Recent Trends in Automation and Automobile Engineering

Volume 3 Issue 2

Design and Analysis of Solar Quadcopter

Rishabh Bahuguna, Rohan Sharma, Shiladitya Biswas, P. Nandakumar*
Department of Mechanical Engineering, SRM Institute of Science and Technology,
Kattankulathur, Tamil Nadu, India,

*Corresponding Author
E-Mail Id: nandakup@srmist.edu.in

ABSTRACT
Quadcopter comes under category of unmanned aerial vehicles. Different types of
quadcopters are used nowadays mainly for surveillance operations due to their
dependability, low-cost and multi-functionality. This project presents novel design for
quadcopter and discusses about all its attributes ranging from mechanical and electrical
components design commonly employed in it. Finite element analysis has been carried out on
its frame to evaluate deformation due to application of various loads. Possibility of a solar-
hybrid system, for boosting overall flight time of copter has also been explored.

Keywords:-Quadcopters, composite material, FEA, solar energy

INTRODUCTION opposite to each other rotate in a particular

Quadcopter comes under the category of direction while the other pair must rotate
Unmanned Aerial Vehicles (UAV) having in the opposite direction. Due to this, the
four rotors and is used for different resultant torque that acts on the structure is
applications such as photography, video zero. This is depicted in the Figure 1.
recording and carrying out surveillance
operations. Its flight is operated by using
on-board computer system. It can also be
remote controlled by a pilot on the ground.
Quadcopters are classified as rotorcraft,
because their lift is produced by four
revolving narrow-chord aerofoils.
Quadcopters uses two sets of alike fixed
inclined propellers, two clockwise (CW)
and two counter-clockwise (CCW). These
use variation of speed to control lift and
torque. The copter is controlled by altering
the speed of one or more rotors, in so
doing it changes its torque and thrust/lift Fig.1:-Motion of propellers.
characteristics by using a microcontroller.
Historically, the first quadcopter was made
Since quadcopters are able to hover and in 1907, which barely achieved an altitude
are capable of Vertical Take-Off and of just few feet. In the year 1920, a French
Landing (VTOL), they have emerged to be engineer was the first to accomplish a
favourites amongst UAV designs. The successful flight up to a distance of 360m.
propellers are attached to brushless DC Even after being invented in the early
motors which are mounted on the ends of 1900s, quadcopters have come back into
the frame. The pair of motors that are the limelight just a few decades ago.

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 Recent Trends in Automation and Automobile Engineering
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Due to the advancement in technology, low. So, application of solar power to

there have been many changes in create a hybrid system for increasing the
quadcopters. Today people are working on overall flight time has also been explored
quadrotor designs which are large enough in this project.
for carrying high payloads, and some so
small that it can fit in the palm of a person. LITERATURE SURVEY
These copters are quite cost effective as In the past few years, research has been
even a middle – class person can afford it. conducted on designing and developing
novel technologies for operating a
People are beginning to understand the quadcopter. Many research papers have
importance of this machine and that is why been published depicting the success
they are now working relentlessly in order researchers have achieved with
to make improvements to current designs quadcopters.
and come up with various new
applications of this product. Few examples Manarvi et al. [1] have designed and
for this include, military application and fabricated a quadrotor using various
surveillance wherein the military forces of CAD/CAM tools. Its mass was
various countries have been successful to approximately 0.346kg and could achieve
arm their copters and keep a check on any maximum height of 10m. It was used for
suspicious activity. And, it is quite well capturing and transmission of images to
known that police is using quadcopter to the ground. However, since it was using
enforce lockdown effectively in various co-axial rotor assembly flight system it
regions of the country. In addition, major could not achieve rolling motion.
E-commerce websites such as Amazon has Therefore, an improved control unit could
been investing in research to create a drone help in attaining greater manoeuvrability
delivery system. and better performance.

Quadcopters today are mostly powered Haque et al. [2] have attempted to create a
using LiPo batteries, which have their own low weight, self-governing, quadcopter for
risks and limitations. So, research is being transporting goods that are ordered online
conducted to find a better power source for by using a smart phone. Their UAV
these copters. One of the most promising structure weighs 0.800kg and has an
options is using solar energy. The risks estimated payload capacity of about 0.300
associated with using a LiPo battery can be kg. The quadcopter aims to transport the
eliminated by powering the copter using product ordered by the customer by
solar energy. The engineering students of following Google Maps. Performance
National University of Singapore were analysis conducted by them concluded that
successful in making solar powered the flight time of the quadcopter reduces as
quadcopter. However, it was a huge they add weight to it.
copter, with an array of 148 solar cells and
a total surface area of 4m2. Park et al.[3] designed an altitude control
system for a quadcopter that must maintain
The objective of this project is to produce a specified flight path with minimal
a novel design and perform structural deviations. They bought a quadcopter and
analysis on a quadcopter after noted its specifications to conduct various
understanding its principle and flight simulations in order to achieve their
dynamics. In addition, after reviewing objective. The result analysis of the
previous literature on this topic, we note simulations concluded that the
that the flight time of a quadcopter is quite specifications of the quadcopter presented

