Difference between revisions of "X-UAV Mini Talon VTOL Project"

Revision as of 10:45, 4 November 2019

© Mark Qvale - October, 2019

Contents 1 Introduction 2 General Specifications 3 Components/Flight Gear 3.1 Power Set-up 3.2 Front Motor Mount Evolution 3.2.1 Front Motor Mounts Assembly 3.3 Rear Motor Mount 3.3.1 Rear Motor Mount Assembly 4 Project 3D Print Files 5 Flight Control 6 First Flight! 6.1 Damage/Repair 7 See Also 7.1 Some of the Vendors I used for this project 7.2 Comments? Questions?
	Ready for lift-off!

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Introduction

First, some acknowledgements-
Many thanks to ATX_Heli from RCGroups and the APM dev team, Tridge, also from RCG and the APM dev team with his excellent write up on "Tiltrotor support for plane" and Greg Covey who did a really great write-up of his E-Flite Convergence conversion to APM. Their combined help and write-ups were invaluable to this project!

My MiniTalon #4 was getting long in the tooth after nearly 2-1/2 years and hundreds of flights so I decided to use it as a test platform for this project. (Please see X-UAV Mini Talon Build Number 4 for any build information not found here.) I have been resisting doing a VTOL version of the Mini Talon because I knew it would be an all consuming project that would take some time. It has been!. It has also been a really fun and challenging project and hopefully the results will speak for themselves.

To begin, when I first started on this project I set up some simple design parameters to aim for:

• Relatively light weight - <1750g with a 5200/4S Lipo pack
• Minimum Carbon Fiber components - To keep any RF interference low
• Three-motor tilt rotor configuration - This should help with the weight
• Bolt-on rear motor mount - Keeps stock motor mount
• No additional booms or struts added to the fuselage (modified wings only)
• The ability to use the Matek F405-wing flight controller and all the flight control components already on the plane
  
  

So far nearly all of this has been achieved with only one small (4.2g) support bracket in the fuse and a little extra weight above my initial parameter (+42g)

Below are my build notes, print files and a flight review of this new Mini Talon configuration.

General Specifications

Initial Build
Seller - ReadyMadeRC, USA
Aircraft - X_UAV Mini Talon
Modification Date - October, 2019

Components/Flight Gear

Power Set-up

To determine front and rear motor sizes I first looked at how the weight of the plane would be distributed with respect to the three lift points and a CG of 60mm from the leading edge. The image below shows the weight mapping for the current 1792g AUW:

From this picture I determined the front motors need to lift 709 grams each and the rear motor, 374 grams for a theoretical stable hover. What I then did was look for motors as light as possible that could produce near these thrust numbers at 60% or less throttle.

With this information, I started with Racestar 2508-1275 motors on the front and a Cobra CPL2207-1800 motor on the rear. The Racestar motors worked well enough for my initial hover tests but I felt I needed a little more power and so they were replaced with Brotherhobby 2806.5-1300 units to get a bit more lift power and more headroom on the motor current.

Racestar 2508 and Brotherhobby 2806.5

For motor control I have chosen HGLRC Trex 60A, BLHeli_32 Opto ESC's with Active Freewheeling enabled. On all three motors I am using MR30, 3 pin connectors so they can easily be changed or reversed. Props were determined from bench testing with a 4S pack. The 8x5 Graupner front props are one of my favorite 8" Multirotor props and they also work extremely well on fixed wing.

Power Parts

• Front Motors - Brotherhobby Avenger 2806.5-1300kv
• Rear Motors - Cobra CPL2207-1800kv
• ESC - HGLRC T-Rex 60A BLHeli_32 ESC
• Left Front Prop - Graupner E-Prop 8 x 5 CCW
• Right Front Prop - Graupner E-Prop 8 x 5 CW
• Rear Prop - HQProp 6 x 4.5 Bull Nose-CCW
• Battery - Multistar 4S/5200, 10C, 438g
  
  

Brotherhobby specification

Cobra specification

Front Motor Mount Evolution

This design has had many revisions to date and likely will have a few more. Again my goal was to make it light, simple and strong.

While I won't show all the versions and revisions of the front mounts, here are a few:

Version 1/2

Version 3 was very similar with a stretched out mount. It looked nice but I felt it still blocked too much of the prop thrust.

Version 3

For a short time I considered an offset mount so that I could use a larger prop and not have the forward flight position too far forward. The problem with this idea is, I would need a much larger, more powerfull servo.

Version 4

Version 4 parts

The first flight tested version (6) uses the main mount piece from V4 and a straight motor mount together with an 8mm x 135mm CF tube to get the moment forces spread across more of the wing.

The latest version eliminates the need for the CF tube by using a longer arm that is ribbed to get the strength way up

Current arm design

Front Motor Mounts Assembly

First - Glue!!
For this project I have used Gorilla Clear Grip Contact Adhesive which is very similar to E6000, UHU-Por and other thick flexible foam glues. Generally, E6000 is my favorite but it does soften the foam for the first few hours and can cause problems when parts need critical alignments. So I went with the Gorilla.

The front assemblies are not identical for the left and right wings. There are separate prints for left and right arms and left and right motor mounts. When mounted correctly, the servo opening faces in the direction of the wingtip as shown in the layout picture below. The main structure consists of a full length arm and a motor mount bracket which is supported by the servo on one side and a ball bearing on the opposite side. There is a bottom cover which hides and protects wiring and a top cover which helps secure the arm to the top of the wing.

Below is an image of the right side motor/arm assembly:

Complete parts list for one right front assembly:

After printing the arm, install the two M2 and one M3 nuts into the holes in the servo bay. If the nuts seem tight, heat them up with a lighter before pushing them into position. Next, tap the two cover mount bosses to M3.

Arm prep

The arm is glued into the position shown in the picture below. Be careful to get the 90° angle correct and also that there is no "twist" relative to the leading edge.

Wing layout

After Printing the motor mount, clean up the servo side hole with a 7mm drill bit and the bearing hole with an 8mm drill bit. This should be done by-hand and not with a power drill. Next, tap the two servo arm attachment holes to M2.

Motor mount prep

Using the above assembly image, install all the parts onto the arm.

Mounted!

Rear Motor Mount

For the rear mount I wanted to keep it simple, light weight and easy to install using the stock rear motor mount.

Rear mount assembly

Rear Motor Mount Assembly

The rear motor assembly consists of a CF boom tube, motor plate and two support pieces to hold the boom. The front support is cut and glued into the fuselage at a distance of 110mm to 115mm from the rear edge of the fuselage. One side of this bracket is flanged so a little inlay work should be done to keep it flush. The top of this bracket is flush against the roof of the fuselage. The rear support bolts directly to the motor mount and will fit mounts with 33mm to 34mm hole spacing. There are two holes for nylon anti-rotation screws that need to be tapped to M3.

Rear VTOL Assembly

Support bracket cut

Rear mount assembly parts:

DESCRIPTION QTY Motor/Prop Assembly 1 SHCS M3 x 6mm 4 M3 Flat Washer 4 12mm Tube Clamps w/screws 2 Motor Mount Plate 1 Rear Support Bracket 1 52224, Tube Front Support Bracket 1 52225, Tube, 12mm x 10mm x 190mm   1

Inside view of front support bracket

Below is a drawing of the motor plate I made from 2mm CF sheet. You could use 3mm plywood treated with thin CA or G10 fiberglass if CF sheet is not available. Your dimensions may vary depending on the hole spacing for the tube clamps you buy and the motor you elect to use.

Rear motor plate detail

Project 3D Print Files

LOTS of prototype pieces were done for this project!!

All prints are setup with 40%-90% infill and a 0.8mm to 1mm shell thickness using Hatchbox ABS filament. Weights are shown as printed. See the bottom of this section for more print information.

