Propeller quality issue

2020-03-23 | Tobias | 2 Comments

Who knew propellers would be that hard? Already from the very beginning with the Crazyflie 1.0, we had problems with very unbalanced propellers resulting in reduced flight performance. The fix at that time was to manually test and sort out the bad propellers. This worked well until the manufacturer’s injection mould got too worn down and we had to reject a lot of propellers. The manufacturer didn’t want to continue selling us the propellers unless we accepted them all. The hunt for a new manufacturer begun and after trying several, we finally, just in time for the Crazyflie 2.1, found one that could deliver well balanced propellers.

That could have been the end of a happy story but recently we found out that the new propellers tend to break too easily. The root cause seems to be that the center hole is too tight, causing tension in the plastic which makes it more fragile and prone to break.

We don’t fully understand when this started but it looks like it was not that frequent in the beginning when the Crazyflie 2.1 was released and that it has increased from the batch manufactured in the end of July 2019. We don’t have data on how many propellers are bad but our estimation is around 20-40% and it is booth CW and CCW propellers. It also includes the spare part bundles manufactured in the second half of 2019.

Currently out main focus is to fix this propeller manufacturing issue. As soon as we have done so, we will lunch some form of replacement propeller program so that those of you that have gotten many bad propellers can get new ones for free. We don’t have any time estimate right now, and due to the world covid-19 crisis we have a feeling it can take a while. We are very sorry about this!

Insert propeller so it sits firmly, but not further

Workaround

There is an easy, but not ideal, workaround for this and that is to not push the propeller all the way down on the shaft. Instead stop when force is getting high and it holds the propeller in place. This will prevent the tension in the propeller to become big enough to break.

For those that have ordered after the 16th of March we have fixed the propellers by drilling the center hole slightly larger. This solves the problem for those units until we have fixed the root cause at the manufacturer.

What has our intern, Zhouxin, been up to?

2020-03-09 | Zhouxin Ge | 2 Comments

This is it. The end of my internship. It feels strange to leave this unique office in a place called Malmö. My time spent here was more than just doing an assignment as part of a MSc. degree with the objective that I would gain working experience and contribute to a company.

My last day at the office of Bitcraze, Arnaud was already on parental leave

My time here gave me so much more. I have learned here a healthy way of thinking and problem solving which is part of the unique Bitcraze company culture. Next to that, it felt more like working with friends than just working with colleagues. Going to the office is a delight, as there is always humor, openness and honesty. I got to know everyone and enjoy the French, Swedish and Dutch-American hospitality and culture.

At this point you might think that I only have been drinking coffee and made sure that coffee in the office was not below level. Luckily that was not the case. I had the privilege to be the first user for a new deck. This deck has been in development for quite some time now and has been glossed over in some earlier blog posts. It is the yet to-be-released AI-Deck! At the moment the early-access AI-Decks are a delayed due to the COVID-19 virus. Bitcraze will update you on the blog when they know more.

My task within Bitcraze, in more detail, was to improve user friendliness of the AI-Deck by providing a framework for future users and at the same time to explore user friendliness of the whole ecosystem around the AI-Deck for an engineering student with beginner experience in embedded programming (e.g. me).

At the verge of giving the Crazyflie some AI capabilities, while being micromanaged.

So my mission began. A logical step was to see if the convolutional neural network from the PULP-DroNet project would run on the AI-Deck and fly with the Crazyflie, as the AI-Deck is an evolution of the PULP-Shield developed for this project. More information about this can be found here.

Unfortunately, this was not an easy feat as the PULP-DroNet project is using the pure version of the PULP SDK and an outdated autotiler. While the development partner for the AI-Deck, Greenwaves Technologies, uses the PULP SDK as a base with added functionalities in their SDK, which made it divert from the SDK used in the PULP-DroNet project.

Though, I was able to run the convolutional neural network in a simulated environment and compare this to the original DroNet that was implemented using Python and a Bebop. It was interesting to find out that the convolutional neural network of PULP-DroNet was behaving differently than the original DroNet in Python. There can be many explanations for this, but the main hypothesis is that this is caused by quantizing the network of PULP-DroNet from 32-bit floating point to 16-bit fixed point. In addition, the aforementioned network is trained on a larger dataset which included data created by a Himax camera.

