Drone Development from Concept to Flight: Design, assemble, and discover the applications of unmanned aerial vehicles

Drone Development from Concept to Flight

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To my parents and family, for their support and motivation and for exemplifying the power of determination. To my teachers and mentors, for being my torchlight and guide throughout the journey of life.

– Sumit Sharma

Contributors

About the author

Sumit Sharma is experienced in unmanned systems with a specialization in drone architecture development and testing for different applications. He is experienced in drone mechanics, avionics, design, and manufacturing. In his early career, he was involved in the development and testing of the first approved agriculture drone and later getting it approved by the DGCA. Along with this, he has contributed to the development of a survey drone for aerial surveys. He was also involved in the development of high-speed and long-range surveillance drones for defense tenders. He has been involved in early agriculture spraying pilot projects and was a part of the project that aerial sprayed the locusts that hit Rajasthan in 2020.

I want to thank my parents, mentors, colleagues, and subordinates who have worked closely with me and always supported me to grow.

About the reviewers

Justin Starr, Ph.D., is the endowed professor of advanced technology and the mechatronics program coordinator at the Community College of Allegheny County (CCAC). He works to integrate advanced technology into CCAC’s course offerings, including augmented reality, unmanned aerial vehicles, electron microscopy, and collaborative robots. Previously, Dr. Starr served as CTO of RedZone Robotics, a manufacturer of water and wastewater inspection robots. He holds 14 U.S. patents for inventions in robotics, artificial intelligence, and automation. Justin earned his A.S. in general studies from CCAC, his B.S. in engineering science from the University of Virginia, and his M.S. and Ph.D. in materials engineering from the University of Florida.

Garvit Pandya is the founder of the drone manufacturing firm Innovative Unmanned Systems and a qualified engineer with a master’s degree in aeronautical engineering with a specialization in unmanned aerial vehicles. He has been working on drones for the last 7+ years, during which he has worked on various projects for army and DRDO units (ADRDE, Agra, and CHESS, Hyderabad) and conducted more than 250 fixed-wing flight operations for a DRDO unit. He has developed various UAV systems for defense and service sector requirements. He has authored a book on drones titled Basics of Unmanned Aerial Vehicles, which is available worldwide. The book is listed as a reference book on the curriculum for the Ph.D. in drone technology program at IIT, Guwahati, India.

I am thankful to all the friends, colleagues, and other connections that were directly or indirectly, knowingly or unknowingly, involved in the reviewing process. May God richly bless you all!

I am also thankful to my whole family for all their support, tolerating my busy schedule, and sticking by my side.

Ravi S Shukla is the project manager of a defense electronic manufacturing firm named Alpha Design Technologies Pvt Ltd. His last job was as a technical manager and project associate for IoTechWorld Avigation and IIT Roorkee. He has been active in the UAV industry since 2017. He has rich experience in all types of UAS, such as copter, plane, and rover. Ravi was also involved in forming drone regulations in India. He has great experience in managing different types of projects, such as R&D, design and development, and the full line of production.

I truly believe all of us in the technical world are standing on the shoulders of giants. The giants for me are the open communities, such as CubePilot, ArduPilot, Discord, Mission Planner, and QGCS, where access to information is unrestricted and people are interested in helping one another. I am deeply indebted to all the communities and the people running them. I am also thankful to my whole family for their support.

Table of Contents

Preface

Part 1: Fundamentals of Flight Engineering

1

Getting Started with UAV and Drone Engineering

Introduction to unmanned systems – unmanned ground, air, and water vehicles

Various unmanned vehicles

History and evolution of drones

Need for an unmanned system

What are unmanned aerial systems?

Types of drones and their relevance to applications

Types of drones and their specifications

System composition of a UAV

Major mechanical and structural components of a drone

Airframe

Avionics systems and subsystems of drones

The propulsion system or drive train of a drone

The power system of drones

Command and control system

Summary

2

Understanding Flight Terminologies and the Physics of Motion

Introduction to thrust, weight, lift, drag, and cruise

Thrust

Weight

Lift

Drag

Cruise

Introduction to the flight axis and its terminologies

Roll movement

Pitch movement

Yaw movement

Throttle

Thrust-to-weight ratio (TWR)

