Hexfire Hexacopter

Description

Second Generation Hexacopter Drone, designed from scratch but remixing some parts for some smaller elements. Work in progress. Background & Context on Design 1. Strength and tension in the body is provided structurally through the layers and aluminium (rather than nylon) spacers. Without the base and top of the drone body attached, there would be too much flex in the mid-layer "pinch plates" that clamp the carbon fiber arms, especially the 2 side arms given the battery entry/exit points on the base layer. Through this approach, the need to use carbon fiber within the body is eliminated. All structural layers have been 3D printed at maximum density for strength, using Zortrax Z-ULTRAT material. Only time will tell on the fatigue factor of the printed layers. 2. A circular PDB has been used that fits within mid layer "pinch plates". Small ESCs have been selected that fit between the arm clamps, held in place with zip cables. The PDB selected incorporates both 5v and variable voltage UBECs that protrude through the top of the "pinch plates" to minimize the space required. 3. In order to make drone assembly straightforward, the arms can initially be clamped into place using separate individual clamp modules. These modules are then braced through the addition of the top "pinch plate" when it is subsequently seated and bolted into place. 4. In order to maximize strength and minimize point failures, large penny washers are used throughout the body to spread the load across as broad a surface area as possible. 5. Weight: 4.33Kg with payload (battery and Gimbal/GOPRO4) Progress: 17 Dec 2018: • First test flight successful in Loiter mode - was very stable and controllable • 2 x 5 minute flights to collect initial logs • 8% of battery capacity used in flight. • Signal strobes and retractable legs tested successfully • GOPRO gimbal stable and controllable • Pan-Tilt FTP module working fine, albeit a bit "juddery" • On analysis of logs, vibration was minimum - well within acceptable parameters and motor usage was well balanced. • Some "squealing" from one or more motors - reason unknown at this stage - may be the result of motors "rubbing" against the walls of the motor mounts, but no friction burns or marks are evident. More analysis required. • All thumb screws on folding arm joints were still tight and solid upon test completion. 24 Dec 2018: • Useful orientation flights - some niggles to resolve with power monitoring, antenna positioning for best range, GoPro video to FPV and some strange yaw lag on the gimbal. • Quick video can be found here: https://youtu.be/Lrt3pcgFPik • The motor "squealing" seems to just be a vibration effect with no adverse impacts. • Added red strobe LEDs on 2 front arms for orientation purposes - tested and work well. Carbon Fibre Tube Lengths: • Arms cut to 325mm (20mm outer-diameter tube) • If making collapsible suggest cutting arms 85mm from body end • Printable template/guides have been provided for hole drilling • Leg length 250mm (16mm outer-diameter tube) • Leg strut length 350mm (10mm outer-diameter tube) • Gimbal mount strut length 250mm (10mm outer-diameter tube) Parts List: For Landing Gear: • 2 x Tarot Replacement Small Retractable Landing Gear Device • For Legs: 3k Carbon Fibre Tube OD 16mm x ID 14mm • For Cross Struts: 3k Carbon Fibre Tube OD 10mm x ID 8mm • 2 x Tarot 16mm/10mm Aluminium Landing Skid T Piece • For Cross Strut Cushioning (Optional): Armaflex