Yvon's KAP Rig #6

edited July 2016 in KAP Gear Sources
I started designing my KAP rig #6.

See KAP rig #5 thread here:
arch.ced.berkeley.edu/kap/discuss/index.php?p=/discussion/5398/yvon-s-kap-rig-5#latest

My KAP rig #5 is working perfectly as I wanted. I'm impressed that I can reach about 400ft with the 25mW video transmitter. Although, I noticed when the wind is getting strong, the rig moves a lot. It's probably caused by the large surfaces area exposed to the wind and also the relatively small picavet.

I started designing a new revision of this rig. This will be my 6th rig. The main improvements are:
- reduce the rig weight as much as possible.
- reduce the surface areas exposed to wind.
- enlarge the picavet and make it foldable for travelling
- create a real PCB for the electronics instead of prototyping by hand. This will eliminate almost all harnesses (reduce weight) and make it easier to assemble the rig.
- create a real PCB for the remote control

And, to add to Tom's comment in the rig#5 discussion:"...I was planning to use a hollow tilt axle, and to run the shutter and video cables through that and into the tilt frame...", I have a few ideas I’d like to try. If it works, it’ll allow me to reduce the overall size of the rig.

It'll take several months before I'm done with this one but at the end I'm planning to publish all the drawings and software if anyone is interested.

Comments

  • Looking good YvonH.

    Rig # 5 was almost perfect.

    Agree with your points above. Weight and surface area of the KAP rig are always items to reduce if you can. You may wish to explore the offset rigid pendulums (faluga??) discussed on other treads.

    Looking forward to seeing the results!

    WW
  • edited July 2016
    Thanks WW.

    Here's a draft concept of what I want to do for the camera connections in the same idea as what Tom mentioned before. I still need to tweak the size of the opening and try it to see if it works.

    Basically, I replaced the tilt axle screw with an opening and the tilt module rolls on 3 screws with bushings attached to the main frame.

    image

    image
  • edited August 2016
    I'm slowly working on the design of my new rig. Here's an update of the pass through cable concept. The opening needed to be larger than I expected to accommodate the connectors and also the 2 rubber doors (gray rectangles beside the cables connector).

    image

    image

    image

    Also, I started exploring 3D printing as an alternative to FR4 printed circuit material. I got some samples from a friend today.:
    image

  • Finally a first run of the whole set of plastic parts. I'm not done with the design yet and I already made some modifications but these parts helped me better visualize some details.

    image

    image

    image

    image

    image

    image
  • Wow, looks great. What is the weight of the rig minus the camera?

    WW
  • Yes it's looking good. I have a suggestion that you make one end a different colour so that if you're not using a downlink, you can see which way round the rig is. It might look strange but would probably be helpful in direction finding.

    Fly High

    Sue
  • This is just a first run of the plastic parts. I already made some changes in the design but these parts help me better see some details.

    All the plastic parts weight 126g but once I add the motors, electronics, battery, picavet, i'm guessing it'll be below 500g.

    Sue, good idea for the different colors. I'm not decided yet on the final colors but I'll keep your suggestion in mind.
  • Hi all,
    During the Holidays, I worked on the design of the picavet suspension.

    image

    image

    image

    image

    image

    image

    image
  • Looking good.

    Like the collapsible picavet cross.

    WW
  • edited February 7
    Hi all,
    Here's an update on my progress. I'm almost done with the mechanical design, for now anyway. :-)

    As I learn more with 3D mechanical design, I found more tools to make the design easier. I made a 3D PDF file. This allows to rotate, zoom, do cross sections using Adobe Acrobat Reader. The file is about 20Mbytes.

    yvonhache.com/equipement/KAP6/photos/KAP_Forum/KAP600_3D_2017-01-21.pdf

    Commands in a 3D PDF:
    - left mouse button: rotation
    - right mouse button: zoom
    - ctrl - left mouse button: pan
    - In the menus, you can hide components and do cross sections.

    I sent the files to be 3D printed. The next step is to finish the electronic board.

    A few important changes in the last few weeks:
    - cut the upper corners. I didn't like the "square" look. It'll also help reducing the resistance to the wind.
    - I integrated the video transmitter completely inside including the antenna. I'm not sure how this will influence the distance for the video transmission. I'll have to test it.

    image

    image

    image

  • edited March 28
    Hi all,
    Here’s an update on my KAP rig design progress :
    - I finally released my PCB and ordered the components. I should have every here by the end of the week. See images below.
    - I’m now back to the mechanical design trying to finalize the drawings for the 3D printer for a final release of the plastic parts.

    Top Side:
    image


    Bottom Side. This side will be visible on the top of the rig. I put some LEDs to indicate the status of some parts of the circuit.
    image

    Isometric view:
    image

    Top view with some details added:
    image

    For those interested, here’s a copy of the schematic:
    http://www.yvonhache.com/equipement/KAP6/photos/KAP_Forum/299999-0002R-00A_SCH.pdf
  • Amazing work!

    I love that you're going with zigbee instead of traditional hobby radio.
    You should be able to get tons of telemetry back to controller... and be able to change all the settings you want from the comfort of the ground. haha

    Do you have a pic-n-place machine or are you gonna solder that up by hand and bake it?
  • Thanks
    i find the hobby radio too big. With the ZigBee, I made my own small remote control. For now, it's just for moving the camera and taking pictures but my project for next winter will be to add more telemetry and control.

    I don't have a pick n place machine but, at work, we have a supplier here in Dieppe that assembles electronic boards and they agree to solder the 100 pin microcontroller on 2 boards at a very good price. I'll assemble the rest the old fashion way, one component at a time with a soldering iron. :-)
  • Hi all,
    Here's a small update where I'm at with this design.

    I finished soldering the components on the PCB yesterday. The empty spaces are for possible future options. Now I need to test the circuit and program the microcontroller.

    image

    I put the whole rig together to make sure that everything fit and there's nothing missing. I also used it to make the harnesses (motors, battery, camera, video transmitter). On the photos below, the PCB is empty. I will take it completely apart and take pictures of the assembly soon.

    The photos also show more details of the camera cables going through the large opening. It seems to work well. I'll try to show more details when I take assembly photos.

    image
    image
    image
    image


  • Wow - looks great!
  • A fantastic job!

    Question about the push buttons though... they missing the keycaps?
  • Thanks :-)

    These pushbuttons could have keycaps of different colors but in this case I don't use them.
  • Very impressive, Yvon! Bravo!
  • Thanks Broox. :-)

    I did some tests yesterday to make sure the plastic picavet was strong enough. I have to say that I'm impressed with the strength of this plastic. The 2 main arms didn't even flex.

    50lbs (22.7kg) on the pictures below.

    image

    image

  • Next up, baby KAPing!
  • I weighed all the pieces together yesterday and the final weight is as follows:

    - complete rig (including battery and picavet but without camera): 477g
    - total with camera Canon T4i (EOS 650D): 1.179kg

    My Rig #5 weighed 682g. My new rig is 30% lighter.

    I still need to finish programming the microcontroller before the first flight. I hope to be able to finish before June.
Sign In or Register to comment.

Howdy, Stranger!

It looks like you're new here. If you want to get involved, click one of these buttons!

In this Discussion