UNIVERSITY OF ILLINOIS URBANA CHAMPAIGNAdvanced Digital Systems Laboratory - ECE395

Mini Quadrotor Recon Drone

Tyler Steigerwald (tsteige2)Steve Zazeski (szazesk2)

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Table of ContentsAbstract 3

Parts 4

Background 5

Programming 9

Vibration Management 15

Wiring Diagram 16

Aerodynamics & Weight 19

Issues / Suggestions 20

Quadrotor Advice 21

Pictures 22

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AbstractThis project builds a quadrotor aircraft that is autonomously controlled by a PIC

microcontroller with a set of waypoints sent to it before it takes off that the flight controls

follows while using various sensors to avoid obstacles on its way to completing its

waypoints.

Quadrotors use four fixed blade motors and a PID controller to balance itself in 3

dimensional space by adjusting the speed of the four motors. This project takes on the

goal to build a quadrotor in two stages, first to build a stable quadrotor and the second to

automate it with GPS to fly without a human pilot. This semester was focused on making

a working quadrotor using a PIC Microcontroller, four ESC, four brushless motors and an

accelerometer.

At the end of the semester we had a fully built quadrotor that could almost fly but we

plagued with multiple motor failures at the end due mostly to an unplanned issue of

vibration caused by the motors that broke the enamel magnet wire in the coils of the

motors.

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PartsPIC MICROCONTROLLER

PIC18LF44k22 - I/P (L = Low Power 3.3v)40-pin, 28x Analog 10-bit Channels, 7 x Timers, 2 x EUSARTWe choose the 44k22 for its high pin count, multiple serial ports and high timer count. However it claims to be able to run at 64Mhz but using the internal oscillator block, we were never able to actually achieve that speed. That being said, a high Mhz clock actually makes creating the PWM to the ESC (which use servo standards) more difficult.

OP AMPS

MIC4424CN0408We don’t have much info on these as we found these from a previous project. We used them to up the 3.3voltage from the PIC’s output to 5v so the ESC would work with the lower power PIC. In hindsight we would recommend using a 5v PIC instead.

BATTERY

7.4v 1800mah 30C EZ Flite Lipo Battery<http://www.headsuprc.com/servlet/the-1952/7.4v-1800mah-30C-EZ/Detail>

COST $13.95 SENSORS

MMA7341L 3-Axis Accelerometer ±3/11G <http://www.pololu.com/catalog/product/1252>

COST $14.95

LPR510AL Dual-Axis Gyro with ±100/400°/s <http://www.pololu.com/catalog/product/1266>

Two-stage low-pass filtered output Onboard voltage regulator for integration with 5V projectsCOST $19.95

BRUSHLESS MOTORS

Power Up 180 Sport <http://www.headsuprc.com/servlet/the-1591/Power-Up-180-Sport/Detail>

WEIGHT 10 GRAMS (0.35oz) POWER RATIO 2000KV MOTOR STYLE Outrunner 5” PROP THRUST 125 GRAMS at 2.7amps TOTAL THRUST 500 GRAMS at 10.8 amps COST $10.95 ($43.80 total) TOTAL COST : $92.65 + Shipping + Tax + Rotors + Aluminum Frame + Spare Parts

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1.Background Information

Quadrotors are a type of vertical takeoff rotorcraft that were designed to be cheaper and capable of lifting more weight than a single rotor aircraft. Helicopters use a large pitch changing main rotor and a smaller tail rotor to counteract the rotation torque that the main rotor places on the body. Due to the size of the main rotor, to make a helicopter controllable the main rotor has variable pitch to change how much lift is actually being produced instead of relying on the motors to adjust the rotational speed of the rotor. This makes the main rotor very complex and as you need to have controls to change the pitch of a constantly rotating main shaft.

Quadrotors cuts out the complex variable pitch rotor by replacing it with 4 fixed pitch motors. Since the rotors are smaller, the motors are capable of quickly adjusting the overall speed to react to flight situations. Also without the addition pitch adjustment, fixed blades are much stronger and increase the lifting capacity of a quadrotor.

