Flexacopter ---The Making Of---

[holco]

New project for a Heavy-Lifter camera platform.


The objective are,


Multiple system use, such as, Mikrokopter with the V2.0 ESC's / OpenPilot / KKuk / and others.


Hexa setup, + and X mode.


5S setup with one 8000mAh lipo for long efficient flights.


Easy removable 20mm carbon arms with integrated power and led plugs for easy transportation in a custom case with foam padding.


Carbon 180mm frame and carbon supports for the Avroto 2814 short shaft motors.


Compact Wire Rope Isolators (diy).


Diy roll/tilt gimbal (AV-200 look alike).


Good looks!!

Dimensions test for the MK V2.0 ESC's mounting holes,

Production of the Avroto supports in 2,5mm carbon,

http://www.youtube.com/watch?v=QORE_zQUeZk


The results,

 

[holco]

First test model of a diy Compact Wire Rope Isolator, tests show a vibration reduction of 70% with 500g load,

To estimate the power and efficiency of the Avroto M2814 motors I did some testing on 5S with an Graupner E-11x5 prop.


The test I did was with an 15x15 square alum tube, so the numbers will be a little negatief because round tubes are more efficient
(less bouncing back from the prop down wash), because of this there will also be less vibrations coming from the booms.


The Flexacopter flying weight without camera bud with an 5S 8000mAh lipo will be +/- 3100g divided by six = 517g for each motor
with an extra payload of 1500g (heavy DSLR) the numbers for each motor will be 767g.


So the numbers we are looking for are, 517g and 767g


From 87 > 98 sec at the time line you can see the 500g test and the red line indicate that we are pulling 3A multiplied by six = 18A total with 3000g flying weight.


From 137 > 145 sec at the time line you can see the 800g test and the red line indicate that we are pulling 5,8A multiplied by six = 34,8A total with 4500g flying weight.


80% from the 8000mAh lipo give 6,4Ah usable energy, this will give a flying time of 6,4÷18=0,35h 0,35x60=21min flying time with 3000g.


6,4÷34,8=0,18h 0,18x60=10,8min flying time with 4500g.


Not important bud nice to know is that the total lift power of the six Avroto's is 13,8Kg (3200W!!), so plenty of headroom.

http://www.youtube.com/watch?v=0yEaTga9UG4


New design for the Wire Rope Dampers,

a sample for the removable arms power connectors

 

[holco]

Teaser,

Intergrated 140° 1W Led on the front arm, the 2 rear arms will get a green Led.

 

[holco]

Work in progress, battery box whit parts of the wire rope dampers.

MK setup has arrived

We are pretty proud of this

 

[holco]

Last Friday evening (Okt 30) and all day Saturday, we have given considerable gas to speed up this project, below the results so far.




Rhinoceros and CNC goeroe Pieter Jan proud like a monkey!!

End me of course also!!

 

[holco]

Feet's are made of POM

The Flexacopter frame is ready (Nov 13) , next step build in the electronics.

 

[holco]

Removable arms demonstration,

Wire dampers demonstration.

Buzzer far away from the rest of the electronics.

Build in led.

 

[holco]

The plan was to make a diy mount but............

Work in progress,

Love it, working without the booms

Watch the rejuvenated standoff's at the ESC's to prevent damage at some SMD parts.

Viewing window 5mm lowered for a good airflow.

Elco's fixt with hot-glue / distributie board sealed with plastik70 and created the power connection with dual strain relief.

Test and adjustments suport for the arms, also very easy for balancing work.

 

[holco]

Motors at 3° for a better yaw respons.

transition plate for the mount.

5S 8000mAh lipo's,

Here you can see where the mount adapter plate will be fixed on the battery container, the 3mm holes in the battery box are mutually staggered by 10mm and the adapter plate has slotted holes that gif a fine adjustment of + / - 5mm so that the gimbal can be mounted perfectly In the center of gravity on the longitudinal axis, the adapter plate also has a fixt offset of 9mm on the transverse axis so that the whole can be fitted perfectly balanced under the Flexacopter.

