover commands.
The challenges associated with this project have been broken into three parts: the tensioning system, the
power transmission system, and the landing scheme. Tension is necessary in the tether in order to prevent
entanglement in the rotors, which would inevitably lead to a crash and damage the quadcopter. Tensioning
will be achieved using sensors that can sense the tension force on the tether, an Arduino microcontroller,
and a motor. In order to keep the tether relatively light, it is also necessary to transmit power at a high
voltage, and therefore a low current, before inputting it to the quadcopter at 22V. In order to achieve this,
a DC Power Supply and a boost converter will be used in the base system to transform 120V AC into 240V
DC, and a buck converter will convert the signal to 22V DC on the quadcopter. Finally, in order to
confidently land the quadcopter in a predefined space, the tether will pull the quadcopter in on landing.
While this may require a higher torque motor, we believe a predictable landing zone will be more valuable
than slight weight or cost savings.
At this point in the project, all systems have been designed and analyzed, and they are ready for
manufacture. The DC Power Supply has been acquired, the boost and buck converters have been designed,
and all electronic components for the power transmission system have been acquired. The design of the
tensioning system is complete, and we are planning on ordering all parts during the week of Monday, March
28th. While the tensioning system is important, it is not quite as integral to the success of the power
transmission system, and because of this the power transmission system has been slightly prioritized. April
will be spent assembling, testing, and troubleshooting all aspects of the quadcopter before it is to be
demonstrated on April 29th.
i
1. Introduction
DJI, a world leader in easy-to-fly drones and aerial
photography systems, was founded in 2006 in
Shenzhen, China, and has recently begun operations in
Palo Alto, California. DJI designs and manufactures a
wide range of products including quadcopters (Figure
1), flight controllers, quadcopter accessories, and
camera gimbals. While DJI drones excel in recreational
endeavors, their commercial applications are currently
restricted because of short flight times associated with
limits in battery technology. If a quadcopter could fly,
or even hover, indefinitely, a wide range of applications
would be divulged, particularly in the realm of
temporary communications towers. One can imagine
that this could be useful in instances of large sporting
events or humanitarian aid, where enhanced
communication systems are often needed only
temporarily but at a moments notice. While there are
multiple obvious applications for unlimited quadcopter
hover, there are currently no widely available products
that allow a quadcopter to hover any longer than its
standard battery allows.
2. Customer Specifications
The customer, DJI, specified the following
requirements for this project:
Achieve 100 ft. tethered operational ceiling
Autonomously manage tether tension
Have a minimum 50W peak power margin
Operate independent of standard battery pack
Hover indefinitely while tethered
Based on these specifications, we need to select a wire
gauge appropriate for the tether, design the tethering
system, and create multiple circuits including a boost
converter, a buck converter and tensioning system.
Target values were selected for our Quality Function
Deployment (QFD) (Figure 2) based on specifications
and calculations that maximize the current running
through the tether. Through this QFD, we are able to
quantify the relative importance of each specification
and compare our goals to those of the competition.
After conducting market research, we have identified
two major competitors for our project - the Elistair
SAFE-T and the Drone Aviation Watt 300. The SAFET is a unique smart tethered station for drones that
allows for data transfer and unlimited flight time. The
Watt 300 is a tethered aerial platform that has unlimited
flight time and allows for various missions. As we are
working on the project, we will be considering how
SAFE-T has such a small and efficient tether station,
and how we can incorporate it into our design. Other
than these two companies, most other drones do not
feature any tether, nor do they have the open platform
allowing for sensors and additional equipment as the
M100 does. The following images (Figure 2a and 2b)
show our QFD that review the comparison analysis for
design specifications, target values, and competition.
(1)
3. Concept Generation
During our brainstorming sessions, we came up with
many concepts and ideas regarding the main parts of the
project, namely the tensioning system, power
transmission, and landing scheme. We narrowed these to
the ideas listed below that we thought were the most
feasible and efficient. From there we had a challenge in
figuring out which combination of tensioning, power
transmission, and landing schemes to use. This was
because each concept has its own set of advantages and
disadvantages that had to be weighed appropriately. In
the end, however, we had a consensus on which
combination was the most feasible and efficient.
4. Concept Selection
After generating all possible concepts, we methodically
worked through them to decide which concepts would
be the most feasible and effective. The first step in this
process was to create tables to list the advantages and
disadvantages of each individual design concept. Two
examples of these tables can be seen in Figure 3. Once
these lists were exhausted, we compiled the data into
decision matrices, weighed the relevant criteria, and
used the outcome to make our final decisions. The
individual decision matrices can be seen in their
respective subsections.
