UNCREWED AIRCRAFT SYSTEM (UAS)

DESIGN REPORT
SAE INDIA AEROTHON 2024

TEAM NAME : TEAM CHALLENGERS [AT2024008]

TEAM MEMBERS: SUSHAN S SHETTY

K ANUP PAI
ADARSHA
MOHAMMAD SHAYAAN FAYAZ
CHIRAG SUVARNA
AMOG
BHAVISH RAI B
PRATHAM RAYKAR
RANJITH
SATHWIK SHETTY N
 STATEMENT OF COMPLIANCE
Certification of Qualification

Team Name: Team Challengers

University/Institute: Sahyadri College of Engineering and Management
Faculty Advisor: Dr. Ajith BS
Faculty Advisor’s Email: [email protected]

Statement of Compliance

As Faculty Advisor, I certify that the registered team members are enrolled in collegiate
courses. This team has designed the UAS for the SAE AEROTHON 2024 contest,
without direct assistance from professional engineers, R/C model experts, pilots, or
related professionals.

Signature of Faculty Advisor Date:10-06-2024

Team Captain Information:

Team Captain’s Name : Sushan S Shetty

Team Captain's E-mail : [email protected]
Team Captain’s Phone: +91 63602 98756
 Table of Contents

1 Introduction 6

1.1 Background 6

1.2 Introduction to UAS 6

1.3 Summary 6

1.4 Literature Survey 7

2 Schedule 8

2.1 Team Structure 8

2.2 Milestone 8

3 Methodology 9

3.1 Design and Build 9

3.2 Detailed Methodology of Flight Controller and Onboard Computer 10

3.2.1 System Design for Capturing the Survey 10

3.2.2 Autonomous Methodology 11

4 UAS Performance 13

4.1 Power Required Estimation 13

4.2 Power System (Battery Selection) 13

4.3 Endurance Estimation 14

5 Design and Development 15

5.1 Configuration Selection 15

5.2 Preliminary Design 15

5.3 Conceptual Design 16

5.3.1 Hub 16

5.3.2 Rotor Arm 16

5.3.3 Landing Gear 17

5.3.4 Dropping Mechanism 17

5.4 Material Selection 18

6 Subsystem Selection 19

6.1 Propulsion 19

6.2 Flight Control and Processing 20

6.3 Communication and Navigation 20

6.4 Power and Power Distribution 20

7 UAS Performance and Endurance Calculation 21

8 CG and Stability 23

8.1 COG of the Overall Assembly 23

8.2 Stability Factors 24

9 Structural Analysis 25

9.1 Threaded Motor Arm 25

9.1.1 Static Analysis of Threaded Motor Arm 25

9.1.2 Further Optimization of the Threaded Motor Arm 28

9.2 The Drone Hub 29

9.2.1 Further Optimization of the Drone Hub 32

10 Computational Fluid Dynamics 33

11 Innovative Design 34

12 Conclusion 35

APPENDIX A

-Estimation of Weight

-Estimation of Budget

-Technical Drone Specification

 List of Figures

Sl. No. Title Page No.

1 Team Structure 8

2 Milestone 8

3 Operational flowchart 10

4 Logic for capturing Survey data 11

5 Autonomous UAS subsystem Architecture 12

6 Logic Diagram for Autonomous Payload Dropping 12

7 eCalc Mission Power estimation 13

8 UAS Endurance Estimation 14

9 Drone Configuration 15

10 First Design iteration 15

11 Conceptual Design 16

12 Hub 16

13 Rotor Arms 16

14 Landing gear 17

15 Dropping Mechanism 17

16 Throttle (%) vs Thrust produced (kgf) 21

17 Throttle vs T/W 22

18 Efficiency Curve 22

19 Mesh Control - Rotor Arms 25

20 Stress Analysis - Rotor Arm 27

21 Displacement - Y - Rotor Arm 27

22 Rotor Arm Topology result 28

23 Static Stress Analysis - Hub 31

24 Displacement - Y - Hub 31

25 Resultant Strain - Hub 31

26 Hub Topology result 32

27 Pressure Flow 33

28 Velocity along x Axis 33

29 Final Render 34
 List of Tables

Sl. No Title Page No.

