AeroQuad Build Thread

[John McClelland]

Jerry and I both bought Quad frames from AeroQuad:

https://www.aeroquadstore.com/SearchResults.asp?Cat=36

 

and will be posting our build notes on this thread, hopefully helping others doing similar builds and sharing experiences.  Here is the AeroFPV online manual that we will be using:

https://docs.google.com/document/pub?id=1mtqiK9pbT3gVNhPSN5rgHccKut5oI9nF3SZrUNQtaj8&pli=1

 

Check back from time to time to see how it is going!

 

John

[Daniel Tan]

maybe you guy can consider this frame that I will be bring in in two weeks time.

 

Price will be $150 + shipping..

 

No website but if keen just email to me. Just try to offer an alternative if you guy needs it.

 

Cheers!

[Daniel Tan]

sorry the spec below:

Full fiberglass and motor to motor is 48cm.

2mm fiberglass so it is solid.

[John McClelland]

Hi Daniel

 

Thanks for the info.  Jerry and I have already got our frames and will be dedicating this thread to it.

 

Best

John

[Daniel Tan]

very good.. Will follow the build and interest. I still have my UDB2 and UDB with Rusty Board sitting in holding position now..

 

Cheers.

[John McClelland]

Daniel,

 

If you intend to control your Quad with a UDB, you might consider starting a new thread dedicated to it.  We can all learn from different approaches. 

[Daniel Tan]

Sure John.

 

Thanks

[john mac]

The next post will have some background info and links to other
helpful sites for reference.

On Jan 14, 9:51 pm, "John McClelland" <mcclelland.j...@gmail.com>
wrote:

> Jerry and I both bought Quad frames from AeroQuad:https://www.aeroquadstore.com/SearchResults.asp?Cat=36
>

> and will be posting our build notes on this thread, hopefully helping others doing similar builds and sharing experiences.  Here is the AeroFPV online manual that we will be using:https://docs.google.com/document/pub?id=1mtqiK9pbT3gVNhPSN5rgHccKut5o...

[John McClelland]

Code and documentation for the MP-H Quad project is found at:
http://code.google.com/p/matrixpilotheli/wiki/QuadDoc

In the documentation you will find a parts list and supplier info for things
you will need to build the Quad. It is rather generic, but we will be doing
the build with the AeroFPV frame at:
https://www.aeroquadstore.com/ProductDetails.asp?ProductCode=FRAME-001

It assumes you have a Tx, Rx, and UDB already.

The code is an adaptation on MP-H for Helis found at the same Google Code
site. Right now it supports Pitch, Roll, and some Yaw stabilization. I say
some since we haven't included Heading Hold yet, but coming soon. Waypoint
navigation will be included at some point as part of the Heli development.

Now back to the build......

After ordering all the parts and odds and ends I spent about $400, but you
will want some spares. This was mostly tied up in the frame, motors, ESCs
and batteries.

All parts have been ordered, but only the frame has arrived as of now.
Jerry has his new frame as well. He will have to comment on other parts
etc. He was a great help to me in figuring out what to buy and where.

The AeroFPV assembly manual is at:
https://docs.google.com/document/pub?id=1mtqiK9pbT3gVNhPSN5rgHccKut5oI9nF3SZrUNQtaj8&pli=1

So I have done a fit up of the frame without attaching any of the other
components, like ESC and motors, just to see how it will fit together and if
there might be any otential issues. Things went together pretty well. The
instructions leave somethings ill-defined, but you can figure them out. We
will make a list of steps that could use some clarification. But basically
I got it all together in one night.

As we get further along, we will post pictures of the various stages of
assembly.

I will try to attach a picture of the fit up in the next post.

John

----- Original Message -----
From: "john mac" <mcclell...@gmail.com>
To: "UAVHeliBoard" <UAVHel...@googlegroups.com>
Cc: "John McClelland Gmail" <mcclell...@gmail.com>
Sent: Saturday, January 15, 2011 3:08 PM
Subject: Re: AeroQuad Build Thread

[John McClelland]

Photo of fit up is at:
http://code.google.com/p/matrixpilotheli/downloads/detail?name=Fit%20up%20of%20AeroFPV%20frame.JPG&can=2&q

Sorry about quality...will get better background.

[john mac]

Been a while since posting to this thread. Still waiting for the rest
of the parts to arrive. In the mean time, Jerry and I have been
working on an alititude hold function for the Quad (should port well
to helils too). About to start testing on Jerry's existing Quad to
see if/how it works.

