BionicOpter

Inspiration
Dragonfly flight
Lightweight design with intelligent kinematics

The mechanics of dragonfly flight are unique: dragonflies can man- Integration of functions in the smallest of spaces
oeuvre in all directions, glide without having to beat their wings The unique flight behaviour is made possible by the lightweight
and hover in the air. Their ability to move their two pairs of wings design of the model dragonfly and the integration of its functions:
independently enables them to slow down and turn abruptly, to sensors, actuators and mechanical components as well as com-
accelerate swiftly and even to fly backwards. munication, open and closed-loop control systems are installed in
a very small space and connected to one another.
A natural model for flight
With the BionicOpter, Festo has applied these highly complex Highly complex system with easy operation
characteristics to an ultra-lightweight flying object at a technical Despite its complexity, the highly integrated system can be opera-
level. For the first time, there is a model that can master more ted easily and intuitively via a smartphone. The flapping fre-
flight conditions than a helicopter, plane and glider combined. quency, amplitude and installation angle are controlled by
software and electronics; the pilot just has to steer the dragonfly
In addition to controlling the flapping frequency and the twisting there is no need to coordinate the complex motion sequences.
of the individual wings, each of the four wings features an amp-
litude controller. This means that the direction of thrust and the New innovations with bionics
intensity of thrust for all four wings can be adjusted individually, The BionicOpter was developed as part of the Bionic Learning
thus enabling the remote-controlled dragonfly to move in almost Network. Together with colleges, universities and development
any orientation in space. The intelligent kinematics correct any companies, Festo has spent many years developing and sup-
vibrations during flight and ensure flight stability both indoors porting projects and test models whose basic technical principles
and outdoors. are derived from nature.

Inspired by nature: the complex wing-flapping principle of the dragonfly ... ... technically achieved for the first time with the BionicOpter from Festo

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Fascinating: just like its model in nature, the artificial dragonfly can fly in all directions

Whether it is energy efficiency or lightweight construction, the Dynamic flight behaviour in all directions in space
integration of functions or the ability to learn and to communicate, Up and down, forwards, backwards and to the side: the flapping
throughout evolution, nature has developed a wealth of opti- wing design of the BionicOpter enables it to fly in all directions
misation strategies for adapting to its environment, and these in space and hover in mid-air just like a helicopter. Unlike a heli-
strategies can be applied to the world of engineering. copter, however, the dragonfly does not need to tilt forwards to
generate forward thrust. This means that it can fly horizontally as
After bird flight had been deciphered with the SmartBird, the well as float like a glider. Its lightweight design means it is able to
developers took on their next-biggest challenge: modelling the start autonomously.
dragonfly at a technical level with even more functions and even
less weight. Open and closed-loop control on board
All these manoeuvres can be executed with ease using a smart-
Lightweight construction across all parts phone. During operation, the remote-control system simply trans-
With a wingspan of 63 cm and a body length of 44 cm, the model fers the signals that tell the object which direction to fly in and at
dragonfly weighs just 175 grams. The wings consist of a carbon- what speed. The microcontroller calculates all the parameters that
fibre frame and a thin foil covering. The structure is made of can be adjusted mechanically based on the recorded flight data
flexible polyamide and terpolymer. This makes the entire system and the pilots input.
flexible and ultralight, but still sturdy. The small ribcage houses
the battery, nine servo motors and a high-performance ARM The processor actuates the nine servo motors to translate these
microcontroller, all installed in the smallest of spaces just like the parameters into movement using beat frequency, a swivel device
sensors and wireless modules. and the amplitude controller.

Free movement: even the most complex flight manoeuvres ... can be performed easily and intuitively

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Individually controlled: since the wings have nine degrees of freedom, each of them can be set and moved in a specific manner

