Introducing the Techwing

Hey every one!

so I have been deep in the bowels of my garage for the last couple months, working on a new flying wing design.

pnael forces wingCpwing

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Here are some specs:
Wing span 38 inches
weight as flown 20 Oz
battery 2200 3s lipo
motor AX 3802 1100 kv outrunner

Magnetic encoder and brushless gimbal controller

For the techpod 2.0, I want to have a high precision camera gimbal capable of continuous rotation in two axis. I have always likes the brushless gimbals that are so popular today. The control and drive systems are very nice but are not setup for continuous 360 degree rotation. furthermore the IMU algorithm is very CPU intensive and prone to needing the gyros calibrated frequently etc.

I decided to replace the IMU with a AS5048B  rotary magnetic  encoder for position feedback.  The  AS5048B outputs the 14 bit absolute position of a magnet rotated near the IC. After you include noise, it is good for about 0.06 degrees of accuracy.  Here is a short video of it going from 90.5 degrees to -90.5 degrees every 10 seconds.

Here is a quick hack of the brushless gimbal software.

_BruGi+AS5048

170 minute techpod flight with APM 2.5

So I did a test flight yesterday, here is the result.
170minflight
here are the Tlogs.

170 minute flight time, 76.5 miles over the ground.

this is the equipment list:
Techpod Kit

Foxtech 370kv motor

APC 12*8 prop

Castle ice2HV 40 ESC

2x Zippycompact 6s 5000 mah lipo

APM 2.5

6x Hitech 65-hb servos

Variable pitch Techpod

Hey everyone, Here is something cool that I have been working on that I think you may enjoy.

Variable pitch prop

Variable pitch prop

So, I had been pondering how to make an inexpensive variable prop. I was thinking about using a heli head from a hk450 or perhaps a tail rotor. I eventually saw a post on DIYdrones.com where a guy was using a tail rotor from a HK500 (can’t find post). I got inspired and found a HK600 tail rotor has the same shaft diameter as the turnigy G10 I use on the techpod. this is what I have come up with.

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variable pitch test rig

I measured 15 degree max forward pitch and 12 degree reverse pitch. at 15 degrees forward pitch it drew 40 amps from a 3 cell lipo and puts out just under 5 lbs thrust.

I got the blades here and the tail rotor assembly here. I removed one side of the tail rotor plates and replaced both the shaft in the tail rotor and the shaft in the motor with one long 5 mm shaft. I had to notch it a few times for the set screws.I then made a plate to help support the rotor plate so I could then brace it with some 4-40 all thread rod and nyloc nutsI also made a custom motor mount for the techpod.

After the motor was secured, I cut out a mount for the pitch servo. Then I cut a hole in the foam so I could attach the servo mount to the techpods rear fuselage brace. I grabbed a bell crank from the local hobby shop and mounted it to the rear brace as well.

I have the techpod mostly assembled and should have the batteries for it later today. I hope to be able to start test flying over the weekend. If everything works out well, I plane on offering this as an mod kit for the techpod.

techpod 2.0

tech2 tech2_1 tech2_3 tech2_2Hey everyone!

I wanted to share some conceptual drawings of the next gen techpod. It will include a fully functional pan/tilt/zoom camera mounted on a stabilized gimbal with 360 degree continues rotation on two axis.

Fuselage assembly

The Main steps to assembling the fuselage

  1. assemble spar box and rear bulkhead
  2. attach motor mount
  3. add fiberglass
  4. mount motor
  5. route motor wire
  6. Insert and align boom/tail assembly
  7. custom fit your gear at this point
  8. Fit and glue fuselage halves together

assemble spar boxand rear bulkhead

1. measure 1/2 inch inboard from the end of  6.top spar box piece and mark. then measure the center line and mark.drill a 1/8th inch whole in 6.top spar box piece

mark 1/2 inch inboard

mark 1/2 inch inboard

IMG_20130319_205310

mark center line and drill cross marks with 1/8 inch drill bit.

2. mark fuselage halves using a screw in the wholes you drilled

IMG_20130319_225542 IMG_20130319_225612IMG_20130319_225700

3. poke an access hole for the set screws on the mark you just made. I used one of the aileron push rods.

IMG_20130319_225725

IMG_20130319_225745

4. epoxy 6.top spar box piece to 5.rear spar box

5.epoxy 6.bottom spar box piece to 3.rear bulkhead

IMG_20130319_170804

6. slide two parts and test fit the 39. Spar end tube

IMG_20130319_172840

make sure it clamps on the nylon tube

7. sand slot until the camping action works well if needed

IMG_20130319_183017

sand if needed for good clamping action

8. assemble and install t-nut with CA

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drill hole with 3/16th inch drill an secure with CA

9.  epoxy 1. Rear brace to 3. Rear bulkhead and make sure they are square

square rear brace and glue with epoxy

square rear brace and glue with epoxy

attach motor mount

Epoxy   2.Motor mount  to 1.Rear brace.  Make sure it is square. you may have to sand lightly to make it fit. The production units are a bit tight here.