Best,
John

On Jan 15, 3:59 pm, "John McClelland" <mcclelland.j...@gmail.com>
wrote:
> Photo of fit up is at:http://code.google.com/p/matrixpilotheli/downloads/detail?name=Fit%20...

>
> Sorry about quality...will get better background.
>
> John
>
> ----- Original Message -----
> From: "John McClelland" <mcclelland.j...@gmail.com>
> To: "UAVHeliBoard" <UAVHel...@googlegroups.com>
>

> Cc: "John McClelland Gmail" <mcclelland.j...@gmail.com>

> Sent: Saturday, January 15, 2011 3:44 PM
> Subject: Re: AeroQuad Build Thread
>
> > Code and documentation for the MP-H Quad project is found at:
> >http://code.google.com/p/matrixpilotheli/wiki/QuadDoc
>
> > In the documentation you will find a parts list and supplier info for
> > things you will need to build the Quad.  It is rather generic, but we will
> > be doing the build with the AeroFPV frame at:
> >https://www.aeroquadstore.com/ProductDetails.asp?ProductCode=FRAME-001
>
> > It assumes you have a Tx, Rx, and UDB already.
>
> > The code is an adaptation on MP-H for Helis found at the same Google Code
> > site.  Right now it supports Pitch, Roll, and some Yaw stabilization.  I
> > say some since we haven't included Heading Hold yet, but coming soon.
> > Waypoint navigation will be included at some point as part of the Heli
> > development.
>
> > Now back to the build......
>
> > After ordering all the parts and odds and ends I spent about $400, but you
> > will want some spares.  This was mostly tied up in the frame, motors, ESCs
> > and batteries.
>
> > All parts have been ordered, but only the frame has arrived as of now.
> > Jerry has his new frame as well.  He will have to comment on other parts
> > etc.  He was a great help to me in figuring out what to buy and where.
>
> > The AeroFPV assembly manual is at:

> >https://docs.google.com/document/pub?id=1mtqiK9pbT3gVNhPSN5rgHccKut5o...

[john mac]

This is the next installment of the Quad Build using the AeroQuad
frame and UDB with Quad firmware. It is a long post, so if you are
not interested in the build just delete now.

All the parts for the Quad have arrived!

I ended up going through Quantum Hobby to get the motors (everyone
else was out of stock). They were very helpful and I recommend using
them. And as you will see later, they had excellent after sale
customer service.

The ESCs were ordered through HobbyKing. My experience with them has
been that their prices are very good, but shipping is a pain. I used
their International Airmail option and it took about a month to get
here...plus their tracking system is pretty bad, you don't know where
it is until it shows up at your door. But if you have the time to
wait and can make a big enough order to make the shipping costs
worthwhile, you can get some good deals. Others may have had
different experiences. Mine is based on 2 orders.

The first step was to mount and wire up the ESCs to the motors and the
power distribution system.

Right now, we do not have a power distribution board to make things
easy, so all four ESCs are wired together using crimp connectors,
terminating to a Deans connector for the battery. The photo will show
my wiring and I will add a wiring diagram as well. Since these wires
carry a lot of juice, care must be taken to be sure the proper wire
sizing is used and things are properly insulated and not prone to
insulation being worn off by vibratons. I used black insulating tape
over all connections as a backup to the insulation of the crimp
connectors themselves. I tied the wires to the frame as well to
prevent vibraton. Jerry is working on a power distribution PCB. That
will make things much nicer when available.

The connections from the ESC to the motors required wire extensions to
go from the ESC wires to the motor bullet connectors. I used 12 AWG
for the extensions. There are 3 wires per ESC/motor combo and I
needed about 12" extensions on each. I used crimp connectors for the
ESC side and the bullet connectors supplied with the motors on the
motor side. I chose not to run the extensions through the arms,
worried about sharp edges at ends. So I ran the extensions under the
arms and used tie straps to fasten them. I suggest using more than
the minimum number of ties needed so if one breaks, you don't have the
wires flapping up into the props.

The next step was to make a platform for the UDB to be fastened. I
made a plexi plate that I fastened to the cage frame with double
sticky foam tape for some additional vibration isolation. I use a
Velcro strip on the plate and the back of the UDB to fasten it down.
This is the same scheme I used for my TREX and it works well. The
size of the plate and layout of the Velcro should allow a future "X"
configuration of the UDB at 45 degrees from the normal configuration.
It is possible to Velcro the Rx to this same plate (even the GPS). I
will have to check for RF interference before I decide on having Rx
and GPS that close to the UDB.

I have fairly "thin" LiPo batteries (5/8" x 1 5/8" x 6 3/8") that fit
nicely between the landing skid tray and the ESC plate. Normal LiPo
batteries may not fit in that tight space. I think Jerry reconfigured
the spacers to give more room for batteries in his setup.

