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Design and Manufacturing of Quadcopter

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 Design and Manufacturing of Quadcopter
Osama Jamal Al-zogphy, Osama Ibrahim Khalil, Abanoub Monir reda
th
October 6 University, Egypt, osga2020@outlook.com ,ofox@gmail.com,abanoubmounabanoubmounir465@gmail.com

Supervisor: Dr. Abdelrady Okasha Elnady, Associated Professor

th
Faculty of Engineering, Mechatronics Department, October 6 University, Egypt, rady_nady@yahoo.com

Abstract– Quadcopter is a type of multirotor unmanned

aerial vehicles. It is newly used in multiple fields such
as surveillance, military operations, fire sensing, II – Movement mechanism
Agriculture, Spyware, and a lot of other uses. Their
frequent use in multiple places is due to their Quadcopter can describe as a little vehicle with four propellers
reliability, cost effectiveness and multi-functionality. connected to rotor situated at the cross casing. The speeds of
This paper presents the design procedure, selection of these four rotors are independent and it controlled by
all component and manufacturing of a quadcopter. ardupilot. Pitch roll and yaw attitude of the vehicle can be
control easily. Pitch roll and yaw attitude off Quadcopter are
I. INTRODUCTION shown in Figure (2.1).
Quadcopter, is also known as drones, unmanned aerial
vehicles (UAV), it consists of four motors which are fixed at
the end of the frame structure. Quadcopter consist of four
rotors which are fixed at the end of the frame structure. In this
case, a pair of rotors along. The arms of the frame rotate in
clockwise direction while the remaining pair of rotors rotates
in anticlockwise direction. And because of its unique design
comparing to traditional helicopters, it allows a more stable
platform, making Quadcopters ideal for tasks such as
surveillance and aerial photography. And it is also getting very
popular in UAV research in recent years. There are two
classifications of quadcopter depending on direction of Motor
movement, plus and X configuration. In plus configuration Figure (2.1)
every two-motor working in same direction and the other
working in opposite direction as show in Figure (1.1). In X
Yaw Motion (ө): Rotation around the vertical axis is called
configuration every two diagonal motor working in same
Yaw, the Rudder controls Yaw Left and Right.
direction and other two motor work in opposite direction as
Roll Motion (Ф): Rotation around the front-to-back axis is
show in Figure (1.2).
called Roll.
Pitch Motion (ө): Rotation around the side to side axis is
called Pitch.
We can simplify the situation of the quadcopter into four
modes as will be explained:
1- Forward and backward mode:
Forward movement is control by expanding velocity of back
rotor of two engines, and the retrogressive movement is
control by diminishing the speed of front rotor at the same
time will influence the pitch point of the quadcopter .as show
in figure (2.1.1)

Figure (1.1) Figure (1.2)

Figure (2.1.1)

1
2- Left and right mode:
For left and right movement, it can control by changing the
yaw point of quadcopter. Yaw edge can control by expanding
counter-clockwise rotors speed while diminishing clockwise
rotor speed and can control it additionally by diminishing
counter-clockwise rotors speed while expanding clockwise
rotor speed as appeared in figure (2.1.2).
Figure (2.1.2)
3- Hovering or static position mode:
The hovering of quadcopter is done by two propellers
are rotating in clockwise and counter-clockwise
respectively with same speed. Static position is done by
two rotors rotating in clockwise and counter-clockwise
position, the total sum of reaction torque is zero.
4- Take-off and landing mode:
Take-off is mechanism of quadcopter that lift up from
ground to float position and landing position is versa of
take-off position, in remove the controller ought to disperse
the ability to each engine similarly to make an take-off , and
furthermore in finding the controller ought to limit the power
similarly to keep away from any harm in part .
III – Components selections:
3.1 - DC brushless Motors
The motors spin the propellers to provide the drone with lifting
thrust. drone almost use brushless DC motors, as they provide
thrust-to-weight ratios superior to brushed DC motors. Motors
are typically given two ratings: Kv ratings and current ratings.
The Kv rating indicates how fast the motor will spin (RPM)
for 1V of applied voltage. The current rating indicates the max
current that the motor may safely draw. So, for our project we
select Brushless DC motor of type (MT 2204-2300 Kv).
Also ,there are two type of brushless motor in-runner as show
in Fig (3.1.1) and out-runner as show in Fig (3.1.2) and
everyone has some specifics, the In-runner brushless dc motor
have low torque and high speed ,but out-runner have high
torque and low in speed , so we need high torque and the speed
is not necessary so we will use out-runner brushless motor.
2
Figure (3.1.1) Figure (3.1.2)
3.2 - Propellers
Propeller is a type of fan that converts rotational motion into
thrust. Generally, propellers are classified on the basis of their
diameter and pitch and are represented in terms of product of
diameter and pitch. There are some types of propeller mostly
use nylon, carbon in our project we select plastic propeller .
3.3 - Electronic speed controller
The electronic speed controller controls the speed of the motor
or advises the motor how quick to turn at a given time. For a
quadcopter, 4 ESCs are required, one associated with each
motor. The ESCs are then associated legitimately to the
battery through either control appropriation board. Each ESC
has a present rating, which showed the greatest current that it
might give the motor without overheating. ESCs must be
chosen to ensure that they can provide enough current for the
motors. Depending on calculation we selected Simonk 30 A
ESC for our project.
3.4 - Battery
The battery provides electrical power to the motors and all
electronic components of the aircraft. Lithium polymer
batteries (Li-Po) are most popular battery uses in drones due to
its light weight, energy density, longer run times and ability to
be recharged, but also it has a problem that if the charge
finished completely it will not woke again. Due to our
calculations we select Battery (Zippy 2200).
3.5 - video link
To make image processing we must use camera and also video
link in our project we select video link of type (Ts 832) show
in figure (3.5).
Figure (3.5)
3.6 - Remote control
The main objective of R/C is controlled the quadcopter
remotely , and there are two condition to select the suitable
one ,the first is the number of channels you need and , in our
project we need four channel ( X for Roller, Y for Pitch , Z for
Yaw , Throttle (to control speed of motors) ) , the second
condition is the range of control .
 So, We = 707 gm
To find WPL:
1- Wight of video link = 22g
3.7 - Camera (Micro FPV Camera) 2- Wight of camera = 8 g
Is characterized by input power 5V, resolution 1024, WPL = 30 gm
And size 21*19*17 mm and weight 8gm. So, the WGL will equal:
WGL=737gm.