A single Crazyflie obtained self-awareness and spun up a swarm of Crazyflies to gain world domination

While porting PULP-DroNet to the AI-Deck should be possible, the obstacles found along the way made it too troublesome and out of scope for my internship. So I moved on with the main objective, making a framework/example for the AI-Deck using the SDK provided by Greenwaves Technologies, which is called the GAP8 SDK. It contains a set of tools that should make the use of the AI-Deck easier, namely the NNTool and Autotiler tool. These tools make sure that you can automate the conversion of your neural network that is designed and trained in Python (Tensorflow and Keras) to a neural network code that can utilize the GAP8 functionalities.

My internship came to an end before I could overcome the last hurdle for a working example. To still bring this example to you, I have committed the doc/code I wrote and handed over the knowledge that I have accumulated throughout my internship when working with the AI-Deck and its environment to the capable minds of Kimberly and Tobias.

Along the way I have learned a lot about embedded programming and being a first product user. In addition with embedded programming and programming in general comes a different mindset than a conventional planning and deadline fixed mindset you get from university. With these valuable lessons in mind, I will be heading back to the TU Delft to start with my master thesis in either reinforcement learning for aircrafts or dense optical flow nets for quadcopters. Thank you Bitcraze for your time, experience and hospitality!

Drawing with the Crazyflie

2020-03-02 | Kristoffer Richardsson | Leave a comment

There has been some work done earlier to use the Crazyflie for generating images, for instance the dot-drawing by Paul Kry and light painting. I wanted to see if it is possible to put a brush or pen on a Crazyflie and use it to draw lines on a paper. I decided to use a fun Friday to try it out. The idea is simple: mount a pen on the Crazyflie, put a paper on a wall, write a script to draw a figure, fly!

The first thing I looked into was to investigate if a Crazyflie can fly with a brush or pen mounted on it. I wanted to keep the weight down and my initial approach was to use a cotton swab (0.6 g) dipped in paint. I found one that was long enough to extend in front of the propellers and I mounted it by squeezing it between the battery and the PCB. Flying was no problem with such low extra weight.

For positioning I decided to use the Lighthouse system. It is very accurate, simple to use and the easiest way to get started. I mounted a piece of cardboard in the YZ-plane of our lighthouse coordinate system, where I could attach a drawing paper. The idea of setting up the drawing surface parallell to the YZ-plane was to make the scripting easier. I (of course) used the Crazyflie and lighthouse system to measure that the cardboard was mounted at the right position.

Finally I wrote a simple python script that utilized the high level commander to move towards the drawing surface and yawing at the right position to draw a stroke on the paper. It sort of worked, but the cotton swab has to be “refilled” before each stroke which took a lot of time, and the results were a bit random.

I decided to try out a pen instead. The upside is that it does not require refill, on the other hand it is much heavier which makes the Crazyflie a bit sluggish when flying. I mounted the pen on the top side of the PCB, squeezed under the Lighthouse deck, and moved the battery to under the Crazyflie to distribute the weight.

Initial tests – both cotton swab and pen

The script was updated to draw the outline of the Bitcraze logo. I had a couple of variations where I tried to draw the full outline in one long stroke, as separate strokes, going up or going down and some other flavours.

So was it successful? Currently the Crazyflie is not a new Picasso, but the painting skills could maybe be improved with some more work. I think the main problems were:

the pen is too heavy and requires too much force on the paper
the controller cannot handle the situation in a good way. In essence I set the set point a few millimeters “into” the paper to push the pen against the surface which seems to be confusing as the controller can not reach the set point.
Flying that close to the drawing surface creates an air flow that disturbs the flight.

Video showing the Crazyflie drawing the logo

The Bitcraze logo (17×17 cm), drawn by the Crazyflie

Crazyflie flying with Lighthouse V2!

2020-02-24 | Arnaud | 5 Comments

We are happy to announce that we have gotten Crazyflie 2 to fly autonomously using the Lighthouse deck and Lighthouse V2 base-stations. This was a very requested features, and while this is not stable and ready to use yet, it is a great milestone toward Lighthouse V2 support.

There exists two incompatible versions of the Lighthouse positioning system. Version 1 was released with the original HTC Vive VR system. In this system base-station are using two rotating laser beam that sweeps the room, one horizontal and one vertical, and an omnidirectional synchronization flash to allow IR light receiver to be located in the room. One limitation of this version is that up to two base-station can be used and no more, this is mainly due to the fact that beam identification is done using a TDMA scheme: base stations switch-on their laser in a dedicated time-slot one after each-other and adding more time slots for more base-stations will greatly reduce the update rate of the system.

Lighthouse V2, was released with the HTC Vive PRO headset and is also used by the Valve Index. The big change is that laser sweeps now carries modulated data and that there is only one rotor with two angled slit instead of the two rotors for V1. The V2 sweep data is described as ‘Sync on beam’ and contains timing information of how long it has been since the synchronization event (ie. when the rotor crossed 0 degree). The sweep data also allows to identify the base-station that has transmitted the sweep. This removes the need for an omni-directional synchronization pulse and allows more than two base-station to operate at the same time in the same space, since their sweeps can now be identified and timed.

The lighthouse V2 system is very elegant and scalable. However, actually decoding the signal from the sweeps has taken a lot of time since it is not documented and we needed to find-out what the encoding actually was. There has been effort on the internet to understand how the system worked, the most useful one is this github ticket that goes from raw data acquisition to fully unlocking the beam encoding.

I have been working on-and-off for a long time on making an FPGA design for the lighthouse deck to acquire and decode Lighthouse V2. The main blocking point until now was that I had not been able to reliably acquire useful signal from the system in order to allow real-time decoding on the Crazyflie. Added to that, there was some inconsistency between what we though the system was doing and what we could gather from the base-stations debug console. Recently though, the last piece of the puzzle, was to discover that the beam encoding was not Manchester, as we though, but Bi-phase mark code FM1 (BMC). Once this decoding was used everything made sense and worked.

Added to that, I started using SpinalHDL instead of raw Verilog to write the FPGA design which allows for much quicker iteration, much less frustration, and it also allowed me to easily make the design multi-clock which is required to decode the BMC signal: the beam decoder runs at 48MHz, and the rest of the system works at 24MHz. This design is required since the FPGA we use in the lighthouse deck is not fast enough to run everything at 48MHz.

The result, is a new FPGA firmware for the lighthouse deck that receives, identify and decode Lighthouse V2 sweep signal and send them over to the Crazyflie. The Crazyflie still has a little pulse packing to do (putting together pulses from a single sweep received on multiple sensors) and then can use pulse timing information to calculate azimuth and elevation at which the base-station sees the Crazyflie. This information is the same as the one we get from Lighthouse V1 and so the same algorithm can be used to calculate the Crazyflie position.

I hacked a proof of concept was this last fun Friday and it flies!

If anyone is curious the code for this demo has been uploaded as an out-of-tree driver and the code for the FPGA parts is already in the lighthouse-fpga project. The current Crazyflie code is too incomplete to be usable, but it is a nice starting point if anyone wants to play with Lighthouse V2 and the Crazyflie right away ;-).

As a side note, the Bitcraze team will shrink temporary as I, Arnaud, will go in parental leave until mid-August. I look forward to this new adventure and I trust the lighthouse V2 development and the forum will be in good hands in my absence.

Crazyradio VS BLE

2020-02-17 | Kristoffer Richardsson | Leave a comment

The Crazyflie supports wireless communication using both the Crazyradio PA and BLE (Bluetooth Low Energy https://en.wikipedia.org/wiki/Bluetooth_Low_Energy). BLE is used with the mobile phone apps while Crazyradio PA usually is used together with a PC.

The lower levels of the radio communication in the Crazyflie is handled by the nRF51 that is capable of handling both types of communication. When using the Crazyradio we are using the manufacturers, Nordic Semiconductor, proprietary Enhances ShockBurst protocol (ESB) which makes it simple to send packages, up to 32 bytes, between each other. When communicating over BLE we are using Nordic Semis S110 SoftDevice which is a BLE stack developed by Nordic Semi to simplify implementation.

When we designed the first Crazyflie, the Crazyflie 1.0/Nano, we choose to use the nRF24L01+ that uses the ESB protocol because of simplicity, good range and low latency. Then came the Crazyflie 2.0 and we wanted BLE for mobile client support. Luckily Nordic released the nRF51 which could handle both. However there is a small drawback, both protocols can’t run concurrently and has to be interleaved. For BLE this has never been any problem as this protocol has the priority, but for ESB it means that when BLE is running there will be a small amount of packet loss.

The CRTP protocol we developed that runs on top of the ESB, handles the packet loss fairly well but as more and more Crazyflies are added we have been seeing communication issues. So last week we dived in to this problem and after some digging we understood that BLE was one of the problems. Therefor we added a switch which disables BLE as soon as a ESB packet is received. This improved the ESB connection and it now seems more stable. If you have the possibility we suggest you to get the latest from the crazyflie2-nrf-firmware master branch, try it out and give us feedback.

This change will hopefully provide more stable communication between the Crazyradio PA and the Crazyflie. From a functionality point of view, most users will not see any difference, but we would like to point out that if you have communicated with your crazyflie using the Crazyradio PA, it will not be possible to connect with a mobile phone until the Crazyflie has been re-booted. Note that a simple radio scan with the python client has the same effect and disables BLE.

New release: 2020.02

2020-02-10 | Tobias | Leave a comment

When there is a possibility to name a release with only two’s and zero’s one has to take that opportunity right! Adding to that, it was about time to make a new release, and there is actually another reason. As we wrote about in the “What’s up 2020” blog post, it’s time to look back, finish up and make things more stable. This includes improving documentation, more examples/tutorials etc. With this release we create a good baseline to start this work from.

The release changes are outlined below.

Crazyflie/Bolt/Roadrunner firmware

Basic App layer
Basic P2P communication
Improved Lighthouse positioning
Structural and architectural improvements
Bug fixes

Python client and library

Bug fixes
More examples
Full external pose support

Out of Control

2020-02-03 | Kimberly McGuire | 2 Comments

Two weeks ago, we had a blogpost about the state estimators that are available within the Crazyflie. So once the Crazyflie knows where it is, it would need to be determined where it wants to go, by means of the high level commander (implemented as part of the crazyswarm project) or set-points given by CFclient or directly from scripts using Crazyflie python lib. But exactly how would the crazyflie get to those desired positions in the first place? The differences between the current state estimates and the desired state, will need to be transformed to inputs given to the motors. Unfortunately, quadrotors like the Crazyflie do not have easy dynamics to maintain, so if you want to learn more, see this blogpost to read more about it!

So in order use the thrust of the motors in an useful way to get the Crazyflie to do what you want to do, there are several controllers to consider, which you can see on this quick overview here underneath. It shows the different control paths that can be taken from the high level commander all the way to the power distribution of the motors. Bear in mind that these are still simple representations and that the actual implementation is of course a bit more complicated, but at least it will give you a rough idea of which paths are possible to pursue.

PID Controller

So the default settings in the Crazyflie firmware is the proportional integral derivative (PID) control for all desired state aspects. So the High Level Commander (HLC) will send desired position set-points to the PID position controller (which used to be done off-board, so outside of the Crazyflie firmware before this blogpost). These result in desired pitch and roll angles, which are sent directly to the attitude PID controller. These determine the desired angle rates which is send to the angle rate controller (which is… you guessed… also a PID controller). This is also called Cascaded PID controller. That results in the desired thrusts for the roll pitch yaw and height that will be handled by the power distribution by the motors. (Note that height is mostly handled by the position controller)

INDI Controller

So the Incremental Nonlinear Dynamic Inversion (INDI) controller is an controller that immediately deal with the angle rates to determine the trust. This is a very new addition to the Crazyflie firmware by one of our community members and is based on the implementation of this paper. Currently, the position control is still handled by the same PID controller mentioned in the last paragraph, Nevertheless for handling the angles, it should be faster than the attitude and rate PID controller combined. We have not yet fully tested this out but if you do, let us know how you like it on the Bitcraze forum!

Mellinger Controller

As part of the Crazyswarm project, the controller designed by Daniel Mellinger has been implemented in the Crazyflie firmware as well. Please see this paper about the details of the Mellinger controller. It is a sort of “all in one”: based on the desired position and velocity vectors towards those position, it will calculate right away what the desired thrusts are that need to be distributed to all the motors. This results in a much smoother controlled trajectory of the high level commander and therefore advised to use when the Crazyflie has a precise position estimate (lighthouse and mocap). However, as it is so aggressive, any position estimate of a lesser quality (flowdeck or LPS) will not be sufficient for this controller. See some examples of mellinger controlled flights here and here.

Let us know what you think!

So do you have experience working with these controllers or want to know more about them, please drop us a message on the forum! We are currently working on stabilization and documentation of multiple aspects of the Crazyflie and the controllers is one of them, so we are really interested what your experiences are!

State estimation: To be or not to be!

2020-01-20 | Kimberly McGuire | 2 Comments

How does a Crazyflie manage to fly and stay in the air in the first place? Many of us tend to take this for granted as much research tend to happen on the application level. Although we try to make the low level elements of flight as stable as possible, it might happen that whatever you are trying to implement on the application level actually effects the Crazyflie on the low level controls and estimation. We therefore would like to focus a little bit on the inner-workings of the autopilot of the Crazyflie, starting with state estimation. The state estimation is part of the stabilizer loop in the Crazyflie, an overview of is was made in a previous blog post.

State estimation is really important in quadrotors (and robotics in general). The Crazyflie needs to first of all know in which angles it is at (roll, pitch, yaw). If it would be flying at a few degrees slanted in roll, the crazyflie would accelerate into that direction. Therefore the controller need to know an good estimate of current angles’ state and compensate for it. For a step higher in autonomy, a good position estimate becomes important too, since you would like it to move reliably from A to B.

There are two types of state estimators in the crazyflie firmware, namely a Complementary Filter and an Extended Kalman Filter.

Complementary Filter

The complementary filter is consider a very lightweight and efficient filter which in general only uses the IMU input of the gyroscope (angle rate) and the accelerator. The estimator has been extended to also include input of the ToF distance measurement of the Zranger deck. The estimated output is the Crazyflie’s attitude (roll, pitch, yaw) and its altitude (in the z direction). These values can be used by the controller and are meant to be used for manual control. If you are curious how this code is implemented exactly, we encourage you to checkout the firmware in estimator_complementary.c and sensfusion6.c. The complementary filter is set as the default state estimator on the Crazyflie firmware.

Extended Kalman Filter

The (extended) Kalman filter is an step up in complexity compared to the complementary filter, as it accepts more sensor inputs of both internal and external sensors. It is an recursive filter that estimates the current state of the Crazyflie based on incoming measurements (in combination with a predicted standard deviation of the noise), the measurement model and the model of the system itself. We will not go into detail on this but we encourage people to learn more about (extended) Kalman filters by reading up some material like this.

Shortly said, because of the more state estimation possibilities, we preferred the Kalman filter in combination with several decks: Flowdeck, Loco positioning deck and the lighthouse deck. If you look in the deck driver firmware (like for instance this one), you see that we set the required estimator to be the Kalman and that is of course because we want position/velocity estimates :). Important though is that each input of the measurement effects the quality of the position, as positioning of the Lighthouse deck (mm precision) is much more accurate that the loco positioning deck (cm precision), which has all to do with the standard deviation of the measurement of those values. Please check out the content of estimator_kalman.c and kalman_core.c to know more about the implementation. Also good to know that the Kalman filter has an supervisor, which resets if the position or velocity estimate is gets out of hand.

Of course this blogpost does not show the full detailed explanation of state estimation, but we do hope that it gives some kind of overview so you know where to look if you would like to improve anything. The Kalman filter can easily be extended to accept more inputs, or the models on which the estimates are based can be improved. If you would like implement your own filter, that would be perfectly possible to do so too.

It would be great if you guys could share your thoughts and questions about the state estimation on the crazyflie on the forum!

Crazyflie Bolt: FPV meets Autonomy

2020-01-13 | Sean Kelly | 4 Comments

I started working with the Crazyflie 2.0 in 2015. I was interested in learning how to program a quadcopter, and the open-source nature of the Crazyflie’s hardware and software was the perfect starting point.

Shortly after, I discovered the world of FPV and the thrill of flying with a bird’s eye view. My journey progressed from rubber-banding an all-in-one camera/VTX to my Crazyflie, to building a 250mm racing quad (via the BigQuad deck), and into the world of Betaflight (including bringing Betaflight support to the Crazyflie hardware).