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Rotor RotationSince quadrotors do not have tail rotors to counteract the torque produced by the blades, the quadrotor instead needs to keep motor speeds in proportion of matching pairs to keep the quadrotor from rotating. If all motors are running at the same amount, the quadrotor will hold steady. However, if one of the motors is running faster and thus producing more torque, the quadrotor will start to spin in the direction of the torque.

Hold Position All motors equalize each other torquesRotate Right One motor runs faster to produce torque in the opposite directionFly Right Adjust balance to tilt in the right direction

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Brushless MotorsTo meet the weight requirements to make the quadrotor fly, we used brushless DC motors which are drastically less weight than their brushed counterpart. In the initial test build we tried to build a quadrotor using brushed DC motors but each motor weighed 70 grams and only produced 30 grams of lift at voltages beyond the rated values of the motor. We then used Outrunner Brushless Motors which weighed 10 grams and could produce 125 grams of lift. Outrunner brushless motors work by basically taking a regular motor and reversing it. Instead of rotating the large magnetic core, brushless outrunners rotate small lightweight neodynamic magnets placed on the outside case of the motor. Brushless work by instead of having the motor use a brush to reverse the electric phase, it instead has 3 phases run out to an Electronic Speed Controller or ESC to power the phases in the correct order to control motor speed.

ESC - Electronic Speed Controller

ESC are basically small circuit boards that have a low end microcontroller (often amtel) and op amps to feed the necessary power to motors. You will feed in a Servo Standard Pulse with an encoded duty cycle to the ESC and the ESC will produce the necessary output to the motor. Our project used 10 and 20 AMP ESC but you can buy them in excess of 100AMP. While you could build in the ESC function into your primary microcontroller, they are best offloaded to these devices because they require constant switching of phases which would use up all of your MCU’s processing time. Most ESC give add benefits of motor startup, braking and coasting/shutdown options if it stops seeing a servo signal sent to it. Plus the ESC lets you use only 1 output pin of your microcontroller instead of 3 pins for each motor.

Servo Standard Pulse

Most servo motors use a standardized pulse to send a digital signal of the angle you want the servo to move to with builtin error protection in case the signal line breaks. Every 20ms (50hz) you need to send a pulse that can last from 1ms to 2ms which equals 0% to 100%. So if you want to run at 50% you will send a pulse out that last 1.5ms every 20ms. If the servo/ESC doesn’t receive a 1-2ms pulse every 20ms then it will go into shutdown/coast mode.

Motor Prop [Propellers]When selecting motor propellers you will see numbers like 5030. This means the propeller is 5” wide with a forward pitch of 3” per revolution. Higher pitch means that it will make more lift with each

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rotation of the propeller.

AccelerometersWhen an accelerometer sensor is sitting level on the ground the readings will be < 0 m/s2, 0 m/s2, -9.8 m/s2> but when the unit is turned slightly counterclockwise around the y axis, the results will be <2,0,-7.8>. Using this we are able to easily detect the angle of the quadrotor to maintain a hover or to move forward. However, since the accelerometer’s perspective will change as the quadrotor angles, we cannot use it to tell how far it is moving in any direction. To do this you either need to mount the accelerometer into a gyroscope mount or use a gyroscope to correct for the rotation.

In this project we are simply using the accelerometer to detect balance. More advanced quadrotors actually use just a gyroscope and integrate its output to get the balance as well.

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2.ProgrammingOur program has 3 stages: Startup, Normal and Panic modes. During the startup the usart is started up first to give us debug information as soon as possible. Then the pulses for the motors are started up. When we first enable the pulses, we need to feed a 5% duty cycle pulse to the ESC to notify them to startup. Failure to produce a 50hz pulse will cause the ESC to panic and shutdown. Also the ESC startup will calibrate the ESC to the lowest speed position incase your system does not produce an accurate 5% duty cycle.

TIMERSInstead of using the PWM module of the PIC we decided to go with the Timers and create the signals ourself. We wanted to make sure that the 4 timers would keep a constant 50hz without having to worry about interrupt conflicts that would cause a break in the constant 50hz pulses.