1 Material Selection 18

2 Motor Data sheet 19

3 Flight TIme calculated values 22

4 COG of the overall Assembly 23

5 Mesh Information - Rotor Arm 25

6 Mesh Control - Rotor Arm 25

7 Material Properties - Rotor Arm 26

8 Load and Fixtures 26

9 Load Distribution 27

10 Stress Analysis - Rotor Arm 27

11 Displacement Y - Rotor Arm 27

12 Mesh Information - Hub 29

13 Reaction Forces - Hub 29

14 Free Body Forces - Hub 30

15 Mesh Control - Hub 30

16 Static Stress Results - Hub 31

17 Displacement -Y Result - Hub 31

18 Strain Values - Hub 31

1. Introduction
1.1 Background
SAE Aerothon is a National student competition hosted by SAE India (Society of Automotive
Engineers). It challenges engineering students to design, build, and fly an uncrewed aircraft
system (UAS) that embodies the principles of efficiency and ingenuity.
The theme for this edition of AeroTHON is “Surveillance and Disaster Management.”
The contest is planned in two phases:
• Phase – 1: Design Report & Oral Presentation
• Phase – 2: Flying Competition.
1.2 Introduction to UAS
Multirotor systems, commonly known as drones, have significantly impacted various industries
such as agriculture, surveillance, logistics, and entertainment. These systems are
characterized by multiple rotors providing lift and maneuverability. Multirotor configurations
include tricopters (three rotors), quadcopters (four rotors), hexacopters (six rotors), and
octocopters (eight rotors), each with distinct advantages and trade-offs regarding stability, lift
capacity, flight duration, and complexity.
The quadcopter configuration, utilizing four rotors, is particularly favored for several
reasons. It offers simplicity and cost-effectiveness due to its straightforward mechanical
structure, reducing manufacturing and maintenance costs. Quadcopters balance stability and
maneuverability, allowing precise control in various flight conditions. Their power distribution is
efficient, making them suitable for applications requiring moderate flight times and payload
capacities. While quadcopters lack the redundancy of hexacopters or octocopters, they are
less complex and easier to repair, making them ideal for many civilian applications.
Additionally, quadcopters are generally more compact and lighter, enhancing portability and
ease of deployment.
1.3 Summary/Abstract
This year's competition aims to create, assemble, and pilot a multirotor UAV that can carry out
tasks including surveying, object identification, counting, and delivering cargo to a designated
area. The teams will create a UAS to identify objects in the competition area and carry out both
autonomous and manual tasks, including surveying the environment and delivering a
predetermined payload to a target.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|6

1.4 Literature Survey:
This paper proposes a solution for the autonomous payload dropping using UAVs. It proposed
a two-part system. The first part involves GPS-based autonomous navigation and the second
part employs an object detection algorithm that requires the presence of a target for the
payload dropping. When the target is detected the dronekit-API is utilized to align the UAV
such that the payload-dropping target is in the center of the frame to ensure precision while
dropping the payload.[1]
With an emphasis on creating an interesting lightweight yet sturdy quadcopter chassis, this
study tackles the critical problem of creating a lightweight Unmanned Aerial Vehicle (UAV)
chassis to improve the thrust-to-weight and power-to-weight ratios, which are essential for
optimal flight performance. sophisticated generative design approaches that combine topology
optimization with 3D printing, Autodesk Fusion 360 software, and lightweight materials. The
paper presents effective solutions that dramatically increase overall performance metrics and
structural efficiency in quadcopter chassis designs. With appropriately completed simulations,
the findings show promise for precision agriculture applications and advanced aerial robots.
This highlights the significance of customized design techniques for various engineering
fields.[2]
This study describes the use of 3DEXPERIENCE software in the design of a tiny Unmanned
Aerial Vehicle (UAV). Numerous techniques are used during the frame part design process to
guarantee that the components can satisfy the specifications while adhering to industry and
safety norms. The first stage of the design process involves choosing the drone's materials,
which include polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), and acrylonitrile
styrene acrylate (ASA). [3]

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|7

2. Schedule
2.1 Team structure
Achieving success requires collective effort and dedication. The SAE Micro 2024 project team,
led by Sushan Shetty, consists of enthusiastic young engineers committed to the field of UAS.
The team is organized into three specialized categories—system, aerodynamics, and payload
& propulsion—each with a dedicated head. This structure allows efficient division of the design
process and ensures thorough monitoring, with each team having members and leaders
responsible for their specific areas.

Fig.1: Team Structure

2.2 Milestones
Participating in an event like SAE is the result of months of hard work. To keep the team
informed about key deadlines for design and manufacturing goals, and to track task completion
status, a Gantt chart is being used.

Fig.2: Milestone

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|8

3. Methodology
Our team explored various methods and strategies before settling on our final
configuration. The process and steps we employed during the event have been detailed in the
flowchart.
3.1 Design and Build
The primary design goals for the UAS include maintaining a total weight under 2kg,
incorporating a payload capacity of 200g, ensuring modularity for easy assembly and
disassembly, achieving compactness for ease of transportation, and ensuring durability using
materials like carbon fiber PLA for strength and lightweight.
The structural design of the UAS involves a frame made from carbon fiber PLA, chosen
for its high strength-to-weight ratio and ease of 3D printing. The frame features arms extending
symmetrically from the center, providing stability and balance, with modular components such
as detachable arms and motor mounts for quick replacements and upgrades. The payload
mechanism includes a payload bay designed to securely hold a 200g payload, with a
servo-operated release mechanism controlled via the flight controller. The payload bay is
integrated into the frame to maintain the drone's balance and aerodynamics.
The propulsion system consists of brushless DC motors selected for their efficiency and
power-to-weight ratio, optimized propellers for stable and efficient flight, and high-performance
electronic speed controllers (ESCs) to manage motor speeds precisely. The power system
includes a lightweight Molicel battery with sufficient capacity to power the drone and its
payload for the desired flight duration, and a power distribution board (PDB) ensuring efficient
power delivery to all components.
Assembly and integration involve strategic placement of components to maintain
balance and center of gravity, neat and secure wiring to prevent interference and ensure
reliability, and rigorous testing of individual components and the entire system to ensure
functionality and performance. Software integration includes configuring the Pixhawk Cube
with appropriate parameters for stability and control, setting up the Jetson Nano with
necessary libraries and the YOLOv8 algorithm, and developing scripts using the MAVSDK
library to enable seamless communication and control between the flight controller and
onboard computer.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|9

