V1.0

This miniQuad build is meant for racing. My goal is to build a low-budget version of this:

Charpu’s quad is around 1000 ‎€ and I think I can achieve about the same performance with a fourth of that money.

I am using the same technique as I did with the big Quad V2.0. A sandwich frame, but instead of the round profile booms, I am using square profile because it is easier to make the connection between the carbon fibre bars.

Specs:

The dxf files for the frame are my own design and can be downloaded for free from here under GNU license.

Since the quad is built for racing it is calculated to hover at 30% thrust. The total weight of the aircraft is 535g, battery included.

Formula Student experience

One year ago I joined this amazing student team. DUT15 is the name of the car that 80 people worked on so hard to bring it to life. Today I am proud to say that we are the overall winners of FSUK 2015, on the Silverstone circuit and the overall winners of FSG 2015 on the Hockenheim circuit!

SAMSUNG CSC

 

About the car

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DUT is a 4WD electric car, each wheel being powered by a motor.

  • Total weight (no driver): 160kg
  • Motors: 4 x AMK 35kW
  • Accumulator: 7.2kWh LiPo
  • Acceleration: 0-100Km/h in 2.3s

Design presentation:

 

From sketch to victory

I worked on the car as a part time Powertrain engineer. During the period of 9 months the entire team went through conceptual preliminary and detailed design, as well as manufacturing and testing. During the design phase, I was responsible for the water cooling system of the four motor controllers.  During the manufacturing phase I was in the mechanical crew milling the suspension brackets and lathing the shafts of the car.

updut2

All in all, it was an amazing experience. I improved my design and manufacturing skills and most important, I had a lot of fun building this car!

V2.0

I am creating the second version of the quad because I wasn’t happy with the performance of the first one. It was too heavy for the generated thrust. The 4 NTM 3536 motors were producing only 150% of the aircraft’s weight. That means the quad was hovering at 66% throttle which is not ok for my requirements, since I want to transport a 400g camera onboard.

My plan is to change the battery from a 3S (11.1V) to a 4S (14.8V) and change the propellers to generate more thrust. I also want to minimize the weight, so I am completely changing the frame structure. I am going again for a sandwich structure. I am using the 14mm booms for the main structure, which will be reinforced by the bottom and upper plates made of PCB. By doing this, I will also benefit from the copper paths and thus, have a distribution board for my ESCs.

The dxf files for the frame are my own design and can be downloaded for free from here under GNU license.

SRP rocket

Few days ago I had the amazing opportunity to go to ‘t Harde, at a military base to launch few rockets. Among these was my team’s rocket (John) which was designed and build by Aleksandar Petrov, Chris Niemeijer, Aleksader Parelo, Hardi Njo and myself. The goal was simple, yet challenging: to fire up a rocket up to 1 km with an egg on board and land safely to protect the payload.

And this is what happened (video by Hardi Njo):

Unfortunately, the egg did not survive and that is because the parachute did not deploy, but we did achieve about 800 m of altitude as the rocket was quite stable. That is mostly because of a detailed design in OpenRocket where the CG and the CP were properly placed. Another reason might be the fins that were 3D printed at an accurate angle between each other. The parachute wasn’t supposed to be deployed using pyrotechnics. The cone was meant to be pushed by a spring out of the body. In this way, the airflow had only one job: to open the parachute. This did not happen because of the timing. The spring was released too early, when the rocket was few moments before its apogee and the aerodynamic force was still pressing the cone downwards.

The interesting fact was that the main body of the rocket survived, despite the crash at about 200 km/h with the ground. The conclusion: it was over designed, but it was a fun experience laminating it, layer by layer.

Other rockets taking part to the event:

V1.0

A new RC project is coming! This time, the achieved CAD skills from TU Delft helped me to simulate the entire model and therefore make the optimal design:

QuadDrawing-page-001BottomFrameDrawing-page-001

The dxf files for the frame are my own design and can be downloaded for free from here under GNU license. I chose to make the frame out of 2mm carbon fiber because I found cheap sheets on http://www.hobbyking.com. Unfortunately, I couldn’t find a laser that cuts carbon fiber sheets, so I cut them with the Dremel.

Specs:

  • Motors: 4x3536 NTM (910kV, 350W)
  • Props: 4×12″
  • ESC: 4x30A
  • Accu: 5000mA
  • Frame and booms: Carbon fiber
  • Controller: HKPilot 2.7

Each motor produces 1.2kg of thrust and the final weight of the aircraft is 3.2kg. It stays in the air very stable because of the 320mm long booms.

The final product looks like this:

IMG_3750

V1.0

After the flying wing project from TU Delft – semester 1, I decided I should build my own wing with the skills achieved. So I designed it with the following specifications:

  • Wing span: 8500mm
  • Sweep angle: 30°
  • Taper ratio: 1.2
  • Propeller: 8″
  • Motor: 1400kV, 210W
  • Accumulator: 2x3S (11.1V) 1100mA

And before the first crash:

IMG_3468

Unfortunately, I couldn’t film the crashes but I can tell that I had a lot of fun building and piloting it.

The Beast is ready for the first lap

I was concerned that this project is never going to be finished, but here it is, a rear wheel drive buggy with front suspension!

After 2 years I decided to finish this project this summer. To be honest, not only did I slightly overtake my budget of 1,000, but I also had to work extra hours besides the 4 hours per day working schedule.

Nevertheless, a lap in this thing worths every single cent and time invested in it!

Infoeducatie contest – first on the podium

The project ended in a successful way, with the first prize of the national contest Infoeducatie 2013 and a special prize from Google. After a one week camp I managed to connect with different people working on very interesting projects. I got valuable feedback which I tried to implement quickly in order to improve my project. Here are a few pictures with Xtion Arm and with the rest of the competitors from Robotics and Software sections.

Roboti14
Xtion Arm – final version.
Roboti09
The robots of the camp… and their developers.
download
News paper post with the winners of the camp.

Xtion Arm v2.0

As I am qualified to participate to “Infoeducatie” National Contest, robotics section, I have started to build a new arm, 1:1 scale, stronger and which is capable of moving in 3 axis. In order to do this, I used 3 independent motors for the shoulder joint, one for elbow and one for rotation (in the biceps). In all, there are 5 motors (this model) 12 V DC, which I chose for its included gearbox with a powerful ratio (1:131) and as well as for its compactness.

Here are my sketches for the lathe man:

And here is the result:

IMG_1060IMG_1204

For the skeleton, I used plexiglass as in the previous version, but this time a thicker one (6 mm).  Here is the draft:

IMG_1103

The following pdfs are exported from CAD. This project is open source, so feel free to cut your own parts using my sketches.

plexitmp | plexi–6mm | plexi–8mm

Here are the parts after laser cuts:

IMG_1173

Putting the pieces together:

Building the frame which holds the arm:

The final result: