Category: Mechanic

One of the goals during this project has been to only use open-source tools for development. The main incentive for this is that we want everyone to be able to take part in the development and look at the all the parts of it once it has has been released. Also it was a great opportunity to see how far we could push open source free development software in a non-trivial embedded project.

Some of the tool has worked great and some has caused us some headaches since we have worked with the proprietary alternatives during the daytime. Our conclusion is that a project like this is definitely doable, but some parts does still require more work (and some frustration). The open-source tools for firmware development and PC client are state of the art and could be used instead of there proprietary counterpart (of course most of the time there is no GUI and some more setup or manual job might be required, but this comes with the benefits of a greater flexibility). However the hardware design tolls are still behind there (expensive!) proprietary counterparts and often requires a great deal of efforts to reach the wanted result.

Of course it’s great that these open-source alternative exists and that a lot of great developers puts time into making them. Without them this project would not have been possible!

The firmware – For firmware development we use a wide number of applications: gedit, Eclipse, Mercurial, gcc, make, openOCD and gdb. On Crazyflie we run  FreeRTOS. As we built the development environment with cross platform tools the development can be done seamlessly on Linux or Windows, on the console or with Eclipe. The radio dongle has been developed from scratch (ie, just from the datasheet) with the help of sdcc to compile for the 8051 contained in the nordic chip.

The client software – For the client side software we use Python, libusb, pyusb, QT/PyQt. Even though there was a lot of discussion within the group (Ruby vs Python, qt vs gtk) we landed on Python due to all the bindings that works out of the box on Linux and Windows. This enables you to quickly create applications. Combining this with QT/QTDesigner and you get a nice GUI application.

The hardware – Since the very first prototype we switched from Eagle CAD to Kicad to use a fully open source e-cad program. It does the job perfectly fine but the routing part requires a lot more time as many of the time reducing functions are still lacking compared to proprietary programs.  For complex boards, if time is an issue, Kicad is not the e-cad to use, but for simple board and typical DIY boards it does the job fine (ie. our experience of kicad is a lot smoother for the radio dongle than for the copter).

The mechanics – For the mechanics we have used freeCAD which is one of the few open-source 3D CADs tools that we have found. When we started out we had a lot of problems with this software because it keep crashing during the design. After the stable release of the 0.12 branch it’s gotten better but we’ve still had some problems with crashes. Over all we managed to design and 3D print many revision of the motors holder with freeCAD.

The website – On our server we are running WordPress, Mercurial and Redmine, all these on a Linux and Apache. We will probably also run phpBB later on.

 

Sensor poll

Waiting another week did not make things clearer whether to mount all sensors or not, but the quotation to buy and mount them did. The $20 we estimated was too low, depending on the amount of boards we make of course, but we would probably have to add another $10 to that which made the decision simple. It is mainly the barometer that is very expensive so we might still decide to mount the magnetometer. First we will do some tests though to find out how much “value” it really adds. For people that wants the barometer it will still be possible to manually mount it afterwards making it a win-win decision.

The coming week we are reviewing the new revision of the hardware before we press the order button. With the previous prototype we had a few violent incidents where one of the arms broke off. Fixing it wasn’t to hard. We used an aluminium tube we cut to the right size and glued over the arm and it holds up well. For this next revision we have changed the board outline around the arm joint to be smoother as this seams to be the weakest point. If everything goes according to plan the next prototype should be the last before we can order a larger batch.

During the last week we also did a little test making an small Android app and plugging the radio dongle in one of our Galaxy Nexus. It’s detected and can be used via the USB API.  It’s nothing that we are planning on spending any time on right now but in the future…

 

 

 

One of the ideas with the Crazyflie was to make a simple flying platform and what’s simpler than just attaching the motors directly to the PCB? On our first prototypes we used hot-glue to attach the motors which work out pretty well. The problem was that when you crashed the motors often came loose, and in some cases, so did the wires attached to the motors. Reparing this turned out to be pretty teadious and it makes flying it a lot less fun, since the iteration time for trying new things becomes longer. We did a few tests with different protections, like soldering a ring of piano-wire, but when we decided to make a kit out of the Crazyflie we realized that we needed something that was easier to manufacture.

Since we could not find any off-the-shelf motor mounts we decided to make our own. Our idea is to place the motor in the mount and the mount on the wing. We have tried a few different solutions but the current leading design is one where we feed the cable from the mount out under the wing and to the soldering point for the wire. We have also made a telescopic version so it is possible to adjust the arm length for adjustable flight dynamics or to attach bigger propellers. After some more testing we will decide which one we will go for.

The CAD work is done in an open-source CAD tool named FreeCAD. After struggling for a while with an unstable versions, the 0.12 branch finally became very stable. The images below is the second iteration of prototypes that we have done using Shapeways. It’s is a 3D printing house in the Netherlands that has a great service where you upload models, choose what material you want them printed in, and then two weeks later you receive them in the mail! The durability is pretty good as well. We have only managed to break one, and that’s after a lot of violent crashes and a more fragile design.

 

FreeCAD showing a model of the motor mount prototype

 

Prototype 1 (shown in CAD model above)

Prototype 2

Crazyflie with Prototype 1 motormounts