Image	Part Number	Part Description	Weight/Infill	Print File	Compatibility Notes
	52226	MT VTOL Left Front Arm 80mm	15.7g/90%	52226.STL	80mm Left Front Motor Arm
	52227	MT VTOL Right Front Arm 80mm	15.7g/90%	52227.STL	80mm Right Front Motor Arm
	52228	MT Left VTOL Motor Mount Bracket	8.2g/90%	52228.STL	Fits motors with 16mm to 19mm mount holes
	52229	MT Right VTOL Motor Mount Bracket	8.2g/90%	52229.STL	Fits motors with 16mm to 19mm mount holes
	52222	MT VTOL Front Lower Assembly Cover	3.4g/40%	52222.STL	Wiring cover for the front wing mount
	52223	MT VTOL Front Upper Assembly Cover	2.2g/40%	52223.STL	Clamping cover for the front wing mount
	52224	MT VTOL Rear Motor mount Forward Support Bracket	4.2g/80%	52224.STL	Front support for the 12mm CF tube
	52225	MT VTOL Rear Motor Mount Support	5.3g/75%	52225.STL	Rear support for the 12mm CF tube UPDATE - Fits 33mm & 34mm mounts

Print instructions

Below is a list of the parts with some print parameters I used. All prints should load automatically in the correct orientation.

• Front arms are printed upside-down with support fill. Main part infill is 90% - 100%, support is 24% and support type is "Everywhere".
• Motor mounts are printed with the bottom edge against the print platform, Do NOT print these with the motor face down. Quality should be .1mm to .2mm, speed - slow and main part infill 90% - 100%. Support should not be needed.
• The front top cover is printed with the forward plate against the print platform. Main part infill is 40% or more for strength.
• The front bottom cover is printed with the flat side down. Main part infill is 40% or more.
• The rear-mount forward bracket is printed with the bottom edge down. Infill is 50% or more.
• The rear-mount rear support is printed with the motor face down. Infill is 75% or more.

Flight Control

For flight control I stayed with the Matek F405-wing with Chibios/Arduplane running with Q_Plane parameters enabled. For the initial vertical flight test I ran it with all default parameters on the flight control parts. The only adjustments (to the parameters) were the motor tilt angles needing to be set-up at 0 and 90 degrees. For the first flight shown in the Transition video, I changed the parameter which controls pitch trim between vertical and forward flight, a couple of recommended yaw parameters and I added a little expo to my transmitter to soften up response in vertical flight.

Of course with adding two motors, two servos and a mag compass there are a few more wires to deal with! The Matek board does a great job in keeping the wiring simple and manageable.

Below are the Matek board pin-outs I used, what they are connected to and any APM parameter change made to get the assignment correct.

First Flight!

19 October, 2019
So, in a word AWESOME!! Going from a hover to forward flight was a little nerve racking but when I finally threw the switch it blew my mind how fast and stable the plane was. The video below does not do the acceleration justice! I threw the switch when the plane was at about 20ft altitude and then stood there in complete shock watching it effortlessly rocket away. In forward flight it is a little harder to turn sharply and this may be due to the position of the forward props and also I have the max-roll setting quite low in Arduplane. It flew very much like my last twin did so very stable and extremely quiet. It would cruise easily at ~4-4.2A although the plane speed was a bit low. I'll have to try some different props going forward.

Unfortunately I never got to switch it back to hover mode because I wasn't paying attention to forward speed when I turned into the wind for a landing, I got impatient and cranked the rudder to turn more sharply and she snap rolled/tip stalled without enough altitude to recover. This would be unusual in any of my standard Mini Talons and I'll have to check the rudder settings to see if I have them over saturated (likely).

Anyway, even though I stuffed it, I'm extremely happy with how it performed and will get it back together very soon.

Take-off ready!

Video

Damage/Repair

Looks a bit "shorter"...

Center box rebuild

New front deck

All fixed and ready for testing!

See Also

• X-UAV Mini Talon Build Compilation
• X-UAV Mini Talon Build Number 4
• Parts Catalog - Mini Talon
• Current Parts Catalogs

Some of the Vendors I used for this project

ReadyMadeRC

GetFPV

Aloft Hobbies

Cyclone FPV

Comments? Questions?

email me!