applied

sciences
Article
Design and Dynamics of Kinetic Launcher for
Unmanned Aerial Vehicles
Mirosław Kondratiuk * and Leszek Ambroziak
Department of Robotics and Mechatronics, Mechanical Faculty, Bialystok University of Technology,
Wiejska St. 45C, 15-351 Bialystok, Poland; [email protected]
* Correspondence: [email protected]




Received: 30 March 2020; Accepted: 21 April 2020; Published: 24 April 2020


Abstract: Assisting in the starting procedure of Unmanned Aerial Vehicles (UAVs) is one of many
very important areas of modern aviation research. Supported start-up saves fuel or electrical
energy, increases operator safety and level of autonomy, extends the application area, and, in some
applications, even enables the operator to shape the motion characteristics of the initial phase of a
UAV’s flight. Currently used solutions, depending on an aircraft’s class, are based on the utilization of
rubber, pneumatic or electromagnetic launchers. All of these launchers are used for the medium class
of UAVs and all of them use the potential energy previously stored in stretched rubber, compressed
air or electrical voltage. In this paper, authors propose the novel concept of a launcher powered
through kinetic energy stored in a rotary wheel driven by an electric motor. Using the transmission
systems of the drive and the controlled clutch and an electromagnetic brake, it is possible to precisely
control the speed and acceleration of the launched object. Within the paper, the authors present and
discuss the applied equations of dynamics, the results of a simulation that was carried out using the
MATLAB/Simulink software and a conceptual CAD model of preliminary engineering solutions
for the kinetic UAV launcher. The work is summarized in the conclusions section, which details the
practical implementation of the device.

Keywords: kinetic launcher; kinetic energy storage; unmanned aerial vehicles; launch control

1. Introduction
Many different types of devices are used nowadays in the starting procedures of Unmanned
Aerial Vehicles (UAVs). The use of a UAV launcher can provide the following advantages:

• energy savings (fuel, electricity);

• compensation for insufficient on board power reserves;
• enables the take-off of UAVs without chassis;
• can be used when runway is limited or inaccessible (muddy terrain, high grass, stones, etc.);
• increases the level of operator’s safety;
• provides new possibilities for UAV design (location of wings and propulsion sources,
chassis elimination);
• ensures special start conditions (acceleration, velocity, initial angle of attack, etc.).

The most important argument among those mentioned above is operator safety. Aircraft with a
mass less than 10 kg can be thrown by operators but that can expose them to injury since the wings
or propellers sometimes have sharp edges. Another reason for using launchers is related to research
concerning formation flight. A wide range of works within this field has been conducted for many
years throughout the world [1–3] as well as in Poland [4]. Some concepts require small flying objects

Appl. Sci. 2020, 10, 2949; doi:10.3390/app10082949 www.mdpi.com/journal/applsci

Appl. Sci. 2020, 10, 2949 2 of 13

to be located in a predetermined time and in precisely defined positions [5,6]. This can be achieved by
launching airplanes sequentially at certain speeds and at specified intervals. This task can be achieved
through the use of launchers with controlled motion parameters. Numerous types of launchers are
utilized depending on the class of a UAV [7] with rubber driven catapults being the most common
in connection with small planes (up to 5 kg). Their design usually consists of a frame and a set of
rubber ropes which act as the drive. However, for micro aerial vehicles (MAVs), for example, so-called
“bungee” launchers constructed with only rubber elements without any frames are used. The size
of a rubber launcher depends on the aircraft’s dimensions as well as its mass with the possibility
to apply these types of catapults to UAVs weighing from a few to over a dozen kilograms [7,8].
Rubber launchers can have a modular structure and can be disassembled into smaller components
making them easy to transport. Some very important disadvantages of these types of devices are their
limited ability to control motion parameters and the relatively quick wear of their elastic elements
which is the reason special systems are sometimes used to monitor the tension of their rubber drives.
Work on the design and construction of rubber driven launchers is carried out, among others, at the
Bialystok University of Technology (BUT) in Poland. Pneumatic launchers can be used for small and
medium class of aircraft. In these types of catapults compressed air is utilized as the driving medium.
Great energy stored through compressing air makes it possible to launch UAVs weighing several dozen
or even hundreds of kilograms [7]. The construction of such devices requires the use of special carriage
to which the airplane being launched can be attached during the starting phase. After UAV start it is
necessary to initiate a controlled braking process of the carriage. In pneumatic launchers, maintaining
motion parameters, both during the launching and the braking phase, can be quite complicated due
to the system’s high inertial forces and thermodynamic properties [9]. Steam driven devices are also
used in starting procedures, especially in respect to large flying objects. They are most commonly
used on aircraft carriers to assist the launch of big manned aircraft and unmanned tactical airplanes
weighing up to several dozen tons [7]. Thermal energy generated by the ship’s reactors is used to
evaporate water into steam which is then used to power steam launchers. Rocket propulsion is also
used to accelerate tactical objects such as the so-called “smart” missiles that are nothing more but flying
unmanned aerial vehicles. These types of devices are most commonly used for military purposes.
The need for motion control, repeatability of startup parameters, protection against overloads and
operator safety has numerous researchers working, in Poland as well as abroad, on controlled launcher
design. The investigation of electrically powered devices has been particularly popular and has been
considered both in the past [10–12] as well today [13–17], even concerning for UAVs of a few hundred
kilograms weight [18]. A prototype of a synchronous magnetic launcher for MAVs having a mass up
to 2 kg has been developed at the BUT [8,19–21] with research into a similar prototype for aircraft
weighing 10, 20 and 25 kg also initiated [22]. Today, the main technical problem associated with
launchers for UAVs is the accumulation of energy. The use of solutions with high energy density is
essential. Depending on the design, there are several solutions for storing energy: capacitors and
batteries—in magnetic launchers, pressure tanks—in pneumatic and steam launchers, elastic parts—in
rubber driven launchers, etc. A feature that is common to all of these solutions is the storage of energy
in its potential form. However, it is possible to develop a launcher which can be powered by kinetic
energy. The storing of kinetic energy through the utilization of rotating flywheels has been known for
a long time. Their simple mechanical design ensure high reliability and durability while the transfer of
torque from such a source is possible through the use of different forms of clutches [23]. Currently,
active electromagnetic clutches and brakes provide some new possibilities for using stored rotational
energy to power UAV launchers.

2. Kinetic Launcher Idea Description and Mathematical Model

In the paper we propose the use of kinetic energy stored in a rotating flywheel, which, after being
converted through a system utilizing an active electromagnetic clutch and brake into linear motion,
can be employed to launch a UAV. The system was designed for medium class of unmanned airplanes
Appl. Sci. 2020, 10, 2949 3 of 13

not exceeding a mass of 20 kg. A construction involving the use of stored rotational energy to launch
medium-class UAVs was proposed. The name suggested for this type of catapult is the Kinetic
Launcher (KL) for UAVs. The device consists of two subsystems: the rotating drive and the drive
transmission with a synchronous toothed belt. The main components of the mechanism are presented
in Figure 1.

Figure 1. A CAD model of the kinetic launcher design.

The device needs a base consisting of a special frame on which all its components will be mounted.
The drive transmission of the launcher requires the use of synchronous toothed belts making the
conversion of the energy stored in the flywheel into kinetic energy of the launched object possible with
minimal losses. The belts are mounted on driving gears (located at the base of the launcher frame)
and on driven gears (in its top part). Torque control is possible through the utilization of an active
electromagnetic clutch and brake subsystems which need to be closed in control system loops with
feedback signals in the form of the launched object’s linear displacement, velocity or acceleration.
Measurements can be made using an encoder sensor mounted on the driven wheels in the top part
of the launcher frame. Naturally, the proposed device requires supports which will allow the setting
of the required start angle as well as a carriage on which the launched object will be fastened. This
carriage will move along linear tracks which are necessary to stabilize the motion of the launched UAV
and minimize friction. The rotating drive part of the KL is composed of a shaft mounted flywheel, a DC
motor with an asynchronous belt transmission used to drive the flywheel, driving gears attached to the
shaft, an active electromagnetic clutch connecting the flywheel and the driving shafts, a fixed braking
shaft and an active electromagnetic brake connecting the driving and the braking shafts. The rotating
drive of the KL along with a list of its main components has been presented in Figure 2.
Appl. Sci. 2020, 10, 2949 4 of 13

Figure 2. The rotating drive part of the kinetic launcher.

2.1. Structure of Kinetic Launcher

Figure 3 shows the parts of the kinetic launcher’s rotating drive and presents some crucial signals
and parameters.

bs - flywheel damping rate, [Nm/rad/s];

ω s0 - initial angular speed of the flywheel, [rad/s];
Is - flywheel moment of inertia, [kgm2 ];
ω s (t) - angular speed of the flywheel, [rad/s];
Mt (t) - driving torque transmitted by the clutch, [Nm];
ut (t) - electromagnetic clutch control signal, [dimensionless];
bnω - damping rate of the rotating drive elements, [Nm/rad/s];
rn - radius of the drive wheels of the launcher, [m];
In - total moment of inertia of the driving and driven wheels, [kgm2 ];
ω n (t) - angular speed of the driving tooth wheels, [rad/s];
Mh (t) - braking torque transmitted by the clutch, [Nm];
uh (t) - electromagnetic brake control signal, [dimensionless].
Appl. Sci. 2020, 10, 2949 5 of 13

Figure 3. Parts of the kinetic launcher’s rotating drive.

The damping of the rotational motion of the flywheel and the drive were considered in the model.
The DC motor is necessary to put the flywheel into motion and bring it up to an appropriate speed.
After that, the motor is idle and rotates freely together with the flywheel. In the construction of
the device three shafts were proposed: the flywheel shaft, the driving shaft and the braking shaft.
All shafts are mounted on bearings. Torque transmission between the shafts is achieved through
an active electromagnetic clutch and a brake controlled using dimensionless ut (t) and uh (t) signals,
respectively. On the side opposite the flywheel, the braking shaft is fixed to the launcher frame.
Figure 4 depicts the synchronous drive transmission subsystem.

g - gravitational acceleration, [m/s2 ];

µn - Coulomb friction coefficient, [dimensionless];
baero - aerodynamic damping rate, [N/m/s];
mo - mass of UAV, [kg];
mw - mass of launcher cart, [kg];
v(t) - velocity of the UAV and launcher cart, [m/s];
bnv - damping rate of the linear motion, [N/m/s];
α - angle of launch, [rad];
ω n ’(t) - angular speed of the driven wheels, [rad/s].

Figure 4. The synchronous drive transmission subsystem.

Appl. Sci. 2020, 10, 2949 6 of 13

In order to transmit motion from the driving gears to the driven gears we proposed using a
pair of synchronous toothed belts. This is a well known textbook approach often used in these
types of solutions [23]. The toothed belts have to display some level of resilience and elasticity since
we are aware that they can significantly influence the behavior of the device. We have introduced
the ωn (t) and ωn0 (t) signals which describe the angular speed of the launcher’s driving and driven
gears, respectively. Nevertheless, if we take into account the relatively not-so-small total length
and negligibly low flexibility of the belts, we can simply assume that: ωn (t) = ωn0 (t). Thus, we are
certain that v(t) = rn ωn (t) holds over the entire distance required to launch of UAV. In the model,
we introduced two masses. One of them is connected with the launching carriage and other linearly
moving parts while the second represents the UAV being launched. These masses strongly impact the
dynamic behaviors of the system both in the starting as well as in the braking phase.

2.2. Mathematical Description

In the system described in the previous subsection we introduced the angular speed of the flywheel
ωs (t) and the angular speed of the driving gears. These two variables are connected through the
torque transmitted by the active electromagnetic clutch Mt (t). Thus, the dynamic equation involving
viscous losses in the flywheel bearings can be expressed in the following way:

dωs (t)
Is = − Mt ( t ) − bs ω s ( t ) (1)
dt
The dynamic equation of the driving mechanism is more complex. It involves the torque
transmitted by the active electromagnetic clutch Mt (t), the braking torque caused by the active
electromagnetic clutch Mh (t), viscous losses in the bearings of rotating parts (bn ω), viscous losses in
the linear track (bnv ), aerodynamic drag (baereo ), gravity (g) and Coulomb friction (µn ). The impact of
the above mentioned parameters has been expressed using the following formula:

dωn (t)
In = Mt (t) − Mh (t) − bnω ωn (t) − bnv rn 2 ωn (t) − baero rn 2 ωn (t) f sep (t) −
dt  
2 dωn ( t )


rn + rn g sin (α) + µn grn cos (α) sign (rn ωn (t)) mw + mo f sep (t) .
dt

In order to describe how the UAV disengages from the launcher, we have introduced a launching
carriage/UAV separation function f sep (t) which can be expressed in the following manner:
(
1 for x (t) ≤ xh
f sep (t) = . (2)
0 for x (t) > xh

Parameter xh represents the linear distance where the braking phase starts. Assuming a lack
of flexibility of the transmission toothed belt we can create equations for linear displacement x (t),
velocity v(t) and acceleration a(t) of the launcher carriage with the attached UAV [23].
Z
x (t) = rn ωn (t) dt. (3)

v ( t ) = rn ωn ( t ) . (4)
dωn (t)
a (t) = rn . (5)
dt
Appl. Sci. 2020, 10, 2949 7 of 13

The dynamics of the active electromagnetic clutch and the brake can simply be described as a
standard RL circuit [23,24]. Equations involving time constants Tt , Th and maximum torque capacities
Mt0 , Mh0 are presented below:

dMt (t)
Tt + Mt ( t ) = Mt 0 u t ( t ) . (6)
dt

dMh (t)
Th + Mh ( t ) = Mh0 u h ( t ) . (7)
dt
Transmitted and braking torques can be controlled, respectively, by binary ut (t) and uh (t) signals.
They can be generated as the output of the control algorithm with feedback implemented on a
microcontroller. One of the simplest approaches to this is to use the xh parameter.
(
1 for x (t) ≤ xh
ut (t) = . (8)
0 for x (t) > xh
(
0 for x (t) ≤ xh
uh (t) = . (9)
1 for x (t) > xh

3. Simulations
Equations from Section 3.2 were implemented through the use of the MATLAB/Simulink software.
Several simulations were conducted. Some model parameters were constant. Their values are
presented in Table 1.

Table 1. Constant parameters of the simulated model.

Parameter Value Unit

Is 4.75 [kgm2 ]
ω s0 210 [rad/s]
mw 5 [kg]
mo 20 [kg]
rn 0.12 [m]
In 0.50 [kgm2 ]
Tt 0.05 [s]
Th 0.05 [s]
Mt0 500 [Nm]
Mh0 500 [Nm]
α 10 [deg]

Damping and friction coefficients were changed in subsequent simulations. Distance xh was
also modified. Its value directly determined the required length of the launcher.

3.1. The 1st Simulation

In order to check if the proposed conception was correct, the first simulation was conducted
without accounting for damping and friction. The xh value was arbitrarily set to 2 m. The results of
that simulation are shown in Figure 5.
Appl. Sci. 2020, 10, 2949 8 of 13

Simulation time was set to 0.65 s. The initial value of the angular speed ω s0 = 210 rad/s presented
in the Table 1, in accordance with Equation (11), corresponds to the rotational speed ns0 = 2000 rpm.

π · ns (t)
ωn ( t ) = . (10)
30
The flywheel’s mass moment of inertia was approximately calculated for a steel cylinder having
a mass of approximately 150 kg, being 0.1 m thick and having a diameter of 0.25 m. Angular speed
graphs showing the flywheel’s rotation ωs (t) and that of the driving gears ωn (t) have been depicted
in Figure 5. According to the law of energy conservation, when torque is transmitted from the
flywheel to the driving gears its angular speed drops. When the position of the launching carriage
with the UAV attached is equal or greater than xh , the active electromagnetic clutch disengages
initiating the braking phase. At this point, due to inertial forces, the UAV becomes detached from the
launcher. The braking forces act only on mass mw. This explains why the absolute maximum values
of transmitting and braking torques are equal and absolute maximum deceleration value is much
higher than the acceleration value. We also proposed the use of an active electromagnetic brake in
our kinetic launcher that causes the deceleration of the launching carriage which is clearly visible on
the acceleration graph. Unfortunately, the inertial character of the active magnetic brake extends the
braking distance. In the first simulation this was about 2 m putting the total length of the launcher at
approximately 4 m. The application of some other technique for decelerating the launching carriage,
such as mechanical bumpers or rubber catch ropes, can significantly decrease the total length of the
kinetic launcher, even to the xh value. The application of some other technique for decelerating the
launching carriage, such as mechanical bumpers or rubber catch ropes, can significantly decrease the
total length of the kinetic launcher, even to 16 m/s.

Figure 5. Results of the 1st simulation.

3.2. The 2nd Simulation

In the second simulation we increased xh value which was set to 6 m. The simulation time was
set to 1 s with the initial speed of the flywheel unchanged(ns0 = 2000 rpm). The results are presented
in Figure 6.
The results of the second simulation revealed that the chosen xh distance was too big because
the rotational speeds of the flywheel and driving wheels attained the same values. Thus, there was
no torque transfer and acceleration in the motion of the UAV. Moreover, the length of the launcher
Appl. Sci. 2020, 10, 2949 9 of 13

needed to be about 9 m. With xh = 6 m, in the second simulation, the UAV start velocity reached a
level of about 21 m/s. That value can be also achieved with the elimination of the torque transfer dead
zone.The results of the second simulation for xh = 3.25 m are presented in Figure 7.
The establishment of a proper distance for the initiation of the braking phase provided another
advantage—a decrease in the total length of the launcher. In the investigated case it was approximately
6 m. Naturally, the characteristics of the system’s dynamics are strongly dependent not only on the xh
value but also on the initial rotational speed of the flywheel. For instance, if we assume ns0 = 3000 rpm
and set xh = 7.25 m, a speed of about 32 m/s can be attained at the total length of the launcher at 14 m.
The results of example described above are shown in Figure 8.

Figure 6. Results of the 2nd simulation for ns0 = 2000 rpm and xh = 6 m.

Figure 7. Results of the 2nd simulation for ns0 = 2000 rpm and xh = 3.25 m.
Appl. Sci. 2020, 10, 2949 10 of 13

Figure 8. Results of the 2nd simulation for increased flywheel speed ns0 = 3000 rpm and xh = 7.25 m.

Of course, the increase of the launcher’s total length may cause several technical problems
(especially those connected with the construction’s stiffness). Additionally, it is also necessary to
remember the flexibility of the driving toothed belts [23].

3.3. The 3rd Simulation

In the third simulation the previous settings of the initial flywheel speed of ns0 = 2000 rpm and
initial braking distance xh = 2 m were used. Then, varying values for damping and friction coefficients
were introduced. These are presented in Table 2.

Table 2. Values of the damping and friction parameters in 3rd simulation.