The wiring of the Rx/UDB/ESCs was according to Jerry's Quad
documentation at:

http://code.google.com/p/matrixpilotheli/wiki/QuadDoc

This requires the extra input and output channels on the UDB. I made
up the single cable version Jerry references, and it works well.

I am using a Spektrum DX-7 Tx and AR6100 Rx. The only real
programming option on the DX-7 was to set up the Flight Mode 3
position switch for Mode control. This is documented in various
places on the DIY site, but never actually found the "complete" way to
do it. So I will summarize it here.

Use the ACRO (airplane) mode for the Tx (not Heli). To select the
inputs, press Down + Select during power up of the Tx. Go to the
Input Select screen. Set Flaps to System (this is the Flight Mode
switch). After power up of the Tx again, go to the Flap Sys screen.
Set the 3 positions to the desired output lengths:

Switch FLAP Elev Corresponding pulse length
NORM DN90 0 2296
MID DN25 0 2814
LAND UP50 0 3412

Auto 100%

With these settings you should use 2600 for the low threshold in
options.h and 3100 as the high threshold.

The Auto value is important since the DX-7 will go into Automatic
Landing mode when the throttle is above this value and adds an offset
to the values you set as soon as you move your throttle above
it....changing your Mode values. This was the step I didn't see in
the comments on DIY, and it will get you! If you check you modes at
zero throttle, all will look fine. As soon as you apply throttle you
will get a different Mode output.

You can look at the Mode output on the FLAP channel on your Tx screen
as you move the throttle up and down. It should not change. The FLAP
channel is AUX1 on the AR6100.

I bound the RX to the Tx. I have to look at the failsafe values I
want to use later since this is the step where you set them. You can
set them by changing throttle low in the travel adjustment screen of
the Tx during binding, then back to normal after. I don't think we
want to zero the throttle on loss of signal, but have to think about
what we do want. It is zero for now.

Now is the time to load the Quad firmware onto the UDB, also found on
the Quad site above.

That basically got me to the stage to test things out.

First you calibrate the ESC per Jerry's documentation (PROPS OFF!!!).
this basically defines the min and max throttle settings for each of
the ESCs.

Now you need to set the rotation direction of each of the motors . A
good reference at this stage is:

http://code.google.com/p/arducopter/wiki/Quad_ESC

The Front and Rear motors should rotate CW and the Left and Right
motors should rotate CCW. If a motor is rotating the wrong way you
can reverse any two wires from the ESC to that motor. Note that this
rotation defines which prop to use on each motor (tractor or pusher),
but don't put the props on yet.

It was at this stage that I noticed a random clicking which sounded
like it came from the Right ESC as I ran the throttle up and down.
After isolating the problem it turned out to be faulty wires going
into the Right motor. If I wiggled the wires going into the motor
body, the motor would change speed and at times stop. I contacted
Quantum Hobby and Tim immediately got back to me to return it for
replacement. I am going to order a spare motor and he will ship the
replacement and new motor for free. Good people to work with.

Even with the faulty motor, I was able to tilt the Quad in pitch/roll/
yaw and see the motors responding. So things look pretty good so
far. Will have to wait for the new motor to go much further.

I will send links to the photos in the next post.

On another front, we are close to testing the ultrasonic sensor for
altitude hold in a hover.

Long post, but good progress.

John

[john mac]

Here are the photos and diagrams:

Wiring diagram: http://code.google.com/p/matrixpilotheli/downloads/detail?name=Wiring%20Schematic.JPG&can=2&q=#makechanges

ESC wiring: http://code.google.com/p/matrixpilotheli/downloads/detail?name=ESC%208.JPG&can=2&q=#makechanges

Motor extensions: http://code.google.com/p/matrixpilotheli/downloads/detail?name=ESC%204.JPG&can=2&q=#makechanges

UDB platform: http://code.google.com/p/matrixpilotheli/downloads/detail?name=UDB%20platform.JPG&can=2&q=#makechanges

Where she stands now:
http://code.google.com/p/matrixpilotheli/downloads/detail?name=Long%20View.JPG&can=2&q=#makechanges

John

On Jan 27, 10:37 am, john mac <mcclelland.j...@gmail.com> wrote:

[john mac]

Here are the photos and diagrams:

Wiring diagram: http://code.google.com/p/matrixpilotheli/downloads/detail?name=Wiring%20Schematic.JPG&can=2&q=#makechanges

ESC wiring: http://code.google.com/p/matrixpilotheli/downloads/detail?name=ESC%208.JPG&can=2&q=#makechanges