(M0, M1, M2, M3 are the motor pulses)

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// Turn on Interrupts ---------------------------------INTCON = 0x20; INTCON2 = 0x04; // TMR0 high priorityRCONbits.IPEN = 1; // Enable priority levels

// Setup Timer0 ---------------------------------------T0CON = 0x80; // set up timer0 - prescaler 1:2TMR0H = 0x63; // Set Countdown HighTMR0L = 0x91; // Set Countdown Low INTCONbits.GIEH = 1; // Enable interrupts So we setup Timer 0 to be a perfect 50hz clock that then starts Timer1 and Timer3. We used Timer3 because Timer1,3,5 configurations are the same while Timer2,4 are different. Timer1 will turn off the output pulse when the desired duty cycle is reached. We setup a variable called motor[x] which holds the duty cycle of all 4 motors. That value is set as Timer1’s value to interrupt. Timer3 is setup to then start the next motor’s pulse. Timer 3 is setup to go off every 3ms giving the last motor an extra 1ms incase anything happens to go wrong. So using this method we can guarantee all 4 motors to get a 50hz pulse yet only use 12ms of the 20ms giving plenty of time for PID calculations.

Below is our timer interrupt code including the low level assembler block to call the high priority interrupts [our timers].

/*******High priority interrupt vector ************************/#pragma code high_vector=0x08void interrupt_at_high_vector(void){ _asm GOTO high_isr _endasm}#pragma code

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/*****************High priority ISR **************************/#pragma interrupt high_isrvoid high_isr (void){

if (INTCONbits.TMR0IF){ // 50hz - 25ms// TIMER0 --------------------------------------------------50hz SYNC INTCONbits.TMR0IF = 0; // Reset Interrupt

TMR0H = 0x63; // Timer Reload to count 1s TMR0L = 0x80; // TMR0 = 25489

//Start Timer3 for 2.5ms PulseT3CON |= 1; // ENABLETMR3H = 0xDA;TMR3L = 0x00;

}else if(PIR1bits.TMR1IF){// TIMER1 --------------------------------------------------PULSE OFF

PIR1bits.TMR1IF=0; // Reset Interrupt Timer1T1CON &= 0xfe; // Disable Timer1bitclear(RB,motorselect);PORTB=RB;motorselect++;if(motorselect>4){ // If all motors are done goto PID

motorselect=0;T3CONbits.TMR3ON = 0;

}}// TIMER3 --------------------------------------------------Next Motorelse if(PIR2bits.TMR3IF){

PIR2bits.TMR3IF=0;TMR3H = 0xBA;TMR3L = 0x00;

bitset(RB,motorselect);PORTB=RB;

// Start Timer1 for Pulse OFFT1CON |= 1; // ENABLETMR1H = motor[motorselect]>>8;TMR1L = motor[motorselect];

}}

PID - PROPORTIONAL INTEGRAL DERIVATIVE CONTROLLER

We start the PID once we leave the startup section of our code and get into normal operation. The first stage of the PID is to read the sensor data from the accelerometer. To remove noise, we have it read the sensor 5 times in a row and take the average of the numbers. During our startup we have already configured the baseAX (Base Accelerometer X value to center the voltage reading at 0) void getSensors(){

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//Get Accelerometer Readings// X-AXISOpenADC( ADC_FOSC_4 & ADC_RIGHT_JUST & ADC_20_TAD, ADC_CH0 &

ADC_INT_OFF,0);

dblchkX=0;dblchkY=0;

for(i=0; i<5; i++){

Delay10TCYx( 5 ); // Delay for 50TCYConvertADC(); // Start conversionwhile( BusyADC() ); // Wait for completiondblchkX = ReadADC(); // Read result

}dblchkX=dblchkX/5;accX = dblchkX - baseAX;

if(accX>7 || accX<-7){

panic=1;}

}

PID is a feedback loop of reading the sensors that have been offset so 0 is the desired value and then reacting to the sensor values by summing the results of porportional, integral and directives to the motor controller.