Parameter Value Unit

bs 1 Nm/rad/s
bnω 1.5 Nm/rad/s
bnv 0.6 N/m/s
baero 0.5 N/m/s
µn 0.35 1

High parameter values were chosen arbitrarily to highlight their impact on the results. The results
of the third simulation are presented in Figure 9.
The influence of damping is clearly visible on the plot of rotational speeds. In the third simulation,
the UAV start velocity reached a value of about 14 m/s. This was 2 m/s less than in the 1st simulation.
The total length of the launcher also decreased from 4 m to approximately 3.2 m. Any discussion
concerning the influence of damping and friction parameters is strictly academic in character. However,
these parameters may play a crucial role in the near future comparison of results concerning simulations
with experimental measurements.
Appl. Sci. 2020, 10, 2949 11 of 13

Figure 9. Results of the 3rd simulation for flywheel speed ns0 = 2000 rpm, xh = 2 m and non-zero
damping and friction parameters.

4. Conclusions
Within the present paper the authors propose the use of a kinetic energy storage system as a
power source for an unmanned aerial vehicle launcher. The work contains dynamics equation of the
model, results of performed simulations and even a CAD model of a kinetic launcher prototype.
In general, main advantages of the kinetic launcher for UAVs are:

• Simple design that allows to actively control the acceleration and speed of the launched objects;
• Much higher energy density than in the magnetic launchers (the stored energy that can be used is
proportional to the square of the rotational speed of the flywheel and can be adjusted for different
class of lauded objects);
• A much more compact solution than pneumatic launchers to provide similar performance
(no large tank, no compressed air preparation device, no complex valves system);
• Easy scalability for different classes of launched objects.

Simulation results clearly revealed that the proposed approach may provide an alternative for
currently used pneumatic and rubber launchers. One important advantage of the described system is
the possibilities it creates for motion control. When compared to magnetic launchers, the proposed
solution is characterized by a much higher energy density allowing it to be used for bigger UAVs.
Only a simple binary algorithm for launch control is presented in the article. However, the use of active
electromagnetic systems as actuators for torque transmission makes it possible to implement any other
control rule. One idea for future research is the investigation of a control system for quasi-continued
stabilization of UAV acceleration during the launch using a PID controller. The work provided many
conclusions connected with the practical realization of the project. First of all, it is necessary to do trials
to verify whether a transmission system based on synchronous toothed belts can carry loads which
may appear during the launch. It may also be necessary to supplement it with belt tension subsystems.
Secondly, the linear motion of the launched object should be supported through a subsystem of linear
tracks. This can improve the stability of the UAV during the launch and make it possible to use the
developed kinetic launcher for airplanes of higher mass. Additionally, the CAD project assumed the
utilization of an electromagnetic actuator for braking. However, other solutions mentioned within the
paper, such as mechanical bumpers or rubber catch ropes may make it possible to decrease the total
length of the launcher. Although the results presented in the paper are very promising, within this
Appl. Sci. 2020, 10, 2949 12 of 13

last paragraph it must be stated that the future of all further investigations are connected with the
construction of a model in the laboratory allowing the verification of all assumptions and simulation
results. The authors recognize this task as quite challenging and treat it as the next stage of any future
work on the kinetic launcher for UAVs.

5. Patents
Presented in the paper concept is under patent protection no PL422977-A1 (Web of Science record
from Derwent Innovations Index).

Author Contributions: Conceptualization, M.K. and L.A.; methodology, M.K.; software, M.K.; validation,
M.K.and L.A.; formal analysis, M.K. and L.A.; investigation, M.K.; resources, M.K .and L.A.; data curation,
M.K.; writing–original draft preparation, M.K.; writing–review and editing, L.A.; visualization, M.K.; supervision,
M.K.; project administration, M.K. and L.A..; funding acquisition, M.K. and L.A. All authors have read and agreed
to the published version of the manuscript.
Funding: The research was realized as part of the Bialystok University of Technology project No
WZ/WM-IIM/1/2019 and funded by the Polish Ministry of Science and Higher Education.
Conflicts of Interest: The authors declare no conflict of interest.

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