Motor extensions: http://code.google.com/p/matrixpilotheli/downloads/detail?name=ESC%204.JPG&can=2&q=#makechanges

UDB platform: http://code.google.com/p/matrixpilotheli/downloads/detail?name=UDB%20platform.JPG&can=2&q=#makechanges

Where she stands now:
http://code.google.com/p/matrixpilotheli/downloads/detail?name=Long%20View.JPG&can=2&q=#makechanges

John

On Jan 27, 10:37 am, john mac <mcclelland.j...@gmail.com> wrote:

[Jerry Chapman]

John,
 
If you remove the C clip from the bottom of the motor, you can pull it apart and see whats clicking.  I had the C clip come off during flight once, and was able to put it back together.  You may not want to take it apart because of the warranty issue.
 
Jerry

 
> From: mcclell...@gmail.com
> To: uavhel...@googlegroups.com
> Subject: Re: AeroQuad Build Thread

> Date: Mon, 21 Feb 2011 12:30:01 -0700
>
> Jerry
>
> Wow that could have been the problem...I will take a look.

>
> John
> ----- Original Message -----
> From: "jlchapman" <rapto...@msn.com>
> To: "UAVHeliBoard" <UAVHel...@googlegroups.com>
> Sent: Monday, February 21, 2011 12:28 PM
> Subject: Re: AeroQuad Build Thread
>
>

> John,
>
> Your Quad looks very good. Looking forward to hearing the details of
> your first flight.
>
> I found something on my Quad that you may want to look at. The 8mm
> cap screws that secures the motors is to long in some cases. The
> screw is protruding past the internal base of the motor by approx.
> 1/8". After examining with a flashlight the internal base mount of my
> 4 motors, the screw was contacting the internal wiring on some of the
> motors. The wire is insulated but over time it may cause problems.
> Most of the screws are fine, but some are touching. This can be
> easily fixed with a washer or a shorter cap screw.
>
> Jerry

>
>
> On Feb 19, 3:15 pm, john mac <mcclelland.j...@gmail.com> wrote:
> > Here are the photos and diagrams:
> >
> > Wiring diagram:

> > http://code.google.com/p/matrixpilotheli/downloads/detail?name=Wiring...
> >
> > ESC wiring:
> > http://code.google.com/p/matrixpilotheli/downloads/detail?name=ESC%20...
> >
> > Motor
> > extensions:http://code.google.com/p/matrixpilotheli/downloads/detail?name=ESC%20...
> >
> > UDB platform:
> > http://code.google.com/p/matrixpilotheli/downloads/detail?name=UDB%20...
> >
> > Where she stands
> > now:http://code.google.com/p/matrixpilotheli/downloads/detail?name=Long%2...

> > > > >> John- Hide quoted text -
> >
> > - Show quoted text -
>

[John McClelland]

Jerry

 

Motor that was causing problem has been shipped back to Quantum.   They have already shipped the replacement, plus I bought a spare.  The other 3 seem fine.

 

I did some more work on it today.  Mounted the battery monitor/alarm and the ultrasonic sensor.  On the monitor, I used the plug that goes on the data line.  I also added an in-line fuse on the wires to the monitor.  I just don't trust the diode on the board going if there is a short.  I have seen what happens when you short even the data lines....not a pretty picture.  I mounted it with double sticky to the inside of one of the landing struts so I could see it from the ground.

 

The ultrasonic, I already had the cable I made up to allow both the sensor and the FTDI to share the UART.  I used a nylon post to mount it on the bottom plate of the quad.  This seems to work well.  No obstructions to interfere with the sonar and still protected by the skids.  Readouut seems fine.

 

There is a chance the motors might be hear tomorrow or at least this week.  So could start getting to fly soon.  Normal Quad code, then our new altitude hold with sonar.

[John McClelland]

Jerry

 

When I first tried the ultrasonic sensor, it was mounted under the Quad as i described and the Quad was sitting on the table.  Yup you guessed it, the sensor calibrates itself every power up and wants about a foot of clearance for a good calibration.  I forgot this and of course sitting on the table it had about 3" of clearance.  So the data looked strange.   Then I remembered:)

 

Just a note to not forget.

 

Now this brings up a question about startup.  The Quad needs to be level at power up to get good offsets for the accels and gyros.  It also needs to be at least a foot off the ground for the ultrasonic calibration.  So unless we unhook the sensor each power up (not), I think I need to build a little platform with a good size hole in it for the Quad to sit on during power up with clear view to the ground for the sensor.  Have you encountered this?  What is your solution?