Proportional Control is the standard feedback reaction to balance an objectDerivative Control is a stopping force to not overshoot the balance pointIntegral Control is a error correction force to compensate for off balance weight and other errors

The actual PID operations are quite simple. Proportional control is simply the current reading from the sensor when it is corrected to be 0 when it is level. Derivative control is the difference of the sensor from the last reading. Integral control is the difference added up and stored in a non resetting variable through interactions. In our controller we then took the results and multiplied them by kp=5, ki=1, kd=3 coefficients.

BalanceX = ( 5 * Porportional ) - ( 3 * Derivative ) + ( 1 * Integral );MotorSPeed = Height + MotorOffset + BalanceX + MoveX;

The next page shows a single axis of PID controller code with additional modifications to make the PID work better.

// PID CONTROLLER---------------------------------------------------------integralMAX=2000; // To stop the integral from getting too largeif(accX>50){

accX=50; // Bounds check for glitches that would hurt integral

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}if(height<44000){ // 44000 is basically off the ground, start integral

if(accX > 0){sumAX += 1;

}if(accX < 0){

sumAX -= 1;}if(sumAX>integralMAX){

sumAX=integralMAX;}if(sumAX<-integralMAX){

sumAX=-integralMAX;}

}dAX=accX-lastAX;lastAX=accX;if(dAX>40 || dAX<-40){

dAX = 0; accX = lastAX;

}// BALANCE CONTROLLERS ***************************************************kp = 5; kd = 3; ki = 1;

// ***********************************************************************accXkp = kp*accX;dAXkd = kd*dAX;sumAXki = (ki*sumAX)/3; balanceX = accXkp - dAXkd + sumAXki;if (balanceX > 500){

balanceX = 500;}if(balanceX < -500){

balanceX =-500;}

We limit the integral because if it gets too large it will eventually overflow the variable and have a sudden decrease of integral control and we limit it so that when the quadrotor overshoots the balance point, it won’t take forever to reset it to 0 again. Integral control often has the issue that it builds up too slowly when you need it and it stays around too long when you no longer need it. SAFETY LOCKOUTS

When developing a quadrotor, a lot of things will go wrong and so we had built in safeties to protect ourselves and hopefully the quadrotor from breaking itself.

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Motor RPM Limiters - We stopped our motors from going under 42000 (8000rpm) to stop it from reving up too powerful. At about 44000 it will lift off the ground, so the extra 2000 gives it some movement but not too much.

Balance Limiters - In our PID controller, at the end, we bounds check it and make sure its not

more than about 200 since any more means it probably will crash before it can correct that much of an imbalance. Also this helps if a noise glitch occurs from the balance controller setting the motors to full power to correct for noise.

ADC Limiters - We bound check the incoming accelerometer values and if we ever see a value

that is over +/- 45 degrees we assume this as a noise glitch. Also the panic stop safety will kick in before this value.

Integral Limiters - Since the integral will keep building up, if we start the quadrotor during a test

flight and hold it unbalanced for a time before letting it lift off, the integral could be massive and it would never be able to correct for it.

Accelerometer Panic Stop - If the quadrotor tilts too much, the panic will kick in and basically shut

it down. During initial testing we kept this at about 10 degrees or so because we didn’t want to break our quadrotor.

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3.Vibration ManagementRunning 4 motors at 8000 rpm creates a lot of vibration that is transposed through the frame of the quadrotor. Two major components have various issues with the vibration. Motors

During startup, vibration on the motors could cause the motor to not spin correctly and the ESC will sense the phases not rotating correctly and shut down. If the motors are running, vibration can cause the motors to not spin at the speed the ESC is trying to run them at and cause the quadrotor to spin like a top. Finally, the solid magnetic enamel wire running from the ESC to the motor phase coil would cause a break in the wire to occur right where the wire enters into the coil. This break is almost impossible to fix without cutting the windings out and rewinding the entire motor.

Accelerometer

One device that was mounted onto the frame of the quadrotor that had a huge issue with vibration was the accelerometer. When the motors were off, the accelerometer would produce a very clean and accurate angle to voltage output. However, when the motors were running, the output of the accelerometer would look like pure noise on the oscilloscope.