: FPV for Beginners ;)

: BigQuad Build

Naturally, the announcement of the Bolt (then known as the RZR) piqued my interest, and the folks at Bitcraze graciously allowed me early hands-on with the product.

This post details my progress towards building out a FPV-style drone on top of the Crazyflie Bolt.

Component List

The FPV community has come a long way since 2015. What once was a very complicated process is now well documented and similar to building a PC (well, with some soldering). For latest details on the specifics of building FPV drones, I recommend resources such as Joshua Bardwell or the r/Multicopter subreddit.

Turns out I had enough components lying around for a 4-inch (propeller diameter) build based on 3S (3 cell) LiPo batteries. Again, there’s nothing special about these parts (in fact they’re all out of date). Take this list as a guide, and do your own research.

PDB (Power Distribution Board): This is a circuit board that produces regulated voltages from an unregulated LiPo battery. The Bolt has built-in regulators but is only rated up to an 8A current draw per motor. My 4 inch propellers will certainly draw more than 8A, and so an external PDB is required (plus having dedicated 12V and 5V supplies is nice for peripherals).
4x DYS 1806 Brushless Motors: Brushless motors use magnetic pulses to rotate a motor bell (distinct from brushed motors found on the regular Crazyflie).
4x DYS 20A BLHeli_S ESCs (Electronic Speed Controller): This is a piece of circuitry that accepts a logic-level control signal and applies direct battery power to motor coils to make a brushless motor spin. They have to be rated for the current draw expected by the battery+propeller combination.
Tweaker (by Shendrones) Frame: I’ve been wanting to build a quad around this frame, and the large square hole is interesting for the Bolt (more on that later). One thing to keep in mind is this is an ‘H’ style frame. That is, it’s longer than it is wide, so flight will not be perfectly symmetrical. If you’re interested in building a larger Crazyflie and not so interested in FPV, you’ll definitely want a symmetrical ‘X’ style frame.
WS2812B addressable LEDs: LEDs are proven to make things better. It’s science.
Camera + VTX: For a full FPV setup, you’ll need a camera and a video transmitter. For the most part these run completely independently of the flight controller and so I’ll omit them from this article — what I’ve shown in the picture above is horribly out of date anyway.
RX: Radio receiver. For longer range flights and reduced latency it may be a good idea to use an external radio and UART-based receiver with diversity antennas. However, some specific work went in to the Bolt’s antenna design, so I’ll be sticking with the on-board NRF51 and external antenna.
Flight Controller: The Crazyflie Bolt!

The Build

Again, there are hundreds of fantastic guides on the web that detail how to build an FPV quadcopter. Instead of trying to create another, here are some notes specific to my Bolt build.

Expansion Decks

Since the Bolt is pin compatible with the Crazyflie, I thought it would be interesting to try and take advantage of a couple existing Crazyflie expansion decks in my build: The LED Ring Deck, the Flow Deck v2, and the Micro SD Card Deck.

The LED Ring Deck

The LEDs were the most hands-on feature to enable. Rather than simply attaching the LED ring inside the frame, I mounted a series of WS2812B lights to the underside of my frame’s arms. The LED Ring Deck consists of 12 LEDs connected in series — so I put three LEDs on each arm of the frame and wired them up in a daisy-chain.

Finally, I soldered the lead to IO_2 (the same that’s used by the LED Ring Deck) on a Breakout Deck.

Since this isn’t the official LED Ring Deck, there’s no OW memory ID. The deck must be force-enabled by specifying a compile flag in your tools/build/make/config.mk file:

CFLAGS += -DDECK_FORCE=bcLedRing

With the custom firmware, the under-arm LEDs work just like the LED Ring Deck (other than the lack of front-facing LEDs).

Micro SD Card Deck

Most popular flight controllers feature flash storage or SD card slots for data logging. The FPV community uses storage to log sensor data for PID tuning and debugging. Naturally, this deck is a good fit on my Bolt build, and requires no additional modification.

Flow Deck (v2)

Remember my interest in the square cutout on my frame of choice? That, and my unorthodox choice to mount the Bolt board below my PDB, means I can theoretically use the bottom-attached Flow Deck to achieve some lateral stabilization while close to the ground. In theory, the VL53L1x ranger should work outdoors thanks to its usage of 940nm light as opposed to 850nm.