[Daniel Tan]

Team,

have you consider the potential issue as discussed over the main UDB about the inflight reboot? Quad will not have the ability to glide so it is like also no chance of recovery if that happened.

 

Will adding another dedicated power to UDB a solution?

 

And I have Quad platform ready to do the test so will start looking at the info hear. Hope to build up one soon to test the code.

 

 

Cheers!

dan

[Jerry Chapman]

John,
 
I have an easy solution.  Just take a 5 gallon bucket(Home Depot) and cut 4 notches for the arms.  Set it on there for calibration.
 
Jerry
 

---

From: mcclell...@gmail.com
To: uavhel...@googlegroups.com
CC: mcclell...@gmail.com

Subject: Re: AeroQuad Build Thread

Date: Mon, 21 Feb 2011 15:35:47 -0700

[Daniel Tan]

Guys,

How can I actively participate on this Quad/Multi Rotor with the UDB?

 

I have all the frame ready and would like to quickly able to do the test.

 

Cheers!

[John McClelland]

Hi Daniel

 

Glad to hear you are ready to go.

 

Right now we want to make sure the normal Quad code is doing what we think it is doing.  You can download it from the site and do some bench and flight tests.

 

The next step is to test the altitude hold based on the ultrasonic sensor.  I have code for that written.  Not sure if Jerry or I will be the first to try it out (probably Jerry)

 

After that there is a lot of ideas such as fussion of the baro sensor for in flight altitutde hold, navigation, etc.

 

As far as the in flight reboot, i have flown the UDB a lot and not observed it.  But as new options and hardware is added it may be a concern.  I would not put it high on the list right now, but maybe think about an approach.

[John McClelland]

ultrasonic  http://www.sparkfun.com/products/8502

baro  http://www.sparkfun.com/products/9694

----- Original Message -----

From: Daniel Tan

To: uavhel...@googlegroups.com

Sent: Monday, February 21, 2011 7:28 PM

Subject: Re: AeroQuad Build Thread

Hi,

Which sonic sensor I should get for this code? Can share the link?

 

Thanks

On Tue, Feb 22, 2011 at 10:05 AM, Daniel Tan <dt8...@gmail.com> wrote:

ok I will start the download see if I can set it up. I like the Yltrasonic and fuse with Baro as the ArduPilot Mega has done it.

 

Inflight reboot do happen as I did experienced that year ago but that time no once idetified it as in flight reboot.

 

I also manage to get some nice price sensors from China which work towrds Mikrokopter spec. If those can be used wll greatly bring down the cost.

 

Cheers!

[Daniel Tan]

Hi,

Which sonic sensor I should get for this code? Can share the link?

 

Thanks

On Tue, Feb 22, 2011 at 10:05 AM, Daniel Tan <dt8...@gmail.com> wrote:

ok I will start the download see if I can set it up. I like the Yltrasonic and fuse with Baro as the ArduPilot Mega has done it.

 

Inflight reboot do happen as I did experienced that year ago but that time no once idetified it as in flight reboot.

 

I also manage to get some nice price sensors from China which work towrds Mikrokopter spec. If those can be used wll greatly bring down the cost.

 

Cheers!

On Tue, Feb 22, 2011 at 9:40 AM, John McClelland <mcclell...@gmail.com> wrote:

[Daniel Tan]

ok I will start the download see if I can set it up. I like the Yltrasonic and fuse with Baro as the ArduPilot Mega has done it.

 

Inflight reboot do happen as I did experienced that year ago but that time no once idetified it as in flight reboot.

 

I also manage to get some nice price sensors from China which work towrds Mikrokopter spec. If those can be used wll greatly bring down the cost.

 

Cheers!

On Tue, Feb 22, 2011 at 9:40 AM, John McClelland <mcclell...@gmail.com> wrote:

[John McClelland]

Right it does not need a GPS

----- Original Message -----

From: Daniel Tan

To: uavhel...@googlegroups.com

Sent: Monday, February 21, 2011 8:25 PM

Subject: Re: AeroQuad Build Thread

Great.. will go and get them so can start the Quad fun...

 

I already done the KK Quad and also the MK Quad. Time to get back to the UDB and maximise it.

 

One question. Can the code work w/o GPS lock? as the intend is to do inddor flight with the sonic sensor for low level height. just like the ARDone.

[Daniel Tan]

Great.. will go and get them so can start the Quad fun...

 

I already done the KK Quad and also the MK Quad. Time to get back to the UDB and maximise it.

 

One question. Can the code work w/o GPS lock? as the intend is to do inddor flight with the sonic sensor for low level height. just like the ARDone.