 Fig.3: Operational Flowchart

3.2 Detailed Methodology of Flight Controller and Onboard Computer:

3.2.1 System Design for capturing the survey data:

With the help of the OpenCV library, on the detection of the hotspots, the image will be
stored in the local storage of the onboard computer. The survey data will be stored in the .jpeg
format. The entire flight time will be recorded in the local storage of the onboard computer in
the .mp4 format. Parallelly the video will be live-streamed using the 3DR telemetry module on
a laptop. The SD card present in the Jetson Nano will then be removed and inserted into a
laptop where the files can be accessed and retrieved.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|10

 Fig.4:Logic for capturing survey data

3.2.2 Autonomous Methodology:

Autonomous operation of the UAV is achieved by incorporating Jetson Nano as an
onboard computer which is serially connected to the PX4 Flight Controller. An Intel Realsense
D435i camera is connected to the onboard computer the PX4 Flight Controller. The live
streaming is achieved using the 3DR Telemetry module. Communication between the Jetson
Nano and the Flight Controller is achieved using the MAVSDK library.
The Jetson Nano retrieves the frames from the camera and runs the YOLOv8 Object
Detection. Based on the outcomes of the model, the onboard computer sends the MAVSDK
commands to the Flight Controller. When the target for the payload dropping is detected,
MAVSDK commands are sent to align the UAV such that the target is in the center of the
frame. Once aligned, the UAV is lowered to drop the payload.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|11

 Fig.5: Autonomous UAS Subsystem Architecture

Fig.6: Logic Diagram for Autonomous Payload Dropping

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|12

4. Aircraft Performance:
4.1 Power Required Estimation:
Power estimation and primary electronic selection were done using a wattmeter. The
wattmeter readings were later verified using eCalc, a popular online calculator for estimation
and understanding power estimation.
The wattmeter was connected with an 80A ESC on one side and a 4s Lipo battery for
power delivery. The ESC was connected to the motor, where the motor was made to operate
at 100% throttle, and the wattmeter values were recorded.
From the wattmeter readings of different motors ranging from 650KV to 1300KV and each
motor using their appropriate prop size, we got an estimate of using a 650 KV motor using a
1344 prop, Further the Speed controller in use will be 35A which was the max current drawn
shown during the wattmeter tests, yet as a safety margin we shall be considering an ESC of
60A rating. The below figures show the eCalc value estimation.

Fig.7: eCalc Mission Power Estimation

4.2 Power System (Battery) Selection:

In the realm of surveying, maximizing endurance reigns supreme. Longer flight times
translate to a greater coverage area, allowing you to collect more data and complete projects
faster. While Lithium Polymer (LiPo) batteries boast a slightly higher thrust advantage, and

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|13

quick response to movements due to lower PWM response times, yet a major loss to efficiency
for drones aiming for longer flight times. Hence during the battery selection process, we
decided to move along with molicel batteries which offer a much longer flight time for a
significant weight reduction of nearly 55% and a 100% increase in battery capacity (4.4Ar - 8.8
Ah). In this scenario, the extra thrust benefit of LiPo becomes insignificant compared to the
increasing flight time by nearly 25% achieved with Li-ion. A much larger area per flight,
reducing recharge downtime and significantly improving surveying efficiency. This also
becomes more helpful as fewer batteries can be carried to these survey locations which
significantly decreases the luggage load on the team undertaking the survey.

4.3 Endurance estimation:

From the mission description, we know that the maximum flight time for a particular
mission is 10 minutes, yet having a safety margin we design our endurance for more than the
designated mission time allotment. Using eCalc most prominent online tool for calculating
drone power figures we had gotten an estimation of 10.7 minutes of flight time using LiPo
batteries, Due to the limited
functionality of the paid software we
were able to calculate just a few
limited values required for the
endurance estimation. From the Motor
at maximum draw, we can see the
following values: The motors in use
are the T-motor MN2806 KV650,
which are some most efficient motors
for speed endurance, and agility.
(More regarding the motor selection
procedure in the
Fig.8: UAS endurance estimation

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|14

5. Design and Development
5.1 Configuration selection
While other multirotors like hexacopters and octocopters offer advantages in specific areas,
quadcopters often strike the best balance for payload carrying and maneuvering. Their simple
design with four rotors makes them easier to control and maintain, while the efficient use of
energy allows for good flight times. Additionally, the independent control of each rotor grants
exceptional agility and responsiveness, making them ideal for navigating tight spaces and
performing complex maneuvers. Finally, quadcopters can carry a significant payload relative to
their size and weight, making them a versatile choice for a wide range of applications.

Fig.9: Drone Configuration

5.2 Preliminary design:

Initially, our preliminary design featured a fixed rotor
arm. We conducted a thorough analysis of this
preliminary design, which provided critical insights into
the necessary modifications for improving our drone.
Through a series of iterative refinements, we
systematically implemented these changes, ultimately
leading to our current final design. This process of
continuous evaluation and enhancement ensured that
our final product met all performance and efficiency
criteria.The weight of this this model was 2.5kgs Fig.10: First Design Iteration