Pipe Insulation Lagging Black Nitrile Foam Class O 2m-10mm-06mm-Wall For Gimbal: • 4 x Tarot 10-12mm Lengthened Tube Clamp with Shock Absorbing Rubber Damper • 3k Carbon Fibre Tube OD 10mm x ID 8mm • Tarot GOPRO 3DⅢ Metal CNC 3 Axis Brushless Gimbal PTZ for GOPRO 4 / 3 For Motors & Arms: • 3k Carbon Fibre Tube OD 20mm x ID 18mm • 6 x 20mm CNC Aluminium Lateral Folding Arm Tube Joint • 6 x Knurled Thumb Screws - Stainless Steel – Hand Grip Knob Bolts – M3 – 10mm Thread • 6 x M3 Spring Washers 3mm – Zinc Plated Rectangular Coil Lock Washer • 6 x Tarot 6S 380KV 4008 4108 Brushless Motor • 6 x Tarot 680 PRO T Series 1355 Carbon Fibre CW CCW Propellers • 6 x DYS 40AMP MINI OPTO BLHELI MULTI-ROTOR ELECTRONIC SPEED CONTROLLER (BLHELI FIRMWARE) For Core Flight Electronics: • Pixhawk 2.1 Standard Autopilot • Here GNSS Module for Pixhawk 2 • Pixhawk2.1 Cable Set (To Provide Additional Cables To Extend Included Set) • FrSky X8R 8/16Ch Telemetry SBUS ACCST Receiver Smart Port Compatible Taranis D8 • 500mW Unmanned 3DR Telemetry Kit V2 (433MHz) • FrSky FLVSS, Frsky Smart Port Lipo Sensor (Measure Total Voltage and Cell Voltages) Compatibility Frsky Taranis Receivers Smart Port Enabled • PDB-DIY-2UBEC - DIY Octocopter Circular Power Distribution Board and Dual UBEC • XT60 Female to XT90 Male Adaptor/Convertor • Craft & Theory Telemetry Cable for FrSky Radios (Flight Deck) • 6s Lipo Balance Extension Lead Cable JST-XH 20cm • RP-SMA Female to RP SMA Male WIFI Antenna Extension Cable Lead 3.94''/10cm Straight WLAN Wireless Aerial Adapter Connector FPV router Pigtail Cord • To Replace Antenna on FrSky X8R: o 2 x HUACAM HCM16 2 x 2.4GHz 6dBi Indoor Omni-directional Antenna 802.11n/b/g RP-SMA Female Connector o 2 x Eightwood Wifi Adapter MMCX Male Right Angle to RP-SMA Female Bulkhead Pigtail Cable RG316 6inch 15cm For FPV Electronics: • AKK X2 Ultimate VTX Switchable with Pitmode and SmartAudio • Caddx Turbo S1 FPV Camera 1/3 CCD 600TVL 2.3mm IR Blocked PAL DC Wide Voltage Yellow • AlceOSD 0v5 - Pin connectors: Right angle (horizontal pins), USB connector: Yes • For Pan-Tilt Gimbal (Optional): 2 x Top-Spring SG90 9g Micro Servos • ImmersionRC 5.8GHz Circular Polarized SpiroNet Antenna V2 (RHCP SMA) For Body Structure: • For Top Section: 6 x M3 x 65mm Round Aluminium Column Alloy Standoff Spacer Stud Fastener Black • For Bottom Section: 12 x M3 x 70mm Round Aluminium Column Alloy Standoff Spacer Stud Fastener Black • 8 x VIBRATION DAMPING BALLS • Aluminium Alloy GPS Antenna Stand Mount Folding for DIY RC Drone Quadcopter For Lighting: • 2 x STROBON v2 Navigation Light (RED) - Output Type: with Wires Power: • MULTISTAR HIGH CAPACITY 10000MAH 6S 10C MULTI-ROTOR LIPO PACK XT90 General Electronics: • TURNIGY HIGH QUALITY 16AWG SILICONE WIRE (RED/BLUE/BLACK) • 3.5mm Gold-plated Bullet Banana Plug Connector Male and Female • For Power Lines: 22 AWG JST Plug Connector 2 Pin Male Female Plug Connector Cable Wire • 500mm RC Servo Extension Cord Cable Wires • 15cm Servo RC 1 to 2 Y Cables Male to Female Extension Leads • 20cm Male to Male Quadcopter Servo Extension Lead Wires • Servo Extension Lead Wire Cable Male to Male JR Plug • NYLON XT60 CONNECTORS MALE/FEMALE General Hardware: • Bolt Base A2 Stainless Steel Penny Repair Washers Mudguard Washers M3 X 9 X 0.8mm Thick • VELCRO® Brand Industrial Strength Velcro Heavy-Duty Stick On Self Adhesive Velcro Tape 5CM Wide • M3 Screws – Various Lengths

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