IMG_20130319_203224

add fiberglass

1. trim fiberglass to fit

IMG_20130321_155608

you want the fiberglass to reinforce the corner of the two pieces. You want to make a fillet.

2. fill motor mount screw holes with vaseline to prevent filling with epoxy. make sure not to get any on the front side of the motor mount as it will cause the epoxy to not bond.

3. lay down fiberglass and work in epoxy(15 minute)

4. allow to cure and add more epoxy if needed to make a fillet.

IMG_20130321_160135

trim edges after curing.It should look like this when done.

mount motor

attach motor with appropriate screws add spacers if needed for prop clearance.

route motor wire

cut tunnels into the insides of the fuse to allow the motor wires to pass

rout

use a razor blade to make clearance for the motor wires. Run 2 on one side 1 on the other,

pro tip: install bullet connectors on the motor side so you can replace the motor if you need to.

 Insert and align boom/tail assembly

1. insert tail and boom assembly

 

2. mix and apply an ample amount of JB weld to glue the carbon fiber to the wood

3. Align the   F.Vertical stabilizer with the 1. Rear brace

4. brace and allow glue to cure

custom fit your gear at this point

now it the time to fit that mammoth lipo or the vertical camera, custom table or whatever you desire

Fit and glue fuselage halves together

Parts identification

wood parts ID 1. Rear brace                        20. Quick nuts

2. Motor mount                   21. Wood screws #6

3. Rear bulkhead                  22. Brass tubes

4. Forward bulkhead          23. Nylon bolts

5. Rear spar box                 24. Nylon washers

6. top/bottom spar box   25. Rudder push rod

7. hood tabs                          26. Padding

8. nylon screw capture       27. Bay window

9. Tilt mounts                         28. Velcro straps

10.  Tilt servo side left          29. Silicon tubes

mtl plastic parts ID

11. Tilt servo side right        30. metal washer

12. camera mount                    31. T-nut

13. pan mount                               32. Wing screw

14. pan/tilt plate                         33. screw (not needed)

15. Vertical camera plate         34. Elevator push rod

16. Plate tabs                                 35. Aileron/flap push rods

17. Bay sides                                    36. Push rod keeper

18. Bay hing                                      37. control horns

19. Fiberglass                                  38. clevises

39. Spar end tube

dome-lam ID

40. Dome

41. Covering

42. Spars

43. Tail boom

44. Spar joiner

45. short tail rod

46. Tail rods

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.

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carbon ID

Fosm ID

A.  Right wing

B. Left wing

C. Left spar cap

D. Right spar cap

E. rear fuse trim pieces

F. Vertical stabilizer

G. Left fuse

H. Right fuse

I. Horizontal Stabilizer

J. Hood

K. Servo cover

Wing assembly

The main steps to building the wings (pictures coming soon)

  1. drill servo arms to fit push rods
  2. Fit and mount servos
  3. adjust servo arms for neutral point
  4. Fit spar cap
  5. Glue in spar cap
  6. attach spar capture tube
  7. install control linkages

drill servo arms to fit push rods

use a #50 or 5/64″ drill so the push rod will fit through

Fit and mount servos

fit servos
add extensions
run the wires and tack them down.

Fit spar cap

  1. notch spar cap to fit wires

Glue in spar cap

  1. coat spar with goo
  2. coat spar cap area with goo
  3. make sure to align end of spare with end of wing
  4. tape weight down spare cap, allow to cure
  5. finish edges with CA and kicker

attach spar capture tube

  1. Cut tube in half
  2. rough surfaces with sand paper
  3. mix JB weld and apply to spar
  4. slide on capture tube
  5. clean up excess
  6. allow to cure

install control linkages

attach control horns with CA and kicker

  1. assemble push rod and clevis
  2. adjust clevis so control surface is centered with servo at neutral point
  3. install push rods

Construction Manual

This is the Construction manual for the techpod.

Part identification

I will take you through all the steps for making your techpod kit into a high performance flying machine. The Techpod can be  broken into a few major parts.

Nick Weber has been kind enough to make a few build videos

Techpod test flight 60 acres


this is some video of me flying the techpod over 60 acres park. Sorry it is so burry the camera was not in focus and I didn’t have time to adjust it. I was running out of daylight.
produstion sample first flight
It used about 0.75 amp hours of battery for about an 18 minute flight. The all up weight was 7 lbs. With 10,000 mah 6 cell lipo.