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|15

5.3 Conceptual design:

Fig.11: Conceptual design

Our initial drone design underwent rigorous optimization. Through numerous iterations, we
utilized Solidworks' topology optimization feature to meticulously analyze and refine the weight
distribution. This iterative process resulted in a final design that was significantly lighter,
boasting a more efficient structure. The weight reduction translates to substantial cost savings
in manufacturing, ultimately bringing the total project budget down. This optimization not only
improved the drone's performance by reducing weight but also ensured it remained
cost-effective for production.
5.3.1 Hub
The hub design prioritizes space utilization for a compact drone profile,
enhancing its agility and maneuverability. This focus on compactness
wasn't achieved at the expense of functionality. We utilized Solidworks'
topology optimization feature to analyze the hub's structure and
strategically remove excess material. This innovative approach ensured
the hub remained strong while achieving a significant weight reduction.
Hub Sizing: The HUB has a height of 174 mm and length of 190 mm and width of 130 mm
and a wheelbase of 512.33 mm.
Propeller Clearance: The usage of T Motor P13*4.4 Prop
gives us a propeller clearance of around 20 mm.
5.3.2 Rotor Arms
Our rotor arms boast an innovative attachment method that
prioritizes both ease of replacement and joint strength. We've
implemented a threading mechanism that secures the arms to

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|16

the hub. This approach offers a distinct advantage: in the unfortunate event of a crash causing
a broken arm, the threaded design allows for a quick and effortless replacement, minimizing
downtime. But the benefits extend beyond convenience. The threading mechanism itself also
contributes to a stronger connection between the arm and the hub, enhancing the overall
durability of the drone in flight. This innovative solution effectively balances the need for a
robust design with the practicality of a user-friendly repair system.
Rotor Arm sizing: The rotor arm measures 150 mm long, 35 mm wide, and 32.5 mm high.
5.3.3 Landing gear:
The landing gear is a simple slider assembly with a robust structure,
which can be easily assembled and disassembled for better
portability. The material used for building the landing gear is ABS-PC,
using additive manufacturing. The Landing gear is then protected with
bushing at the foot for additional padding and shock absorption, The
material of the bushing is TPU, which offers lightweight yet strong
padding for the landing gear and better shock-absorbing capabilities in case of any emergency
landing.
Landing gear sizing: The landing gear measures 100 mm high, 285 mm long, and 280 mm
wide.
5.3.4 Dropping Mechanism
Our dropping mechanism employs a robust dual-servo design for
precise and reliable payload release. Two servos are positioned
on opposing sides of the hub. These servos connect to a specially
designed gripping jaw that securely holds the payload during
flight. For controlled and precise drop deployment, the servos
rotate simultaneously, causing the jaw to open and release the
payload in a smooth, controlled manner. This dual-servo approach not only ensures reliable
release but also offers redundancy in case of a single servo malfunction.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|17

5.4 Material Selection:

Sl. No. Component Material Used

1. Hub PLA + CF (30%)

2. Rotor Arms Nylon 6/10 + CF (30%)

3. Landing Gear ABS-PC

4. Top Plate PLA

5. Inner plate PLA

6. Landing gear padding TPU

Table 1: Material Selection
Reasons for choosing the materials:
PLA for the Top plate and the inner plate was chosen because of the need it to be lightweight,
since it's used to house electronics like ESC, hence a lightweight prototyping material was
sufficient with relatively lesser infill.
PLA + CF (30%) was used for the Hub because of the lightweightness of the PLA and the
strengthening parameter of the reinforced carbon fiber in it. The Hub forms a housing for the
battery and other electronics including the motor arms and Jetson Nano too which are
assembled into the fixture. Moreover, after applying the topology optimization of the chassis,
the Carbon fiber provides extra strength while using lesser infill than that of PLA.
Nylon 6/10 + CF (30%) was used for Rotor Arms because of the lesser vibrations damped due
to its reinforcement with carbon fiber, Also additional features of Nylon 6/10 are the great
tensile strength, flexibility, and sheen of nylon 6 fibers make them durable. The fibers of nylon
6 are highly resistant to abrasion and chemicals like acids and alkalis and are also
wrinkle-proof.
ABS-PC was used for landing gear because of the high strength, stiffness, and retention of
dimensional stability over time of long uses and for the ease of providing freedom of design.
This material can be easily 3d printed for a very economical price and so the material chosen.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|18

6. Subsystem selection
Electronic Components of the UAV:

6.1 Propulsion:

● Motors (T-motor MN2806 High-Efficiency Brushless Motors): These high-efficiency

brushless motors convert electrical energy from the battery into mechanical power,
generating thrust for the UAV.

Motor Voltage Propeller Current Thrust Power Efficiency

(V) (A) (G) (W) (G/W)

15.33 5.46 700 83.70 8.36

15.33 6.49 785 99.49 7.90

15.28 7.59 785 115.97 7.44

T-motor 1344
15.25 8.77 863 133.74 7.04
Antigravity 15.22 10.01 863 152.35 6.66
MN2806-KV
15.19 11.29 1015 171.49 6.35
650
15.17 12.28 1090 186.28 6.10

Table 2: Motor datasheet

● ESCs (Speedybee 60A): Electronic Speed Controllers act as the interface between the

flight controller and the motors. They receive control signals from the flight controller

and adjust the speed and direction of the motors accordingly.