Note: This photo also shows the daisy chain wire connecting banks of LEDs in series

Other Build Tips

It’s good practice to soft mount flight controllers to minimize transferring motor/prop vibrations into the IMU. I used these to isolate the flight controller from the frame — not perfect, but better than a rigid mount.
The receiver antenna must be mounted clear of the carbon fiber frame and electronics. I like to use a heavy duty zip tie and attach the antenna with heat shrink.
The Bolt can be powered from a 5v regulator on your PDB, but if you want to take advantage of the VBat sensor it should be powered from the raw battery leads instead. However, most ESCs support active breaking (ability to slow/stop the propellers on demand). Active breaking is known to produce a lot of back-voltage, which can damage some circuits. To be safe, since I’m using a 3S battery (12.6V when fully charged, 11.1V when depleted) I chose to power the Bolt off a regulated 12V supply from my PDB. This way, the PDB’s regulator will filter out voltage spikes and help protect the Bolt. Readings won’t be accurate at the higher range, but what really matters for a voltage sensor is to know when to land.

Results

It works! There is work needed to improve flight, though:

Control tuning is required. The powerful brushless motors respond much quicker than brushed motors, and so many of the PID and/or Kalman parameters are too aggressive or just non-optimal.
Stabilization with the Flow deck does not work — I haven’t spent much time debugging but my guess is it’s either due to the Kalman tuning, or problems with the VL53L1x depth working outdoors (which also impacts the flow measurements)
Betaflight Support: Betaflight has no driver for the BMI088 IMU used on the Crazyflie Bolt or the Crazyflie 2.1.
Safety Features: Brushless quads are very dangerous and can cause serious injuries. It’d be good to implement a kill-switch and a more aggressive failsafe in the firmware to prevent flyaways.

All in all, this was an enjoyable project and I’m excited to see some autonomous brushed quads coming out of the Crazyflie community!

Production Tests

2019-12-16 | Arnaud | Leave a comment

We are currently finishing production test design for a couple of expansion decks and we figured we never wrote about it and about the more general board production process. In this blog post we wanted to talk a bit about how we test boards in the productions phase, taking as an example the forthcoming active marker deck.

When finalizing an electronic board, we send to the manufacturer documentation that allows to manufacture & assemble a, hopefully, functional board. Although we assume that the individual components are in working order, the problem is that the assembling is not always perfect, so we need to check that everything we do is actually working,. This is what the production test is solving.

The first thing is to find out what to test, for that we need a strategy. The strategy we have been using is to test every step where we have modified or work on: for example we will test all the connections we have soldered in the manufacturing process. We will normally not test all the functionalities of ready-made module. For example, following this strategy, we will usually test all communication interface we have cabled, but we will not test all functionalities of a microcontroller we solder on the board, these are deemed to be already tested and working by the microcontroller manufacturer. This step usually end up with an annotated schematic:

Once we know what to test and roughly how to test it, we document a test rig that will be able to run the tests automatically. Some tests are generic and applicable to all our boards, for example we do test voltages with a multi-meter on every board that has a regulator. Some tests are very board specific. For example, for the active marker deck we want to test IR LEDs and an IR detector, we define a test rig that has reflector to reflect the LED to the detector and we will use the onboard detector to test the LEDs:

Simple block diagram of the test rig for the ActiveMarker Deck

We are normally using a Crazyflie on all our test rig, since it is usually possible to test all functionality from the deck port. We also try as much as possible to integrate the test software into the real software. For the active marker deck it meant adding 38KHz modulated output mode to the LEDs in order to emit a signal detectable by the detector, which will make it to the final firmware. Finally, we have a test software, running on the test computer, that uses the Crazyflie python lib to talk to the Crazyflie and run the test. The last step of all the test is to write the deck One Wire identification memory so that it can be detected by a Crazyflie.

Screenshot of the test program for the test engineer

From these specification, the manufacturer can then build a test rig and start testing boards, non-passing board will be re-worked until they pass or discarded.

Test rig for the Multi-ranger expansion deck

What we have learned in our years at Bitcraze is that testing phase is the most important part of the development process of PCB. Therefore, the earliest we already start thinking about the production tests in the board design, the more smooth the final phase of production of our new products will be.