Introduction to the flight physics of a quadcopter

Engineering to achieve movements across all three axes of rotation

Hover motion

Horizontal movements

Pitch movement or forward-backward movement

Summary

3

Learning and Applying Basic Command and Control Interfaces

Introduction to GCS hardware and software

GCS hardware

GCS software

Types of GCS

Introduction to MAVLink and other open source telemetry protocols

Introduction to RCs and the different available options

Components of the RC transmitter system

Modes of working of an RC controller

Major RC protocols

Transmitter protocols

Receiving protocols

SBUS protocol

Summary

4

Knowing UAV Systems, Sub-Systems, and Components

Technical requirements

Understanding and conceptualizing the system

Designing the propulsion system

Selection criteria for motor and propeller combination

Characteristics of motors to be used

Motor specifications and thrust charts

Motor and propeller selection

Battery selection

Calculating the flight time (endurance)

Designing and developing the airframe

Developing the control system

Electronic speed controllers and flight controllers

Flight controller

Selecting the navigation and communication systems

Communication systems

Integrated GCS system with communicating devices

Selection of GPS and navigation system

Summary

Part 2: System Conceptualization and Avionics Development

5

The Application of Sensors and IMUs in Drones

The inertial measurement unit and its role

Composition of an IMU

Use of IMUs in unmanned systems

The barometer and its role

How does it work?

GPS and magnetometer and their roles

How does GPS work?

The use of GPS in drones

Voltage and current sensors and their roles

Sensor fusion and state estimation

Summary

6

Introduction to Drone Firmware and Flight Stacks

Technical requirements

Introduction to firmware

Components of firmware and their roles

Firmware example

Tools used to develop firmware

Differences between software and firmware

Introduction to drone firmware

How it is different from general firmware

The structure of drone firmware

Introduction to drone flight stacks

Open source drone flight stack

Closed source (proprietary) drone flight stack

Basic PX4 controller loop diagram

PX4 flight stack

The ArduPilot flight stack

Summary

7

Introduction to Ground Control Station Software

Technical requirements

Introduction to GCSs

Major GCS software that is available on the market

Mission Planner or APM Planner

QGroundControl

UgCS

AeroGCS software overview

AeroGCS main dashboard

AeroGCS home menu

Methods of connecting a drone

RPA or drone configuration

Autonomous mission planning

Waypoint planning

Survey planning

Summary

8

Understanding Flight Modes and Mission Planning

Technical requirements

Flight modes and types

Types of fight modes

Assigning flight modes via remote control

How it works

Assigning and changing flight modes in a GCS

Configuring the flight modes of the remote controller switch

Planning and executing an autonomous waypoint mission

Summary

Part 3: Configuration, Calibrations, Flying, and Log Analysis

9

Drone Assembly, Configuration, and Tuning

Technical requirements

Components and tools required to build a drone

Assembling the components of a drone

Airframe assembly

Motor assembly

Assembling and configuring the ESCs

Installing the flight controller

Mounting a PDB on a drone

Installing the battery

Configuring the RC transmitter and receiver

Telemetry connection

Setting up and configuring avionics

Firmware flashing

Configuring the flight controller

Understanding calibration and failsafes

Calibrating sensors

Failsafe setup and configuration

Setting up a maiden flight

Performing a maiden flight

Summary

10

Flight Log Analysis and PIDs

Technical requirements

Introduction to flight logs and their applications

Types of logs stored

Working with GCS software on logs and their graphs

Steps to download logs from the flight controller using QGC as the GCS

Analyzing download logs

Interpreting graphs

Understanding PID controllers and their uses

Methods to detect bad PIDs in drones and how to fix them

Rate controllers in a drone and tuning PIDs

Summary

11

Application-Based Drone Development

Technical requirements

Survey-based drones

Why aerial surveying is required

The role of drones in aerial surveying

Payloads used in survey missions

Integrating the payload with the drone

The Real-Time Kinematics (RTK) and Post-Processed Kinematics (PPK) positioning systems

Mission planning for a survey mission

Image stitching and post-processing

Final deliverables

Agricultural spraying drones

Spray tank integration with a drone

Agriculture spraying flight planning

Precautions and safety

Aerial delivery drones

Payload release mechanism

Safety regulations in the drone ecosystem

System redundancy

Summary

12

Developing a Custom Survey Drone

Technical requirements

Geospatial surveys

The use of geospatial surveys in the industry

Setting up the requirements for a survey drone

High-quality imaging sensors

GPS

Autonomous flight planning

Long flight time

Real-time monitoring and telemetry

Durability and weather resistance

Payload capacity

All-up weight or gross weight

Selecting the drone’s components

Airframe

Propulsion system or power trail

Flight stack selection

GPS module selection

Camera or payload

Telemetry system and selection considerations

Wiring and assembly

Drone configurations

Motor and ESC calibration

ESC calibration

Summary

References

Index

Other Books You May Enjoy

Preface

Hello readers! Welcome to the exciting world of drone development! Drone Development from Concept to Flight is a comprehensive guide that takes you on a journey from the initial concepts of drone technology to the exhilarating experience of launching your own unmanned aerial vehicle (UAV) into flight. Whether you are a hobbyist, a student, or a professional seeking a deeper understanding of drone technology, this book is designed to be your companion every step of the way.

