Mechanical design and manufacturing of an insect-scale flapping-wing robot

Despite the prevalence of insect flight as a form of locomotion in nature, manmade aerial systems have yet to match the aerial prowess of flying insects. Within a tiny body volume, flying insects embody the capabilities to flap seemingly insubstantial wings at very high frequencies and sustain beyond their own body weight in flight. A precise authority over their wing motions enables them to respond to obstacles and threats in flight with unrivaled speed and grace. Motivated by a desire for comparably agile flying machines, research efforts in the last decade have generated crucial developments for realizing an artificial instantiation of insect flight. The need for tiny, high-efficiency mechanical components has produced unconventional solutions for propulsion, actuation, and manufacturing. Early vehicle designs proved to be flightworthy but were critically limited by the inability to produce control torques in flight. In this thesis, we synthesize all existing technologies for insect-scale manufacturing and actuation, and we introduce a new vehicle design, the "dual actuator bee," to address the need for flight control. Our work culminates in the first demonstration of controlled, hovering flight of an insect-scale, flapping-wing robot. As the ultimate goal for this research effort is the creation of fully autonomous flying robots, these vehicles must sustain their own power sources and intelligence. To that end, we explore the challenges of scaling flapping-wing flight to attain greater lift forces. Using a scaling heuristic to determine key vehicle specifications, we develop and successfully demonstrate a hover-capable vehicle design that possesses the requisite payload capacity for the full suite of components required for control autonomy. With this operational vehicle as a point of reference, we introduce an iterative sizing procedure for specifying a vehicle design with payload capacity capable of supporting power autonomy. In the development of these vehicles, the reliability of their construction has been a substantial challenge. We present strategies for systematically addressing issues of vehicle construction. Together, this suite of results demonstrates the feasibility of achieving artificial, insect-like flight.Engineering and Applied Sciences - Engineering Science

Roll, Pitch and Yaw Torque Control for a Robotic Bee

In the last decade, the robotics community has pushed to develop increasingly small, autonomous flapping-wing robotic vehicles for a variety of civilian and military applications. The miniaturization of these vehicles has pushed the boundaries of technology in many areas, including electronics, artificial intelligence, and mechanics; as well as our understanding of biology. In particular, at the insect scale, fabrication, actuation, and flight control of a flapping-wing robot become especially challenging. This thesis addresses these challenges in the context of the “RoboBee” project, which has the goal of creating an autonomous swarm of at-scale robotic bees. A 100mg robot with a 3cm wingspan capable of generating roll, pitch and yaw torques in the range of $\pm 1\mu Nm$ by using a large, central power actuator to flap the wings and smaller control actuators to steer is presented. A dynamic model is used to predict torque generation capabilities, and custom instrumentation is developed to measure and characterize the vehicle’s control torques. Finally, controlled flight experiments are presented, and the vehicle is capable of maintaining a stable pitch and roll attitude during ascending vertical flight. This is the first successful controlled flight of a truly insect-scale flapping-wing robot.Engineering and Applied Science

Scalability of resonant motor-driven flapping wing propulsion systems

From The Royal Society via Jisc Publications RouterHistory: received 2021-03-16, accepted 2021-08-31, collection 2021-09, pub-electronic 2021-09-22Article version: VoRPublication status: PublishedFunder: Leverhulme Trust; Id: http://dx.doi.org/10.13039/501100000275; Grant(s): RPG-2019-366This work aims to develop an integrated conceptual design process to assess the scalability and performance of propulsion systems of resonant motor-driven flapping wing vehicles. The developed process allows designers to explore the interaction between electrical, mechanical and aerodynamic domains in a single transparent design environment. Wings are modelled based on a quasi-steady treatment that evaluates aerodynamics from geometry and kinematic information. System mechanics is modelled as a damped second-order dynamic system operating at resonance with nonlinear aerodynamic damping. Motors are modelled using standard equations that relate operational parameters and AC voltage input. Design scaling laws are developed using available data based on current levels of technology. The design method provides insights into the effects of changing core design variables such as the actuator size, actuator mass fraction and pitching kinematics on the overall design solution. It is shown that system efficiency achieves peak values of 30–36% at motor masses of 0.5–1 g when a constant angle of attack kinematics is employed. While sinusoidal angle of attack kinematics demands more aerodynamic and electric powers compared with the constant angle of attack case, sinusoidal angle of attack kinematics can lead to a maximum difference of around 15% in peak system efficiency

Mechanical Intelligence in Millimeter-Scale Machines

Advances in millimeter-scale fabrication processes have enabled rapid progress towards the development of flapping wing micro air vehicles with wing spans of several centimeters and a system mass on the order of 100mg. Concerning flight stability and control mechanisms for these mass and power limited devices, this dissertation explores the use of underactuated “mechanically intelligent” systems to passively regulate forces and torques encountered during flight. Several experiments demonstrate passive torque regulation in physical flapping wing systems. Finally, this dissertation concludes with a detailed description of the Printed Circuit MEMS manufacturing process, developed to address the practical problem of building complex insect-scale machines.Engineering and Applied Science