Thirteen degrees of freedom for unique flight manoeuvres The last four degrees of freedom are in the head and tail. The
A motor in the bottom part of the housing provides the drive for body of the dragonfly is fitted with four flexible muscles made
the common beat frequency of the four wings, which is adjustable of nitinol. These shape memory alloys (SMAs) contract when
between 15 and 20 Hz (1st degree of freedom). exposed to heat and expand when they cool down. Passing an
electric current through the SMAs produces ultralight actuators
Like a real dragonfly, the BionicOpters wings can be turned from that move the head horizontally and the tail vertically. (10th, 11th,
horizontal to vertical. Each wing is individually actuated by a 12th, 13th degree of freedom)
servo motor during this process and twisted by up to 90 degrees
(2nd, 3rd, 4th, 5th degree of freedom). Process reliability through condition monitoring
In order to stabilise the flying object, data on the position and the
Four motors at the wing joints control the amplitudes. A linear twisting of the wings is continuously recorded and evaluated in
movement in the wing root infinitely adjusts the integrated crank real time during the dragonflys flight. The acceleration and tilting
mechanism to vary the deflection between approximately 80 and angle of the BionicOpter in space can be measured using the
130 degrees (6th, 7th, 8th, 9th degree of freedom). inertia sensors. The integrated position and acceleration sensors
detect the speed and spatial direction of the dragonflys flight.
The swivelling of the wings determines the thrust direction. The
thrust intensity can be regulated using the amplitude control- For Festo, the principle of continuous diagnostics is a guarantee
ler. The combination of both enables the dragonfly to hover on of operational reliability and process stability whether in bionic
the spot, manoeuvre backwards and transition smoothly from flying objects or everyday industrial use.
hovering to forward flight.

Operationally reliable: flight stability thanks to continuous data acquisition and diagnostics in real time

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Intelligently combined: the interaction of open- and closed-loop control systems enables the flying object to take nearly any orientation in space

As a global manufacturer of pneumatic and electric automa- Highly integrated bionic model
tion technology, Festos core business is helping to shape the With the BionicOpter, Festo is illustrating how these aspects of
production and working environments of the future and offers integrating functions and miniaturisation can be realised. In
its customers innovative solutions for the production systems of addition, the remote-controlled dragonfly also demonstrates
tomorrow and beyond. wireless real-time communication, the continuous exchange of
information and the combination of different sensor evaluations
Intelligent products through digital refinement as well as the identification of complex events and critical states.
Networking figures large in the vision of production of the future. Festos integrated automation concept, based on the automa-
Centralised plant control will continue its evolutionary devel- tion platform CPX, is an approach that already offers a means
opment and, at the same time, greater use will be made of the of achieving this.
opportunities afforded by decentralised self-organisation.
The electrical terminal CPX for valve terminals offers more than
Tasks that are currently still performed by a central master com- just a means of linking the field and master control levels. It has
puter will be taken over by components in the future. Individual diagnostic capabilities and can provide condition monitoring
workpieces will themselves determine what functions they need functions. Its individual modules already make it possible to
plants to provide. This digital refinement will give rise to increas- integrate the actuation of pneumatic cylinders via the modular
ingly intelligent products that can actively support the produc- valve terminals MPA and VTSA with motion controllers for electric
tion process thanks to increased functionality from energy drives. It also offers integrated safety functions. This makes it
autonomy through to condition monitoring in the smallest of possible to access diagnostic values, locate problems quickly and
installation spaces. replace faulty modules.

Ultralight construction: minimal weight ... ... despite a variety of components and functions

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Technical data Project participants

Beat frequency: Between 15 and 20 Hz Project initiator:

Wingspan: 63 cm Dr. Wilfried Stoll, Managing Partner, Festo Holding GmbH
Body length: 44 cm
Weight: 175 g Project team
Degrees of freedom: 13
Project management: Dr.-Ing. Heinrich Frontzek,
Processor: ARM microcontroller Dipl.-Des. Elias Knubben, Festo AG & Co. KG
Motor: 1 brushless VS external rotor
Wing actuation: 8 servo motors Scientific support:
Head and body actuators: 4 shape memory alloys (SMAs) Dr. rer. nat. Nina Gaissert, Festo AG & Co. KG
Sensors: Inertia, acceleration and
position sensors Design and manufacture: Rainer Mugrauer, Gnter Mugrauer,
Battery: 2 LiPo cells, 7,6 volts Effekt-Technik GmbH, Schlaitdorf
Wireless modules: 2.4 GHz spectrum
Wireless remote control: Smartphone or digital Electronics and integration: Dipl.-Ing. Agalya Jebens,
spectrum transmitter Dipl.-Inf. Kristof Jebens, JNTec GbR, Grtringen

Materials used: Credits:

Wing structure: Carbon-fibre rod Preserved dragonfly p 2 (bottom left):
Wing surface: Polyester membrane Stuttgart State Museum of Natural History
Housing and mechanical Photo credits p 2 (top): Ingo Radziwill
system: Aluminium, polyamide (sintered)
and terpolymer (deep-drawn ABS)

Festo AG & Co. KG

Ruiter Strasse 82
73734 Esslingen
54814 en 4/2013

Germany
Phone +49 711 347-0
Telefax +49 711 347-21 55
[email protected]
Film www.festo.com/bionics