In the pages that follow, we will delve into various aspects of drone development, covering essential topics such as drone physics, the fundamental components utilized in drone construction, and the intricacies of flight control systems such as ArduPilot and PX4 flight stacks. Understanding the physics behind drone flight is crucial for anyone aiming to design and build their own UAV, and this book provides a solid foundation in this realm.

The core of any successful drone project lies in the selection and integration of components. From motors and propellers to sensors and communication modules, we explore the diverse range of hardware that brings a drone to life. Moreover, we delve into the sophisticated software systems that govern drone behavior, with a particular focus on the widely used ArduPilot and PX4 flight stacks. These systems form the brains of your drone, enabling it to navigate, stabilize, and execute missions with precision.

To empower you further, we guide you through the intricacies of mission planning using popular ground control software such as Mission Planner, AeroGCS, and QGroundControl. These tools play a pivotal role in defining the trajectory, waypoints, and overall mission parameters of your drone, ensuring successful and controlled flights.

Assembling and configuring a drone can be a challenging yet immensely rewarding task. This book provides step-by-step guidance on the assembly process, accompanied by tips for optimal configuration to suit your specific requirements. From connecting the electronic components to tuning the flight controller, we cover the entire process to help you achieve a successful drone build.

The thrill of witnessing your drone take its first flight is unparalleled. We walk you through this momentous occasion, offering insights into troubleshooting common issues and ensuring a smooth and controlled inaugural flight. Whether you are a novice or an experienced enthusiast, the information provided will guide you toward mastering the art of drone piloting.

In the latter part of the book, we explore specialized applications of drones, with a focus on agriculture and surveying. You will discover how drones are revolutionizing these industries, providing valuable data and insights that were once difficult or impossible to obtain.

Embark on this educational and practical journey with us as we demystify the process of developing drones, turning your concepts into reality and propelling you into the exciting realm of autonomous flight. Happy droning!

Who this book is for

This book is for beginner-level drone engineers, robotics engineers, hardware and design engineers, and hobbyists who want to enter the drone industry and enhance their knowledge of the physics, mechanics, avionics, and programming of drones, multicopters, and UAVs. A basic understanding of circuits, assembly, microcontrollers, and electronic instruments such as multimeters and batteries, along with fundamental concepts in physics and mathematics, will be helpful for reading this book.

What this book covers

Chapter 1

, Getting Started with UAV and Drone Engineering, serves as the foundational chapter in our comprehensive guide. This chapter provides an accessible introduction to the exciting world of unmanned vehicles and drone engineering. The chapter further introduces the key components used in drone construction, paving the way for a hands-on understanding of hardware integration. Whether you are a novice or an enthusiast, this chapter is your gateway to the thrilling journey of developing drones from concept to flight.

Chapter 2

, Understanding Flight Terminologies and Physics of Motion, unveils the critical elements of drone flight. This chapter decodes the intricate language of aviation, clarifying terms essential for any drone enthusiast. You will delve into the physics of motion, gaining insights into lift, thrust, drag, and gravity—the fundamental forces shaping UAV dynamics. With a focus on clarity, this chapter lays the groundwork for comprehending the intricacies of drone movement and sets the stage for successful flight control system implementation.

Chapter 3

, Learning and Applying Basic Command and Control Interface, is a pivotal chapter introducing readers to ground control station (GCS) software and hardware. Delving into the remote controller interface, the chapter provides hands-on guidance for users to master the crucial aspects of controlling roll, pitch, and yaw. This essential knowledge empowers enthusiasts to navigate and manipulate their drones with precision, making it an indispensable resource for beginners and those seeking to enhance their drone piloting skills.

Chapter 4

, Knowing UAV Systems, Sub-Systems, and Components, is a comprehensive chapter unraveling the intricacies of UAVs. You will explore the diverse landscape of propulsion systems, power systems, and navigation systems, gaining a nuanced understanding of each crucial component. From delving into the mechanics of propulsion to understanding the intricacies of power distribution, this chapter provides essential insights for enthusiasts and professionals alike. Elevate your comprehension of UAV technology with this in-depth exploration of systems, sub-systems, and components.

Chapter 5

, Sensors and IMUs with Their Application in Drones, is a vital chapter exploring the world of sensors and inertial measurement units (IMUs) in drone technology. You will uncover the significance of GPS and compass integration, gaining insights into how these sensors contribute to precise navigation and orientation. This chapter serves as a guide for understanding the role of these critical components in enhancing a drone’s capabilities, making it an indispensable resource for enthusiasts, engineers, and professionals seeking to optimize their UAVs for accurate and reliable performance.

