The Mesicopter

A Meso-Scale Flight Vehicle for

Atmospheric Research
Stanford University
Prof. Il an Kroo, Dept. of Aero/ Astro
Prof. Fri tz Pri nz, Dept. of Mech. Eng.
Graduate Students:
Sam Shomans, Rudol f Lei tgeb, Shel l y Cheng,
Peter Kunz, Scott Bowi e, Mi ke Hol den
The Concept: Meso-scale Flight
I What i s a meso-scal e vehi cl e?
N Larger than mi croscopi c, smal l er than conventi onal devi ces
N Mesi copter i s a cm-scal e rotorcraft
N Expl oi ts favorabl e scal i ng
N Uni que appl i cati ons wi th many l ow cost devi ces
I Objecti ves
N Is such a vehi cl e possi bl e?
N Devel op desi gn, fabri cati on methods
N Improve understandi ng of fl i ght at thi s scal e
The Concept: Applications
I Atmospheric Studies
N Wi ndshear, turbul ence
moni tors
N Bi ol ogi cal / chemi cal
hazard detecti on
I Planetary Atmospherics
N Swarms of l ow-mass
mobi l e robots for uni que
data on Mars
I Why rotorcraft for meso-scal e fl i ght?
N As Reynol ds number and l i ft/ drag decrease,
di rect l i ft becomes more effi ci ent
N Compact form factor, stati on-keepi ng opti ons
N Di rect 4-axi s control
I Scal i ng l aws (and nature) suggest cm-scal e
fl yi ng devi ces possi bl e.
The Concept: Rotorcraft
The Concept: Challenges
I Insect-Scal e
Aerodynami cs
I 3D Mi cro-
Manufacturi ng
I Power / Control /
Sensors
Challenges: Aerodynamics
I Insect-scal e
aerodynami cs
N Hi ghl y vi scous fl ow
N Al l -l ami nar
N Low L/ D
I New desi gn tool s
requi red
Challenges: Micro-manufacturing
I Effi ci ent aero requi res 3-D rotor desi gn wi th
50 m cambered bl ades
I Mi cro-motor desi gn, constructi on
I Integrated power, el ectroni cs
(a)
Equipment at Rapid Prototyping Lab
Approach
I Advanced aerodynami c anal ysi s
and desi gn methods
I Novel manufacturi ng approaches
I Teami ng wi th i ndustry for power
and control concepts
I Stepwi se approach usi ng
functi onal scal e model tests
Approach: Aerodynamics
I Navi er-Stokes anal ysi s
of rotor secti ons at
unprecedented l ow
Reynol ds number
I Novel resul ts of i nterest
to Mars ai rpl ane
program
I Nonl i near rotor anal ysi s
and opti mi zati on code
Approach: Aerodynamics
I New resul ts for very l ow Re
ai rfoi l s
I Very thi n secti ons requi red
I Maxi mum l i ft i ncreases as Re
decreases bel ow 10,000
Approach: Rotor Optimization
I Chord, twi st, RPM, bl ade number
desi gned usi ng nonl i near
opti mi zati on
I 3D anal ysi s based on Navi er-
Stokes secti on data
I Rotor matched wi th measured
motor performance
Approach: Rotor Manufacturing
1. Micro-machine bottom
surface of rotor on wax
2. Cast epoxy
3. Remove excess
epoxy
4. Machine top
surface of rotor
5. Melt wax
Approach: Micro-Motor Development
I 1mm di ameter mi cro-motor
constructed usi ng SDM
I Fabri cati on compl ete, fi rst
spi nni ng tests underway
I Ini ti al rotor tests use 3mm
brushl ess DC motor
Steps in micro-motor fabrication
Approach: Battery Technology
I New l i thi on-i on technol ogy provi des
130 mW hr/ g -- wi l l power prototype
mesi copter for 30 mi n of fl i ght.
I SRI partners devel opi ng di rect-
wri te battery under DARPA
program. Hi gh energy densi ty system
i ntegrated wi th smal l -scal e structure.
Approach: Sensors / Controls
I Innovati ve passi ve stabi l i zati on under
test at l arger scal e
I Mi cro-motor control l ers i n devel opment
I Inter-chi p communi cati on concept
studi ed by i ndustry partner
Status
I 1.5 cm rotors desi gned, tested
I 4-Rotor concept constructed,
i ni ti al tests compl ete
I Si ngl e rotor performance
characteri zed usi ng 3mm,
325mg motor, external power
Status: Initial Prototypes
I 4-Rotor desi gn fabri cated,
assembl ed 3/ 18/ 99
I Ini ti al tests successful
Status: Initial Prototypes
I Ini ti al tests stabi l i zed on pi vot arm
I Wei ght excl udes power and
control l er
I Current esti mates suggest 1.5cm
mesi copter can l i ft batteri es,
control l er as wel l
Current Work
I Rotor testi ng, opti mi zati on
I Mi cro-motor devel opment
I Integrati on of power/ motor control s
I Di scussi ons wi th SRI, Intel , NASA on
batteri es, communi cati ons, sensor opti ons
Continuing Work / Future Visions
I Fi rst fl i ght of worl ds smal l est free-fl i ght
powered ai rcraft i mmi nent
I Program wi l l l ead to:
N New manufacturi ng approaches and
desi gn tool s for mi ni ature devi ces
N Fundamental understandi ng of smal l -
scal e fl ow for terrestri al or Mars ai rcraft
N New generati on of fl i ght vehi cl es that act
i n concert to provi de an unprecedented
sensor pl atform