● Propeller (T Motor P13*4.4 Prop): The T-Motor P13*4.4 Prop is a 2-bladed propeller

designed for multirotor drones. It is made from a durable and lightweight CF+Epoxy

material, providing a good balance between strength and weight. The propeller has a

diameter of 13 inches and a pitch of 4.4 inches

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|19

6.2 Flight Control and Processing:

● Flight Controller (Pixhawk PX4 Cube): This is the central nervous system of the UAV,
responsible for maintaining flight stability, interpreting sensor data, and executing
autonomous flight commands.
● Onboard Computer (Nvidia Jetson Nano BO1): This powerful computer provides the
processing power for the UAV's object detection capabilities. It analyzes data from the
camera payload and identifies objects of interest in real time. It features GPU
acceleration for handling complex computer vision tasks with its 128 Maxwell CUDA
cores, and multiple I/O ports for interfacing with sensors, cameras, and the flight
controller.
6.3 Communication and Navigation:

● Servo (Emax ES08MA II Servo): This servo likely controls the tilt of the camera
payload, allowing for precise aiming and object tracking.
● Receiver (Taranis X8R): This component receives control signals from the pilot's
remote controller, enabling manual flight control.
● Telemetry (RFD 900 and 3DR Radio): These modules provide real-time data
transmission back to the ground station, allowing for monitoring of the UAV's status and
object detection results.
● HEX Here 4+ GPS: This module provides the UAV with accurate GPS positioning data,
allowing for precise navigation and autonomous flight planning.
6.4 Power and Power Distribution:
● Holybro Power Distribution Board: This board efficiently distributes power from the
battery to all the electronic components of the UAV, ensuring stable and reliable
operation.
● Molicel 4200mAh 4s battery: These batteries were selected for their light weightness
and for the efficiency they offer, Two Molicel 4200mAh 4S Li-ion batteries were
connected in parallel. This configuration will maintain the nominal voltage of each
battery (typically 3.6V) but effectively increase the total available capacity to 8400mAh.
● Holybro Power Module PM02: The PM02 Power Module offers a straightforward
method to supply regulated 5.2V power to the flight controller from the battery.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|20

7. UAS Performance and Endurance Calculation:

The success of Unmanned Aerial Systems (UAS) in disaster response, monitoring, and
delivery is greatly dependent on their performance and endurance. These missions require
UAS with extraordinary agility to maneuver through challenging areas, speed for prompt
response, and payload capacity—the ability to carry necessary supplies or specialized
sensors. When it comes to maximizing situational awareness during disaster response or
surveillance, operating altitude is crucial.
A mission's endurance: The amount of time it can fly for on a single battery charge—directly
affects its range and timeliness. For example, extending search activities or reaching isolated
locations could be necessary to maximize endurance in disaster management. Longer
endurance in delivery or surveillance enables covering greater ground or accomplishing
several deliveries in a single trip.
The graphs below show the performance of different motors we considered during the design
phase:

Fig.16: Throttle (%) vs Thrust Produced (kgf)

Where
η is the Efficiency factor.
C is the battery capacity in mAh.
Pm is the total power,
Pe is the power consumption of other electronics.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|21

Using the above formula we calculate the Flight time or endurance of the UAS in minutes:

Throttle (%) Thrust (g) T/W Flight Time

(minutes)

70 2814 1.407 15.29

75 3154 1.577 13.24

80 3468 1.734 11.62

85 3782 1.891 10.16

90 4080 2.040 9.14

95 4380 2.190 8.22

100 4574 2.287 7.63

Table 3: Flight Time calculated values
So the above table shows the calculated values of T-motor Antigravity MN2806-KV650 motors.
These motors were selected because of the following reasons:
1. Higher flight time.
2. Better efficiency which includes lesser power draw.
3. Lower weight.
4. Better operating temperatures.
5. Premium feel and build quality.

Fig.17: Throttle (%) vs T/W Fig.18: Efficiency curve

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|22

8. CG & Stability
8.1 COG of the overall assembly:

Axis Cartesian Value

X -4.696850

Y 104.24048

Z 11.588595
Table 4:COG of the overall assembly
Based on the Solidworks Mass Properties data, the object's center of mass (COM) is located
at [X, Y, Z] cartesian coordinates. This coincides with the center of gravity (CG) since we have
a uniform gravity distribution. From the design, the COM point of the overall assembly is at a
low point. It has the following benefits:
● Enhanced Stability: A low CoG makes the drone more resistant to tipping, especially
during takeoff, landing, or strong winds. This is crucial for maintaining stability while the
drone hovers or maneuvers in different environments, ensuring smoother data collection
or delivery.
● Improved Maneuverability: A lower CoG improves a drone's control and agility,
enabling sharper turns and quicker direction changes. This is beneficial for navigating
through tight spaces, avoiding obstacles, and following intricate flight paths, which is
essential for surveys, deliveries, and missions in competitions like SAE Aerothon.
● Increased Payload Capacity: A lower CoG can improve a drone's ability to carry a
heavier payload relative to its size. This is because the center of mass remains closer to
the center of the lift, reducing the tilting moment and allowing the drone to carry more
cargo for deliveries or survey equipment.
● Better Wind Resistance: A lower CoG makes the drone less susceptible to being
blown off course by wind gusts. This is particularly important for maintaining accuracy
during data collection or ensuring safe delivery in windy conditions.
● Efficient Battery Usage: A stable drone with a low CoG requires less corrective
maneuvering to stay balanced. This translates to smoother flight patterns and potentially
less energy expenditure, extending battery life for longer surveys or more deliveries per
charge.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|23

8.2 Stability Factors:

Stability is achieved from the following factors and design adjustments during the process of
assembly of the UAS:

● Stability is gained when the weight is distributed equally.