Chapter 6

, Introduction to Drone Firmware and Flight Stacks, unveils the core of drone intelligence. This chapter provides a comprehensive overview of drone firmware, focusing on popular flight stacks such as ArduPilot and PX4. You will gain insights into the intricate software systems that govern navigation, stabilization, and mission execution, laying the foundation for successful drone development. Whether you’re a novice or an enthusiast, this chapter is your gateway to understanding the brains behind your drone’s operations.

Chapter 7

, Introduction to Ground Control Station Software, provides a comprehensive overview of various GCS software, which is essential for effective drone mission planning and execution. You will explore popular tools such as Mission Planner, AeroGCS, and QGroundControl, gaining insights into their functionalities and applications. Through real-world examples, this chapter equips enthusiasts with the knowledge needed to navigate and harness the capabilities of different GCS software, ensuring a solid foundation for successful drone operations. Whether you’re a novice or an experienced user, this chapter is your gateway to mastering the tools that facilitate seamless communication and control between the operator and the UAV.

Chapter 8

, Understanding Flight Modes and Mission Planning, is an important chapter that dives into the different flight modes essential for drone operation, such as manual, position, and hold modes. You will gain insight into the functionalities of each mode, empowering you to tailor your drone’s behavior to specific needs. This chapter not only covers the intricacies of flight modes but also introduces the key principles of mission planning, providing a comprehensive guide for enthusiasts to execute precise and automated UAV missions. Whether you’re a beginner or an experienced pilot, this chapter is your gateway to mastering the dynamic capabilities of drone flight.

Chapter 9

, Drone Assembly, Configuration, and Tuning, helps guide you through the intricate process of assembling and wiring drone components. From motors and propellers to sensors and flight controllers, the chapter provides step-by-step instructions for seamless integration. You will also delve into the art of configuration, ensuring optimal settings for your specific drone requirements. This comprehensive guide is essential for both beginners and enthusiasts seeking to master the technical intricacies of bringing a drone to life.

Chapter 10

, Flight Logs Analysis and PIDs, helps in exploring the post-flight analysis of drone performance through flight logs. You will gain insights into interpreting and utilizing proportional, integral, and derivative (PID) controllers to fine-tune your drones. This chapter equips enthusiasts with the tools to optimize flight characteristics, making it an indispensable resource for enhancing drone control and performance.

Chapter 11

, Application-Based Drone Development, is a focused chapter catering to the diverse needs of survey, agriculture, and delivery drone enthusiasts. You will gain insights into tailoring drone technology to specific applications, from optimizing surveying missions to enhancing agricultural practices and efficient delivery operations. This chapter serves as a valuable resource for harnessing the full potential of drones in various real-world scenarios.

Chapter 12

, Development of Custom Survey Drone, is a specialized chapter focused on tailoring drones for surveying applications. You will gain insights into selecting and integrating components specifically suited for surveying tasks, enhancing data collection precision. This chapter serves as a practical guide for enthusiasts and professionals alike, providing the knowledge needed to design and deploy custom survey drones for diverse applications.

To get the most out of this book

Before diving into this book, you should have a basic understanding of physics principles related to drone flight. Familiarity with electronic components and their functions is recommended, along with reading the datasheets, as the book extensively covers component selection and assembly. Additionally, a cursory knowledge of ArduPilot and PX4 flight stacks, mission planning tools such as Git and GitHub, as well as a general grasp of drone assembly, configuration, and flight procedures will enhance your experience. Enthusiasts seeking insight into agriculture and survey drones will find the book more accessible with a foundational understanding of these concepts.

If you are using the digital version of this book, we advise you to type the code yourself or access the code from the book’s GitHub repository (a link is available in the next section). Doing so will help you avoid any potential errors related to the copying and pasting of code.

It is recommended to read, study, and understand the breadth of knowledge that the book covers. Try developing your own drone after going through this book.

Conventions used

There are a number of text conventions used throughout this book.

Code in text: Indicates code words in text, database table names, folder names, filenames, file extensions, pathnames, dummy URLs, user input, and Twitter handles. Here is an example: Mount the downloaded WebStorm-10*.dmg disk image file as another disk in your system.

Bold: Indicates a new term, an important word, or words that you see onscreen. For instance, words in menus or dialog boxes appear in bold. Here is an example: A Fast Fourier Transform (FFT) graph is used to visualize signals. In log analysis, this is used to convert vibration into amplitudes and display it as a frequency in the frequency domain.

Tips or important notes

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