Modular Design of Integrated Duct Fan Quadrotor Structure

Abstract

This thesis will continue the work done by Sethuram Balakrishnan in his master thesis “Duct fanned shielding design for quadrotors”. It includes studies of integrating Balakrishnan’s solution to the outer structure of the DJI Flame Wheel F450 Quadrotor in order to save weight. A report with preliminary work will cover investigation of existing solutions and technology, setting design requirements and explore standards given by the government. The was to reduce mass from the previous design, make it modular and retain the mechanical properties of the quadrotor. Concepts were created and evaluated with the systematic design process explained by Nigel Cross in his book “engineering design methods”. Materials was selected in CES by maximizing the material index for a low mass/stiff construction. Numerical analysis in Inventor was done to verify the structural integrity of the model, and a prototype was constructed to give a real perspective of the model. The process produced a final design that was 500g lighter than Balakrishnan’s design, modular and cost effective. This means a 43,5% reduction in mass. The results in theory are interesting, and if results from physical testing corresponds, it will possibly have implications for production of drones with a need for increased thrust and protected propellers.