IV–Preliminary Design: 4.2 – Estimation of brushless DC motor

4.1- General equation WGL = 737gm

WGL = WE+ WF+ WPL+ WCrew The total thrust =1474 gm
• WGL = Ground launch. Thrust for each motor = Total thrust / Number of motors
= 368.5 gm
• WE = Empty weight.
In our motor the maximum thrust = 450 gm, So we are
• WF = Fuel weight. in the safe side.
• WPL = Payload weight.
• WCrew = Crew weight. 4.3- Estimation of the battery
By apply this equation we get: Battery = current * Flight time
In drone the Fuel weight and Crew weight will equal zero. so, Assume Flight time = 8 min
WGL = WE + WPL
The main forces act on a quadcopter body shown in figure Note that: 1S =1 Cell =3.7 volt
(4.1). 3S = 11.1 volt

Power total = I V

I = 11.5 Ampere
So, Battery that need =
6130 mA
So, actual flight time will equal

2.8 min.
Figure (4.1)

• Lift force: The force generated by the propeller of the

plane and its vertical direction to the surface of the
propeller of the plane.
• Gravity force: The force of gravity resulting from the
4.4 Frame Design
mass of the plane and its direction to the center of the
earth. The difficulty lies in choosing the suitable material for the
manufacture of the quadcopter, since it is necessary to get a
• Thrust force: It is the power generated by the
material that has a degree of strength and hardness to bear the
brushless DC motors that push and move the plane.
impact of motors in addition to the weights that will be on the
• Drag force: Is an impedance force for the movement
Quadcopter such as the camera, battery and other things and
of the plane and is reversible the thrust force.
also must be used Weight to be able to take off without any
problems.
So, We can divide frame in two partitions the first is select the
From that we can find the We and it will equal: material and the second is to select the dimensions which
From datasheets we will collect the weight for every mean we should use an angel 90 between of the two axis’s
component because it will make the quadcopter more balance. And about
1- Wight of battery = 207gm the length of quadcopter the suitable option is make it small to
2- Wight of DC motors =100gm get more stable.
3- Wight of ESCs =100gm
4- From Fig (3.2.2) weight of frame= 300 gm.

3
The most common frame of quadcopter manufacturing used
from aluminum, carbon fiber or balsa wood and we select
PLA material for print by using 3D printing.
After the use of PLA material we encountered a problem
which is that the body was not solid enough so we decided to
10 cm
use part of acrylic to make the body of quadcopter more stable
and more hardness as showen in figure (4.4.1) the sketch
diminution and figure (4.4.2) shows the front view of the 25cm
acrylic part .Size of drone depending on the main function that 24cm
the drone will doing so it will be 24cm width , 25 cm for Figure (4.4.3)
length and 10 cm for hight as show in figure (4.4.3) and it is a
suitable solution because the length of every propeller 8 in and
with this area the propeller will not touch each other .
To avoid any wrong uses from user during these two functions
1. Takeoff 2. Landing we decide to addition two parts made
from acrylic they will be like supports as shown in figure
(4.4.4 ) with all dimensions and figure (4.4.5) shows the front
view of the part.
In our Quadcopter Autodesk Inventor 2017 software has been
used to design .

.
Figure (4.4.4)

Figure (4.4.1)

Figure (2.4.5)

V– Center of gravity estimation

The suitable location of the center of gravity is to be in mid of

drone that’s make control on drone easier and it make drone
stable .
So, depending on components weight , it distributed on the
Figure(4.4.2) drone based on the most suitable position for center of gravity
as shown in figure (5.1).

4
 VI– Conclusion
By using Autodesk Inventor 2017, we design the frame and
printed by 3D printer with PLA-Plus filament , and choosing
the main components depending on our calculations ,with our
Preliminary calculations we were able to find the suitable
distribution for the components to reach the best centre of
gravity point to get the best balance possible .
Some of the problems we encountered during the design were
presented previously and we dealing with it .

Figure (5.1.a) Isometric view

ACKNOWLEDGMENT
We would like to thank Dr.Abdelrady Okasha for his
excellent guidance, continue continuously and suggestions .
We consider ourselves extremely lucky to be able to work
under the guidance of such a dynamic personality .

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Figure (5.1.c) side view

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