● Stability is achieved when all rotors and propellers generate equal thrust in hover and
throttle modes.
● The stability is also maintained by the gyroscope, which measures the rate of rotation
and helps keep the drone balanced.
● The drone is unstable when the rotor alignment is improper due to the high center of
gravity, low moment of inertia, and high wind sensitivity.
● The deeper the CG leads to more stability, the larger the drone the higher the stability.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|24

9. Structural Analysis
9.1 Threaded Motor Arm:
9.1.1 Static Analysis of Threaded Motor Arm:
Static analysis was conducted on the drone arms with a downward force of 2kg and the
following results were obtained
Starting with the Mesh Information that was used to obtain the results:

Sl. No. Standard Mesh Parameters Result chosen

1. Mesh Type Solid Mesh

2. Mesh Used Standard Mesh

3. Tolerance 0.09 mm

4. Mesh Quality High

Table5: Mesh information - Rotor Arm

Mesh control information:

Mesh Control Control-1

Name

Entities: 8 edge(s), 6 face(s)

Mesh Control
Details Units: mm
Size: 0.3
Ratio: 0.3
Fig.19: Mesh Control - Rotor Arms

Table 6:Mesh Control - Rotor Arm

To achieve a much more accurate result the design team added the mesh control parameters
choosing fine mesh on the selected mesh shown below.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|25

Model Reference Properties Components

Name: Nylon 6/10

SolidBody
Model type: Linear Elastic Isotropic 1(Fillet14)(thread
edHands)
Yield strength: 1.39043e+08 N/m^2
Tensile strength: 1.42559e+08 N/m^2
Elastic modulus: 8.3e+09 N/m^2
Poisson's ratio: 0.28
Mass density: 1,400 kg/m^3
Shear modulus: 3.2e+09 N/m^2

Table 7: Material Properties - Rotor Arm

Fixture name Fixture Image Fixture Details

Fixed-1
Entities:7 edge(s), 6 face(s)

Type: Fixed Geometry

Resultant Forces

Components X Y Z Resultant

Reaction -12.607 15.0242 -0.000367784 19.6128

force(N)

Reaction 0 0 0 0
Moment(N.m)

Table 8: Loads and Fixtures

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|26

 Load name Load Image Load Details

Force-1 Entities: 1 face(s)

Type: Apply normal force

Value: 2 kgf

Table 9: Load Distribution

Study Results:
Name Stress1

Type VON: von Mises Stress

Min 1.350e+00N/m^2

Max 1.028e+07N/m^2

Fig.20: Stress Analysis - Rotor Arm Table 10:Stress Analysis - Rotor Arm

Name Displacement

Type Displacement- Y

Min 7.251 e-05 mm

Fig.21: Displacement Y - Rotor Arm -2.611 e-01 mm

Max

Table 11: Displacement Y- Rotor Arm

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|27

The design is a threaded assembly which enables seamless integration and disassembly of
the part making it much more portable and avoiding most of the inconvenience regarding
packing and portability with a much more minimal solution. The material in use is Nylon + CF
(30%)
Reason for Choosing the Material:
● Availability
● Good Yield Stress Value
● highly resistant to abrasion and chemicals
The results are the following:
● Maximum Displacement Achieved: 2.611e-01mm (Nett Downward Displacement)
● Minimum Displacement Achieved: 7.251e-05 mm (Nearly stationery no displacement)
9.1.2 Further Optimization of the Model:

Fig.22: Rotor Arm Topology Result

Making the Most of Micro UAV Design Restraints: Efficiency-Based Optimization

We used topology optimization in the Simulation window of our design program to create an
incredibly lightweight design that is perfect for a mini UAV (unmanned aerial vehicle) for survey
and payload delivery.
Optimizing Topology for Micro UAVs:
A potent mathematical method for optimizing material distribution within a predetermined
design space is called topology optimization. This approach looks for the most effective
material layout while taking loads, weight restrictions, production constraints, and fixed regions
into account.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|28

Steps for Achieving the Topological Optimized Results:
● The Topology optimization was conducted with a mass constraint reduction of 75% of
the original mass and the following results were obtained.
● By keeping only 29% of the original mass we were able to reduce the weight from a
theoretical 52g to just 15 grams still having the same static test results.
● Yet while 3D Printing we might expect an increase of 15% of the overall weight due to
infill and strengthening parameters.
9.2 The Drone Hub:
Mesh Information:

Mesh type Solid Mesh

Mesher Used: Blended curvature-based mesh

Jacobian points for High-quality mesh 16 Points

Maximum element size 2 mm

Minimum element size 0.11059 mm

Mesh Quality High

Maximum Aspect Ratio 47.276

% of elements with Aspect Ratio < 3 98.7

Table 12: Mesh Information- Hub

Selection Units Sum X Sum Y Sum Z Resultant

set

Entire N -7.50693e- 15.2002 6.1316e-07 15.2002

Model 06

Table 13: Reaction forces- Hub

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|29

Selection Units Sum X Sum Y Sum Z Resultant
set

Entire N -0.0011192 3.68001e-0 -0.000343832 0.00117144

Model 4 5

Table 14: Free Body Forces- Hub

Mesh Control Information:

Mesh Control Mesh Control Image Mesh Control Details

Name

Entities: 29 edge(s), 20 face(s)

Control-1
Units: mm
Size: 2.59199
Ratio: 2.59199

Entities: 2 face(s)
Control-2
Units: mm
Size: 2.59529
Ratio: 2.59529

Entities: 2 edge(s), 4 face(s)