Figure 3: Two of the pros vs. cons tables that were created for concept selection
5. Concept Description
The Matrice 100 and its platform were modeled using
SolidWorks to show the ultimate assembly we are
aiming to create (Figure 7). Ideally, the user is able to
carry the quadcopter in one hand, and the Pelican case,
with all components in it, in the other hand.
Operationally, set up would include opening the Pelican
case and unfolding the platform. The tether would be
inside and connect to the platform for the tensioning
system. All materials for the power transmission system
will fit inside the case.
(2)
(3)
6. Parameter Analysis
For the tensioning and landing systems, our calculations
mostly consisted of using known values such as
quadcopter mass or vertical acceleration to determine
parameters such as motor torque, tether tension, spool
(4)
(5)
0
=
(6)
+ 2
7. Final Design
After determining the specific parameters of our design,
we began designing the final layout of the subsystems,
both as individual systems and relative to each other. A
completed CAD model of the entire assembly can be
seen in Figure 11, and engineering drawings can be
found in Appendix 3. In addition, all off-the-shelf parts
have either been ordered or will be ordered shortly so
that we can begin to manufacture the entire system. A
bill of materials can be found in Appendix 4, and
detailed descriptions of each subsystem can be found in
the following sections.
(7)
8. Problem Analysis
Figure 12. SolidWorks Model of Tension Sensor
A mechanism also had to be designed to ensure that the
tether spreads evenly on the spool during reeling. It was
unreasonable to translate the tether, as is done in a
fishing rod, because of difficulties associated with also
translating the tension sensor. Because of this, we
decided it would be more plausible to couple the linear
translation of the spool to its rotation using a linear
actuator and the Arduino microcontroller. By translating
the spool linearly while it is rotating, we ensure that the
tether will be reeled evenly onto the spool. This
mechanism will also operate autonomously without
input from the user.
9. Action Plan
Our Gantt chart, shown in Figure 13, reviews our
timeline for the project. To accomplish our goals, we
have divided the team in three main subgroups: Tension
Team, Power Team, and Landing Team. The landing
scheme design process is just beginning now that we
have a better idea of what type of tensioning system we
will be working with.
12. Conclusion
For this project, we will modify a DJI Matrice 100 to
include a 100-foot tethered system that utilizes a DC
power system. It was determined that DC power
transmission in the tether was favorable over AC power
transmission due to the quadcopters payload limits. DC
power transmission will place less load on the
quadcopter because the only on-board addition will be a
buck converter, rather than a rectifier. Furthermore, we
will be using regulated voltage circuits to power the
converters instead of batteries to minimize the weight of
the drones. Based on our concept selection for the
tensioning system, we will be developing a groundbased, motor-controlled tensioning system while
emphasizing indefinite hovering capability, autonomous
tensioning, and safety. As we move forward with
development, we will be focusing on electrical safety as
we are dealing with high power circuits. Finally, we have
already purchased the majority of the necessary
electronics, the tensioning and landing designs have
been completed, and we will be following our Gantt
chart to maintain a strategic and effective timeline. If we
continue to follow our timeline and do not have to
confront any major unforeseen challenges, we will be
prepared to demonstrate a tethered M100 on April 29th,
2016.
References
1. M-100 Instruction Manual, v1.0, DJI, June 2015.
2. DJI Drone Project Team, DJI, January 2016.
3. Basic Calculation of a Boost Converters Power
Stage, Texas Instruments, January 2014.
4. Basic Calculation of a Buck Converters Power
Stage, Texas Instruments, January 2016.
5. FCA47N60/FCA47N60_F109 N-Channel
SuperFET MOSFET, Fairchild Semiconductor,
June 2014.
14
II
III
Part No.
Part Name
Unit Cost
(USD)
No. Units
Total Cost
(USD)
SparkFun
42BYGHM809
Stepper Motor
16.95
16.95
SuperBrightLEDs
WP18-2
0.19/ft
125 ft
23.75
Reds
B00L0GOMCA
14.25
14.25
47253
104.60
104.60
Arduino
50
Uno R3
24.95
24.95
McMaster Carr
8974K28
Multipurpose 6061 Al
3.08/ft
3 ft
9.24
SainSmart
10201
N/A
Switching Power
LC-045
46.00
46.00
Fairchild Semiconductor
LM555CN
555 Timer
0.25
0.50
Fairchild Semiconductor
LM7812CT
Voltage Regulator
0.29
0.58
Fairchild Semiconductor
LM393N
Dual Comparator
0.29
0.58
Jameco
3201-H-VP
10 H Toroidal Inductor
1.25
16
20.00
Fairchild Semiconductor
RURG3060
Ultrafast Diode
2.81
5.62
Fairchild Semiconductor
FCA47N60F
N-Channel MOSFET
11.75
23.50
S802C31S2WCQ
6.09
6.09
IV