A nano-stepping robotic instrumentation platform

Thesis: Ph. D., Massachusetts Institute of Technology, Department of Mechanical Engineering, 2013.Cataloged from PDF version of thesis.Includes bibliographical references (pages 115-118).The development of an Autonomous Nano-stepping Tool (ANT) system is presented. Each ANT is a small, tripodal, robotic instrument capable of untethered precision motion within a quasi-three-dimensional workspace of arbitrary size. The project aimed to address limitations of conventional benchtop micro/nanoscale measurement and manipulation systems by offering a low-cost, scalable alternative with comparable performance and extended functionality and flexibility. The design, fabrication, and evaluation the various electrical, mechanical, and software subsystems are discussed. Device prototypes are introduced along with a platform-agnostic interface for remote monitoring and control. The device step size and its frequency dependence are examined. A novel, high-resolution capacitive probe concept is detailed and characterized as an example of an inexpensive, low-power, sensor technology with which an ANT may be equipped to perform scanning probe microscopy. Several positioning schemes are discussed, including a distributed vision-based approach which utilized a custom cross-correlation processor.by Adam Joseph Wahab.Ph. D

Design and Performance of Insect-Scale Flapping-Wing Vehicles

Micro-air vehicles (MAVs)—small versions of full-scale aircraft—are the product of a continued path of miniaturization which extends across many fields of engineering. Increasingly, MAVs approach the scale of small birds, and most recently, their sizes have dipped into the realm of hummingbirds and flying insects. However, these non-traditional biologically-inspired designs are without well-established design methods, and manufacturing complex devices at these tiny scales is not feasible using conventional manufacturing methods. This thesis presents a comprehensive investigation of new MAV design and manufacturing methods, as applicable to insect-scale hovering flight. New design methods combine an energy-based accounting of propulsion and aerodynamics with a one degree-of-freedom dynamic flapping model. Important results include analytical expressions for maximum flight endurance and range, and predictions for maximum feasible wing size and body mass. To meet manufacturing constraints, the use of passive wing dynamics to simplify vehicle design and control was investigated; supporting tests included the first synchronized measurements of real-time forces and three-dimensional kinematics generated by insect-scale flapping wings. These experimental methods were then expanded to study optimal wing shapes and high-efficiency flapping kinematics. To support the development of high-fidelity test devices and fully-functional flight hardware, a new class of manufacturing methods was developed, combining elements of rigid-flex printed circuit board fabrication with "pop-up book" folding mechanisms. In addition to their current and future support of insect-scale MAV development, these new manufacturing techniques are likely to prove an essential element to future advances in micro-optomechanics, micro-surgery, and many other fields.Engineering and Applied Science

DESIGN AND CONTROL OF A HUMMINGBIRD-SIZE FLAPPING WING MICRO AERIAL VEHICLE

Flying animals with flapping wings may best exemplify the astonishing ability of natural selection on design optimization. They evince extraordinary prowess to control their flight, while demonstrating rich repertoire of agile maneuvers. They remain surprisingly stable during hover and can make sharp turns in a split second. Characterized by high-frequency flapping wing motion, unsteady aerodynamics, and the ability to hover and perform fast maneuvers, insect-like flapping flight presents an extraordinary aerial locomotion strategy perfected at small size scales. Flapping Wing Micro Aerial Vehicles (FWMAVs) hold great promise in bridging the performance gap between engineered flying vehicles and their natural counterparts. They are perfect candidates for potential applications such as fast response robots in search and rescue, environmental friendly agents in precision agriculture, surveillance and intelligence gathering MAVs, and miniature nodes in sensor networks

Analysis and Realization of a Dual-Nacelle Tiltrotor Aerial Vehicle

Unmanned aerial vehicles are a salient solution for rapid deployment in disaster relief, search and rescue, and warfare operations. In these scenarios, the agility, maneuverability and speed of the UAV are vital components towards saving human lives, successfully completing a mission, or stopping dangerous threats. Hence, a high speed, highly agile, and small footprint unmanned aerial vehicle capable of carrying minimal payloads would be the best suited design for completing the desired task. This thesis presents the design, analysis, and realization of a dual-nacelle tiltrotor unmanned aerial vehicle. The design of the dual-nacelle tiltrotor aerial vehicle utilizes two propellers for thrust with the ability to rotate the propellers about the sagittal plane to provide thrust vectoring. The dual-nacelle thrust vectoring of the aerial vehicle provides a slimmer profile, a smaller hover footprint, and allows for rapid aggressive maneuvers while maintaining a desired speed to quickly navigate through cluttered environments. The dynamic model of the dual-nacelle tiltrotor design was derived using the Newton-Euler method and a nonlinear PD controller was developed for spatial trajectory tracking. The dynamic model and nonlinear PD controller were implemented in Matlab Simulink using SimMechanics. The simulation verified the ability of the controlled tiltrotor to track a helical trajectory. To study the scalability of the design, two prototypes were developed: a micro scale tiltrotor prototype, 50mm wide and weighing 30g, and a large scale tiltrotor prototype, 0.5m wide and weighing 2.8kg. The micro scale tiltrotor has a 1.6:1 thrust to weight ratio with an estimated flight time of 6 mins in hover. The large scale tiltrotor has a 2.3:1 thrust to weight ratio with an estimated flight time of 4 mins in hover. A detailed realization of the tiltrotor prototypes is provided with discussions on mechanical design, fabrication, hardware selection, and software implementation. Both tiltrotor prototypes successfully demonstrated hovering, altitude, and yaw maneuvering while tethered and remotely controlled. The developed prototypes provide a framework for further research and development of control strategies for the aggressive maneuvering of underactuated tiltrotor aerial vehicles