Control-3
Units: mm
Size: 0.5
Ratio: 0.5

Table 15: Mesh Control- Hub

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|30

Study Results:

Study Results: Name Stress

Type VON: von Mises Stress

Min 1.467e-02N/m^2

Max 7.734e+04N/m^2

Name Displacement

Type Displacement - Y

Min -5.024e-03mm

Max 1.386e-04mm

Table 17: Displacement -Y Result - Hub

Name Strain

Type Resultant Strain

Min 1.403e-05

Fig.25: Resultant Strain - Hub Max 1.298e-05

Table 18: Strain Values- Hub

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|31

9.2.1 Further Optimization of the Drone HUB:

Fig.26: Hub Topology Result

Using Solidworks we again applied Topology optimization to reduce the mass which helps us
in increasing the efficiency of the drone. This further helped in saving material and printing time
too. A Weight reduction of 80% was given while providing the assembly features to be under
the preserved region, and finally keeping 31% of the original mass we get the updated weight
to be 346g after 3d printing with the chosen materials.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|32

10. Computational Fluid Dynamics of Drone

Fig.27: Pressure Flow Fig.28: Velocity Along X

The CFD simulation gave insights into the pressure and velocity distribution throughout the
UAV area for both hovering and moving scenarios. A simulated fluid flow of -10 m/s in the
negative x-direction was employed in the analysis, which concentrated on pressure and
velocity along the x-axis.
Hovering Conditions:
Distribution of Pressure: Areas of high or low pressure can be identified by examining the
pressure distribution surrounding the UAV while it is hovering. Understanding lift creation,
stability, and possible drag brought on by pressure imbalances requires knowledge of this
information
Velocity Profile:
When the UAV is in hover mode, the velocity profile along the x-axis can be used to evaluate
the behavior of the airflow surrounding its body. This could point to recirculation or stagnant
flow zones that could reduce efficiency. A speed of 12.72m/s was recorded when 60% of the
throttle was used.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|33

11. Innovative Design:

Fig.29: Final Render

Imagine a drone that fits neatly into your scooter's under-seat storage. Scyther is the design of
micro UAVs of the future, not science fiction. This creative system puts efficiency and flexibility
first, which makes it ideal for jobs in confined spaces and any terrain of service.
Its modular design is the key to its portability. The entire drone, which was designed
with 3D printing in mind using eco-friendly materials, can be assembled in just 9–10 hours,
making it perfect for quick deployment in an emergency or even during unforeseen crashes or
any other circumstances. The rotor arms' complete detachability, held in place by a threaded
design that maximizes ease of assembly and reduces vibration with the help of a pin lock
system embedded into it, is even more remarkable. This cutting-edge system enables
instantaneous configuration changes or rapid repairs. But don't let its size deceive you. The
landing gear on this tiny UAV is surprisingly strong. Its featherweight design belies its ability to
carry a payload as heavy as 4 kg, which makes it ideal for carrying necessary supplies or
gathering comprehensive survey data in tight spaces. With its special blend of strength,
modularity, and compactness, this micro UAV is truly revolutionary and capable of taking on
any task.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|34

12. Conclusion:
The design and development of a quadcopter UAV under 2kg, utilizing advanced
components like the Pixhawk Cube flight controller and NVIDIA Jetson Nano onboard
computer, demonstrate a balance of performance, efficiency, and versatility. The integration of
YOLOv8 for real-time computer vision operations and the use of carbon fiber PLA for a
lightweight yet durable frame further enhance the drone's capabilities. This project showcases
a comprehensive approach to creating a modular, efficient, and robust UAS capable of
performing complex tasks with precision and reliability.

References:

[1] A. Vadduri, A. Benjwal, A. Pai, E. Quadros, A. Kammar, and P. Uday, “Precise

Payload Delivery via Unmanned Aerial Vehicles: An Approach Using Object
Detection Algorithms,” arXiv, pp. 1–10, 2023, doi: 10.48550/arXiv.2310.06329.

[2] A. Balayan, R. Mallick, S. Dwivedi, S. Saxena, B. Haorongbam, and A. Sharma,

“Optimal Design of Quadcopter Chassis Using Generative Design and Lightweight
Materials to Advance Precision Agriculture,” Machines, vol. 12, no. 3, 2024, doi:
10.3390/machines12030187.

[3] A. O. Mohamedzain, H. Chua, K. Yap, P. Uthayasurian, and T. Jiehan, “Novel

Drone Design Using an Optimization Software with 3D Model, Simulation, and
Fabrication in Drone Systems Research,” Drones, vol. 6, no. 4, 2022, doi:
10.3390/drones6040097.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|35

 APPENDIX A
Table A: Estimation of Weight

Sl. Components Quantity Weight of each Total Weight

No. item(g) (g)

