Systematic design methodology for development and flight testing of a variable pitch quadrotor biplane VTOL UAV for payload delivery

This paper discusses the conceptual design and proof-of-concept flight demonstration of a novel variable pitch quadrotor biplane Unmanned Aerial Vehicle concept for payload delivery. The proposed design combines vertical takeoff and landing (VTOL), precise hover capabilities of a quadrotor helicopter and high range, endurance and high forward cruise speed characteristics of a fixed wing aircraft. The proposed UAV is designed for a mission requirement of carrying and delivering 6 kg payload to a destination at 16 km from the point of origin. First, the design of proprotors is carried out using a physics based modified Blade Element Momentum Theory (BEMT) analysis, which is validated using experimental data generated for the purpose. Proprotors have conflicting requirement for optimal hover and forward flight performance. Next, the biplane wings are designed using simple lifting line theory. The airframe design is followed by power plant selection and transmission design. Finally, weight estimation is carried out to complete the design process. The proprotor design with 24◦ preset angle and -24◦ twist is designed based on 70% weightage to forward flight and 30% weightage to hovering flight conditions. The operating RPM of the proprotors is reduced from 3200 during hover to 2000 during forward flight to ensure optimal performance during cruise flight. The estimated power consumption during forward flight mode is 64% less than that required for hover, establishing the benefit of this hybrid concept. A proof-of-concept scaled prototype is fabricated using commercial-off-the-shelf parts. A PID controller is developed and implemented on the PixHawk board to enable stable hovering flight and attitude tracking.