Some more pictures,

 

[holco]

To cold to mug wind and to dark, but we had to make the maiden flight


Here the poor video,

Indoor test wire dampers.

 

[holco]

Flexacopter with the CoPro HD2, look at the NO vibrations after de motors starts up.

And with the GH2,

Bought the Picloc-3X Pro because I was not happy with the limitations from the MK mount control, and so far its looking good

Final settings

 

[holco]

doubler synchronized,


http://youtubedoubler.com/?video1=7...&video2=ApsKE_x93GM&start2=0&authorName=holco


Time to think about a Flight-Case.


The disassembled Flexacopter with the AV-130 mount gives a minimum size of 60x40x22cm, so we need a Flight-Case with minimal 65x45x27cm internal dimensions, so really compact and I think a revolution in minimum size transportation of a hexacopter!!, Aldo small its just to big to take it with you as Hand luggage in a airplane, so we need something thats suitable against the violence of the airport personnel


So first we have to look for a case that fits, if not it will be a custom work flight-case.


Later there will be made some custom foam.

Some extra photos, shot with my new lens for the GH2 ) (Olympus M.Zuiko D 45mm/1,8 )

 

[holco]

 

[holco]

Promotion photo reel.

 

[holco]

Some indoor video's in a factory hall.

Extreme test with a 90mm tele lens without stabilization.

 

[holco]

A lot of people ask me if i can perform a test with and without the
wiredampers between the cameramount and frame/battery.


I tried to get the best possible testresult for comparison, during the
tests the Picloc is shut off.


In the first test a wooden block, on both sides of the wiredampers, lock
the upper and lower support of the wiredampers so they are inaffective.
I used large clamps to keep the dampers tight.


Video was taken with the GH2 camera in the mount and at the highest
possible settings. The props have switched places to keep the
Flexacopter on the ground.
After taking a shot with the wiredampers fixed i repeated the same with
active wirdedampers.


Although it adds little, i have both recordings with the GoPro running
from the rear arm on the Flexacopter.


Have a look at the video's below wich wil show you the effectivenes of
the wiredampers.


Photos of the test setup,


The locked wiredampers.

Wiredampers unlocked.

Video with the locked wiredampers with the GH2.

Video with the unlocked wiredampers with the GH2.

Video with the locked wiredampers with the Gopro.

Video with the unlocked wiredampers with the Gopro.

 

[holco]

DIY Ground-Station

 

[holco]

The plug system of the removable arms has undergone an upgrade.


From now you can just solder the wires to the ESC's and the motors without first determine the direction of rotation of the motor, is the motor running the wrong way than just mount the arm 180° the other way around and set the engine upright again and the engine is running into the other direction


Of course, later you determine the led or buzzer polarity .

 

[holco]

MK still needs a lot of tuning.

 

[holco]

A have done a test with all the props that I have suitable for the Flexacopter, I try to show what prop will give the most smooth image with the current MK gyro settings that still need some tuning.


Setup,


Flexacopter with in the AV-130 mount the GH2 camera fitted with the Olympus 45 mm F1.8 (90 mm telelens equivalent to 35mm film) (F5.6) 720P/50f-sec.


Total flying weight with the 5S/8000mAh lipo and GH2 4520 grams, Picloc Pro is off so no mount stabilization.


I have also noted the Amp rating from the MK indicated during the hoover with each prop, here the outcome.


Graupner 11x5 E (43A)
APC 12x3.8 SF (41A)
APC 14x4.7 SF (38A)
Xoar 14x5 wood (37A)


Outcome regards the video quality.


Graupner 11 x 5 (E) a clear first place.
APC 12 x 3.8 SF and the Xoar 14x5 2nd and 3rd place
APC 14 x 4.7 SF Gets the fourth place


You see also here no Free-Lunch!!
The Graupner 11x5 does it surprisingly good but has the highest consumption, The Xoar 14x5 is despite his shared 2nd and 3rd place far below the video result of the Graupner props but 6A more economical.


I would clearly indicate that this test outcome regarding the video quality in my situation is no guarantee for the same outcome with an other setup.


The 4 videos,