1 T Motor Antigravity BLDC Motor 4 47 188

MN2806 650KV

2 Pixhawk PX4 Cube 1 73 73

3 Speedybee 60A ESC 1 23.5 23.5

4 Nvidia Jetson Nano BO1 1 90 90

5 Emax ES08MA II Servo 2 14 28

6 Molicel 4200mAh 4s battery 2 192 384

7 Taranis X8R Receiver 1 16.8 16.8

8 RFD 900 1 14.5 14.5

9 3DR Radio Telemetry 1 33 33

9 Gemfan 7042 2 blade propeller 4 9 36

11 Holybro Power Distribution 1 22 22

Board

12 HEX Here 4+ GPS 1 47 47

13 Holybro Power Module PM02 1 33 33

14 Rotor Arm 4 20 80

15 Hub 1 350 350

16 Landing Gear 1 160 160

17 Inner Plate 1 20 20

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|36

18 Top Plate 1 30 30

19 Spacers 4 12 48

20 Payload Mechanism 2 6 12

21 Camera 1 72 72

22 Miscellaneous - 40 40

Total Weight 1,800.8

Table B: Estimation of budget

Sl. No. Components Quantity Price of each Total Price

item(₹) (₹)

1 T Motor Antigravity BLDC 4 5,967 23,868

Motor MN2806 650KV

2 Pixhawk PX4 Cube 1 54,999 54,999

3 Speedybee 60A ESC 1 5,000 5,000

4 Nvidia Jetson Nano BO1 1 24,999 24,999

5 Emax ES08MA II Servo 2 718 1,436

6 Molicel 4200mAh 4s battery0 2 3,227 6,454

7 Taranis X8R Receiver 1 3,299 3,299

8 RFD 900 1 42,974 42,974

9 3DR Radio Telemetry 1 7,999 7,999

9 Gemfan 7042 2 blade propeller 4 2,059 8,238

11 Holybro Power Distribution 1 294 294

Board

12 HEX Here 4+ GPS 1 24,705 24,705

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|37

13 Holybro Power Module PM02 1 2,487 2,487

14 Camera 1 35,999 35,999

15 Manufacturing 5,000 2,000

Total Budget 2,44,751

Technical Drone Specifications

Model Scyther

1. Configuration X - type Multicopter

2. Flight mode Both manual and autonomous

3. Endurance 15.29 minutes

4. Max 4.7 km

5. Max altitude 400 Ft AGL (as per DGCA Norms)

6. Weight 1.800 Kgs

7. Avg flying speed 2.2m/s

8. Area coverage Up to 160 m × 160 m in single flight

9. Launch & Vertical take-off and land from/in 1m × 1m patch of land.

recovery

10. Empty weight 0.752 Kg

11. Operating temp. +27℃ to +51℃

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|38

 range

12. Failsafe features ● Emergency Return to Launch position option.

● Autonomous return to home on communication link loss.
● Geofencing option to restrict both horizontal and vertical
flight envelope of the drone.
● Autonomous return to home or land (programmable) in
case of power loss. - Collision avoidance System.

13. Portability Easy as it is modular

14. Ground control ● Ground control and mission planning software for planning
software of flight path.
● Skydroid application for live video data on mobile screen

Sensors

1. Camera Intel Realsense D435i offers high-resolution images with

integration of IMU, thermal sensor and color sensor for
navigation and environment perception

2. GPS Hex Here 4+ GPS provides data for precise waypoint navigation
and flight control.

TEAM CHALLENGERS | SAHYADRI COLLEGE OF ENGINEERING AND MANAGEMENT Page|39

 8 7 6 5 4 3 2 1

F Preliminary CAD Drawing F

150.00

E E

110.00
39
483.24

4.
89
D Isometric view D
(Scale 1:8)
Top View

283.61
C 324.20
C
53.00

78.33
Front View
Right View
B B
Maintain o.2mm tolerance FINISH: DEBURR AND
where ever not Mentioned DO NOT SCALE DRAWING REVISION
BREAK SHARP
EDGES

NA
NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D SCYTHER
MFG

A A
MATERIAL: DWG NO.

1
Q.A
A3

WEIGHT: SCALE:1:4 SHEET 1 OF 1

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only. 5 4 3 2 1
 8 7 6 5 4 3 2 1
Conceptual Design
TEAM NUMBER : AT2024008
F F

51
2.
TEAM NAME : TEAM CHALLENGERS

33
INSTITUTE : SAHYADRI COLLEGE OF ENGINEERING
AND MANAGEMENT

BOM
64.90
Sl.no. Component Name Material
Weight and Balance Information
1 Hub PLA + CF (30%)
E Center of gravity Components Force(kgf) Distance from Moment 2 Rotor Arm Nylon 6/10 + CF (30%) E
datum (mm) (Nmm)
3 Top Plate PLA
Motor 0.216 102.24 22.083
94.85

4 Dropping Mechanism PLA

Battery 0.384 72 27.64
ESC 0.035 62.05 2.17 5 Landing Gear ABS-PC

Payload 0.2 0 0 6 Landing Gear Padding TPU

D 7 Motor - D
8 Propeler Carbon Fiber
Top View

410.05
Center of gravity 7 385.40 8
62.89

3
104.24

C C
2
62.05

224.31
1 Center of Gravity
5 Isometric view
144.87

(Scale 1:8)
72.22

6
B Front View
B
A 4 Maintain ±0.2mm tolerance
where ever not mentioned
FINISH: DEBURR AND
BREAK SHARP
DO NOT SCALE DRAWING REVISION 1
NA EDGES

Right View
NAME DATE TITLE:

SCYTHER
DRAWN AMOG 8-06-2024

CHK'D K ANUP PAI 8-06-2024

APPV'D DR. AJITH BS 8-06-2024

A A
DWG NO.
A3
CH/SAE/001
SCALE:1:5 SHEET 1 OF 1

8 7
SOLIDWORKS Educational Product. For Instructional Use Only. 6 5 4 3 2 1