Managing Vibrations

Rubber Pads - We placed rubber pads under each brushless motor and on the underside where the nuts lock onto the frame. This offered some vibration control but since the ESC were mounted without pads, it’s questionable if this is a reason why the enamel wire was breaking. Smoothing Capacitors - We placed a 3.3uf capacitor between each axis of the accelerometer to ground to remove the noise that we were seeing due to vibration. We tried various capacitance and found too much caused the accelerometer to be way too slow reacting. By reducing the capacitance you increase the noise but decrease the reaction time of the accelerometer. We ended up in a middle ground of noise but then used digital filter/averages to correct the outliers.

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4.Wiring Diagrams

ACCELEROMETER

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GYRO

OP AMP

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5.Aerodynamics & WeightThis project requires a lot of consideration in aerodynamics, center of mass and weight distribution.

Motors 10grams /each x 4 40 GRAMSESC ~15grams /each x 4 60 GRAMSMCU/Board 35grams 35 GRAMSFrame 101grams 101 GRAMSLiPo Battery 88grams 88 GRAMS Total 324 GRAMS

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6.Issues / Suggestions Lighter weight frame - we started off with a 20 gram circuit board frame and it had too much vibration

through it so we upgraded to Aircraft Aluminum. In hindsight this was too much of a change and we should've found a slightly stronger but lighter weight frame. While the motors could potentially lift this, it would be easier to fly if we had a much lighter frame.

Use a 5v microcontroller to cut out the need for OP-AMPs

We accidentally bought a LF 3.3v PIC and regret not getting a 5V. We then bought sensors that used 3.3v but had ESC that needed 5V signals. Also our serial MAX chip wanted 5v as well. Overall we should of done a better job reducing the different voltages that we will be needed. However the GPS module only came as 1.8vdc which could withstand up to 3.3vdc signals. Though we didn’t get around to integrating the GPS.

Motor Rewinding

We damaged a number of motors due to vibration breaking the coil wires and so we decided to learn how to rewind the motors. This actually looked like it was working great. We cut out the old windings which took longer than rewinding the motors. It is actually quite simple. There are 9 sections of the stator and you will wrap three phases. Starting with one 30AWG Enamel Magnet wire you will start at any section and place 10 windings in, then skip 2, and wind that section with the same wire. Make sure you keep your clockwise direction and number of windings the same in all sections. Then skip 2 more and finish the last winding. Repeat with Phase B and C. Then sand off the edges of all wires and using an ohm meter check that there is no short between Phase A B and C. If its good, then wire and solder one end of Phase A, B and C all together. Heat shrink all wires and you have a new motor winding. Sounds great huh? Either the enamel in the lab is bad or we nicked a wire but every motor we rewound worked great for a while and then caught fire. But don’t worry they burn out and smoke really quickly and you are left with this.

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Quadrotor AdviceJust because you should be able to lift it doesn’t mean it should weigh that much

Make everything as light as possible as it will make everything easier. Lower RPMS, less vibration, less amperage, smaller battery, etc.

Get off the protoboard as soon as possible You will waste so much time trying to get half of a quadrotor balancing to only find when you mount everything on it, that it behaves entirely different. Either design a board or use a Perf Board and mount it to the quadrotor as soon as you start trying to make it take off.

Use BluetoothYou will want debug info off the PIC and you will want to have an entire keyboard of buttons to send commands back to the PIC. Also you don’t want any extra wires going to the quadrotor.

Use a Computer Power SupplySure eventually you will want to run it on a battery but don’t waste the recharge time, you can mount the battery on the quadrotor for realistic weight but hook up the quadrotor to the 12V rail and enjoy 15amps of continuous power. The lab supplies cannot give more than a couple amps which just don’t work.

Safety Wires may not helpIf you are looking to use wires to hold your quadrotor in one place, you will find it impossible to balance because as soon as it hit one of the wires it will act like a pendulum and store energy. Your best best is to weigh it down, place it on the floor and have a kill switch ready for when it messes up.

CrashesYour quadrotor is going to crash a lot. Buy extra parts because you will eventually break motors, ESCs and blades. Often if you burn up a motor, you will also burn up the esc. And you really need to have all the motors and esc the same brand and model if you want to balance it.

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