Black Cicada and related projects

journal > 2014 > Black Cicada and related projects


Design criteria

Improvements on the Phantom-based Leaf Hopper

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initial electronics layout trial
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power distribution board mounted with 6mm M3 nylon standoffs to bottom carbon fiber plate
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SunnySky X2204 2300kv brushless motor 3-phase power wiring

Sunnysky X2204 2300kv brushless motor

Brushless motor design offers favorable power-to-weight ratios with relatively less noise, higher efficiency and less mechanical wear. Brushless motors offer more torque per weight, more torque per watt, increased reliability, reduced noise, and a longer lifetime due to no friction of brushes. With no windings on the rotor, they are not subjected to centrifugal forces, and because the windings are supported by the housing, they can be cooled by conduction. Brushless motors have permanent magnets rotating around a fixed armature, eliminating the challenge of connecting current to the moving armature. A solid-state electronic controller (ESC) continually switches the phase to the windings to keep the motor spinning. A brushless motor's velocity is determined by the frequency at which the electricity is switched, not the voltage.

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epoxy added to relieve strain on motor wires
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carbon surfaces are sanded under water
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female bullet connectors mounted to ESC motor cables
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add 2mm male bullet connectors to the motor wires
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attach 2mm gold female bullet leads to the ESC motor cables and shrink insulate
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Blue Series 12A Rapid ESC

Blue Series 12A Rapid Electronic Speed Controller

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ESC power harness connected
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ESC power circuit mounted in bottom section

An ESC, electronic speed controller is an electronic circuit which varies an electric motor's speed by providing a three phase low voltage source of energy for the motor.

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2mm bullet connectors attached to all motors
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prepared motors are mounted on 3mm carbon fiber arms
Black Cicada and related projects 2300KV_Sunnysky_thrust_table
SunnySky X2204 2300kv brushless motor thrust with different propellers

Kv is the motor velocity constant, measured in RPM per volt (not to be confused with kV, the abbreviation for kilovolt). The Kv rating of a brushless motor is the ratio of the motor's unloaded RPM to the peak voltage on the wires connected to the coils.

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flight controller mounted on damped upper plate

The Flight Controller (FC) is the brain of the multicopter. Data from solid state MEMS gyroscopes, an accelerometer, GPS (global positioning system, barometer and other sensors on the flight controller all feed into the Inertial Measurement Unit (IMU) where the Proportional Integral Derivative (PID) control loop algorithm integrates sensor data with operator input via the radio receiver to control the individual motor speed controllers to achieve the desired flight course.

AfroFlight32 STM32F103-based simple multirotor flight controller

Design issues

Successfully connected Baseflight configurator to the Naze flight controller after identifying a faulty micro USB cable.

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Sony 600TVL edges clipped and sanded to constrain to 35mm
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5.8GHz Audio/Video Transmitter
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1/3 Sony Super HAD II CCD-IR camera
Black Cicada and related projects CMQ1684L-7-camera

The FPV (First person view) camera will stream live video back to the operator via the 5.8 MHz radio.

Failed Leaf Hopper DJI radio transmitter

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failed TX antenna?
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debugging antenna failure

Issue is remedied by abandoning DJI transmitter, installing FrSky D4R-II in Leaf Hopper and adding it the Taranis profiles.

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camera mounted to plate and installed in component cage
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3S LiPo battery lead re-routed to back
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12V power harness test
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3DRobotics MinimOSD
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3DRobotics MinimOSD connectors

The OSD (On-screen display) takes analog flight data from the flight controller and writes flight data (battery power, altitude, radio signal strength, distance from home...) as text overlayed over the live video feed streaming back to the operator to assist flight control and planning.

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ImmersionRC 5.8 Ghz Audio/Video Transmitter
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Video Transmitter connectors

The audio/video radio transmitter relays the analog video stream via 5.Ghz radio signal with OSD data overlayed back to the operator goggles.

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Lipo low voltage alarm
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low voltage alarm back
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D4R-II FrSky 4ch telemetry receiver
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D4R-II connectors

The FrSky radio receiver transmits user controls to the flight controller and also sends selected flight data back to the transmitter for real time display and/or logging (telemetry).

GPS

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gps module mounted in front of top plate
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u-blox neo-6m gps module
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u-blox gps antenna and connector

The GPS (Global Positioning System) receiver receives location and time information over radio from the space-based satellite navigation system where there is an unobstructed line of sight to four or more GPS satellites.

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component layout trial

GoPro repair

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cracked GoPro 3 waterproof case latch
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OSD wiring

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OSD, video camera and radio transmitter successfully wired
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programming MinimOSD to set displayed fields
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failing connector on u-blox neo-6m GPS receiver

Leaf Hopper failing motor repair

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desoldering separates PC board

Successful test of GoPro 2 repaired by Bernard

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Weiwei
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Weiwei and Kanie
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terrace - fixed GoPro 2 test
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grounded power strips for Algis
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slipped magnets in X2204S-16 2300KV motors
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magnets out of place
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magnets glued
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Dates: 2014:07:22 - 2014:12:29