Introduction (A.P Industries)

With the advent of the modern drone in 1935, many windows were opened up across numerous fields. Just as aviation began to take its first steps, many designers turned to unmanned aircraft as a means of accomplishing tasks without a pilot. The modern drone today can come in many shapes and sizes. The military uses drones for surveillance and operations, but an everyday person can buy drones of their own for recreational uses. Despite the numerous benefits drones open up, they are limited by one factor: refueling. While many drones can be charged with USB cables, their limited fly times and clunky charging methods hold them back from their full use.

Many current drone stations still have the issue of being bulky, and some are even less capable of charging a drone than conventional plug-in methods. If a drone were able to charge both independently and efficiently, it would eliminate the need for long cables and increase fly times. A drone with the ability to “charge and go” could perform longer without the need to fly back to the owner for a single recharge.

Our proposal, the “AeroPac” utilizes wireless charging and delivers a system that allows small drones to remotely charge on a surface without the need to return to its piloter. The charging pad may be used in a variety of scenarios, whether it be as a mobile charging system, or as a charging station on an elevated structure. The AeroPac is a platform that allows drones to land and charge without the use of cables. This technology can be placed on a variety of surfaces, so long as it itself is provided a power source. The AeroPac is currently compatible with battery and wired power, which opens up the use of mobile power.

Prototype and Mass Production Cost

We split our costs into a prototype and a mass production cost. The prototype cost includes the costs associated with building the prototype. These costs include the USB adapter, the 30 cm ribbon cable, and the micro b plug (Which was purchased through the website ada fruit) The USB adapter costs $4.95, the 30 cm ribbon cable costs $2.75, and the micro b plug is $4.95. The wireless charging module can be purchased through Amazon (which also includes a receiver and a transmitter) The Qi wireless charging module is from a brand called Abovehill and it costs $13.99. The final cost includes the 3D printed part. The cost will be determined after the part has been 3D printed. The printer itself will calculate the cost by how much petg was used to make the prototype. In total the 3D printed parts cost $32.96. For the mass production cost we included the most cost effective parts that will be used if this product were to be mass produced. Although ABS is a cheaper alternative to PETG, we believe that PETG would be better because it is more durable than ABS. The same USB cable would be used from ada fruit which cost $12.65 for the three pieces. If we decided to buy 50 of the 3D printed parts, we would be saving on each of them. The bottom part would save $130.11 costing $520,50 for the 50 parts. And for the top part would save $162.18 costing $649.00 for the 50 parts.

Figure 1 shows main parts ordered online (AdaFruit.com).

Design

Before purchasing any components or starting to model anything, one should think about the requirements. The first obstacle AeroPac had to tackle was weight. Since drastically increasing a drone’s weight can affect the speed and flight time. Another thought that you must have in mind is the clearance of the props and sensors. The last requirement is that the AeroPac should not need any modifications to the drone itself and can be removed.

The Parts that allow for wireless charging are the Qi wireless charging transmitter and Receiver Modules. They work by using resonant inductive coupling between the transmitter and Receiver Modules. For the prototype, we use modules that support 9–12 volt inputs and outputs 1.5A at 5 volts. The next item is the flat ribbon and custom 90-degree male micro-USB connector. These parts were necessary since clearance is one of the thoughts we had. The type of plastic we decided on using is PETG due to its durability since the drone would be landing on it.

Figure 2 shows the drone charger floating above the DJI spark drone (Juan Valentin).

After receiving all of the components, the next stage was the design. Using fusion 360, we imported a scale accurate model of the DJI Spark. Using the model, we created a top plate to mount to the base of the drone, however, mounting the plate on top of the drone was not an option. A hole to where the drone’s rubber feet was also added so that it can be flush with the drone. Next, we added brackets to the top plate so that a velcro strap would fasten the AeroPac to the drone. After that, we created a cut-out so that the underneath sensors remain functional. The final addon for the top plate was to create screw holes so that the pieces would all go together. Using the bottom surface of the top plate, we can extrude outward to construct the primary form of the base plate. Using the extrude tool again, we can create a cavity to install the receiver. At last, we cut out a space where the ribbon cable will reside. After these steps, components of the charging station were ready to 3d print.

Figure 3 shows the 3d model of the wireless charging model alone (Juan Valentin).

After 3d printing the housing of the AeroPac, the assembly of the prototype was straightforward. The first step in assembling the AeroPac was to solder the receiver VCC and ground cables to the ribbon cable. We then attached the ribbon cable to the 90-degree micro USB connector. Immediately after via the usage of hot glue, the receiver and ribbon were secured onto the cavity located in the base section. To finish off, we joined the top and bottom parts with the 4 screws, and finally strapped on the AeroPac with the velcro strap and connected the micro USB.

Figure 4 shows AeroPac charging. The green lights indicate that the device works (Juan Valentin).

Application of the Invention

Our invention can prove to be very convenient as a wireless charge as it removes the issue of cables and finding a powersource to wire your drone up. It can also be beneficial during long distance flights as you could preset charging stations throughout remote areas to dock at. For this accessory, you would simply land the drone onto the charging pad and the QI receiver would pick up the charge and start charging the drone. You would be able to charge it right there rather than manually hooking it up to a cable. The pad can also be deployed on any solid ground, and then the drone will fly to the designated spot for charging. As soon as it is done or when you are satisfied with the battery you can just take off with no risk of damage. The charging pad is capable of running on its own dedicated power source, as well as being hooked up to a local power source, which opens up the possibilities for large scale “rental pads”, on top of personal use pads.

This technology can be used in a wide variety of scenarios, many of which go beyond typical consumer use. “Hives” of AeroPac drones could be installed in towers, and a swarm of drones can be autonomously charged in a single structure. These drones could be used for rescue operations, construction, and surveillance missions. Rather than allowing dead drones to litter an area, a series of AeroPac stations can act as “homes” for drones, which promotes activity as well as extended use.

Conclusion

            To conclude, the Aeropac is a time-saving, lightweight, and convenient accessory for drone users. It is easily attachable/detachable and we plan on expanding this accessory to other drone models in the future, along with incorporating an emergency feature to help save drones from getting lost. We plan to implement a small magnetic pocket in the drone for an Apple airtag (or any other tracking device) so that in the chances of your drone crash landing, you would still be able to locate it without any permanent losses. For future references we are also experimenting with fast charging in order to save more time and get back on the field. Larger drone packs will incorporate faster charging ports, and many of them will be equipped on high altitude regions as makeshift drone stations. Your time is money and it is the lifeblood of this technology, so it is imperative that Aeropac offers a wide range of functionality, as well as future practicality.

 

 

 

References

ADA Fruit. (2022). USB Adapter, Ribbon Cable, etc. Raspberry Pi / Cables Section. Retrieved 2022, from https://www.adafruit.com/category/161

Amazon INC. (2022). Qi Wireless Charging Components. Amazon . Retrieved 2022, from https://www.amazon.com/gp/product/B08X6YW8C5/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1