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2

a favourable quadcopter model that was cells which have an efficiency of

stable, had minimal error in its altitude, approximately 22%. Their demonstrator
and followed the designated flight path. weighed about 8.175kg because they
aimed to achieve very high flight time for
Javir et al [4] focused upon the which they need to use many solar cells,
aerodynamic effects in a quadcopter and which add to copter’s weight. This solar
their work deals with all of its attributes, powered quadcopter had a flight time of
which range from mechanical design-to- approximately one hour.
electronic components used for developing
a suitable UAV design. They have used Rahman et al. [9] designed a small frame
aluminium as frame and developed a new to place the solar panel centrally on the top
design for which they conduct static of the quadcopter. Their main aim was to
structural, modal and harmonic analysis design a device, which could be used to
using ANSYS® software. It is reported boost low input voltage to higher output
that minor deformation occurs in the voltage, and another device that other
structural analysis of the quadcopter’s controls the flow of voltage into the
frame. battery to avoid over-charging of the
battery, which could affect its overall
Jadhav et al.[5] made an automated control function and reduce its life.
system for UAVs using raspberry pi as the
microcontroller and python programming Goh et al.[10] were able to successfully
system allowing the vehicle to fly without create fully solar powered quadcopter
human intervention. The system so using an array of 148 solar cells. It
developed was operated by computer weighed about 2.6kg and achieved an
systems thereby reducing human errors for altitude of 10m. But even after creating a
a safe flight. huge working model the overall flight time
of their quadcopter was only about
Ononiwu et al.[6] designed and simulated 1minute 38second.
a quadcopter which could be used to The above-mentioned literatures grant us
conduct search and rescue tasks. The important information for designing a
approximate weight of the copter was 15N quadcopter. They discuss about the flight
and flight simulations show that it was dynamics, principle of operation,
able to take photographs and transmit electronic components required and
video to the ground. However, the authors necessary calculations for creating a
used aluminium as the frame. Future quadcopter. Previous research also shows
prospects for this project would be to use a that the payload capacity and the flight
composite type frame in order to reduce its time of a quadcopter is quite low and these
weight and increase its flight time. are the areas that require our attention and
should be worked upon.
Parihar et al. [7] discussed about the
components required in building a This research aims to form a new design
quadcopter. They also provide various for a quadcopter using composite materials
calculations in order to determine the size and perform structural analysis on its
of frame, diameter of the propellers and an frame in order to find the amount of
appropriate thrust to weight ratio in order deformation that occurs when various
to achieve successful flight. forces act on it. Also, authors intend to
investigate, utilizing solar power in order
Kingry et al.[8] created a solar powered to create a hybrid system to provide more
quadcopter using an array of C60 solar power to quadcopter’s battery using solar

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2

cells for enhancing the flight time of the horizontal axis. On increasing speed of
copter. front rotors, the copter’s nose will tilt up
resulting in a climb towards upward
METHODOLOGY direction.
Quadcopter is a type of unmanned aerial Roll motion – it is the rotation of the
vehicles, which comprises of various copter around the front-to-back axis. For
mechanical and electronic components. It tilting it about the axis. Thus controls the
consists of a frame, which has four arms left-right motion of the copter.
attached to the central housing of the
electronic elements. Four brushless motors
are fixed to the free end of the arms onto
which propellers of equal pitch are
mounted in order to generate equal thrust
force, which is required to lift the
quadcopter.

All the rotors are placed in the same plane.

Torque is produced due to the rotation of
all the four rotors about the centre of mass
of the copter. Every individual torque is
counter balanced by the torque created
from the opposing rotors. This
arrangement demands that opposite rotors Fig. 2: Different types of motion of
should rotate in the same direction while quadcopter.
adjacent rotors must rotate in opposite
directions. One of the major advantages of All of the above-mentioned motions of the
this quadrotor design is that additional quadcopter are controlled by varying the
sensor equipment such as gyroscope and speed of every motor at a given point of
accelerometer are not required to be time. For vertical take-off and landing, the
mounted separately on it. speed of all four motors must be the
increased and decreased respectively at the
The motion of a quadcopter depends upon same time. Forward and backward
the speed of each propeller. On varying the movement is controlled by increasing the
speed of different motors, the movement speed of rear motors and decreasing the
of the quadcopter can be controlled. There speed of motors present in front and vice
are four basic movements of a quadcopter. versa for backward motion. Finally, for
moving the quadcopter along left-right
Hovering - one pair of motors rotates in direction, yaw angle must be changed.
clockwise direction and the other pair This can be accomplished by increasing
rotates in anti-clockwise direction with the speed of rotors rotating in clockwise
identical speed to make the quadcopter direction and decreasing the speed of
hover. By rotating in such motion, the total rotors rotating in anti-clockwise direction.
sum of reaction torque acting on the copter
is zero. While designing the frame of the
Yaw motion – is the rotation about the quadcopter, one must remember that
vertical axis of the quadcopter. various electronic components have to be
Pitch motion - rotation about the side-to- mounted on it. The arms of the quadcopter
side axis is called pitch. It is done to move should have holes so that they can be
the quadcopter up and down about the connected to the centre plate and to mount

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2

motors upon it. Finally, the design as well decided. Therefore, for a safe design, the
as the choice of materials for the frame length of the arm of the copter must be
should be such that it is strong but light twice the radius of the propeller, this is
enough to lift off and maintain flight. because while rotating the propellers, there
must be a safe distance between the central
DESIGN OF FRAME housing of electronic components and the
After studying the previous literature, one area covered by the propeller’s rotation.
thing was sure, that designing a quadcopter So, if we use a
presents various challenges. Moreover, propeller, (where 0.254m = diameter of
one must keep many points in their mind propeller and 0.1143m = pitch of
while designing it. For instance, the thrust- propeller) then radius, R = 0.127m,
to-weight ratio, i.e. the amount of thrust therefore length of arm,
produced by the rotors to the total weight
of quadcopter must be greater than one so
that the copter can accelerate in the While designing the arms and base plates
upward direction. for the copter, the main aim was to achieve
˃1 (1) weight reduction without compromising
the structural strength of the frame. And,
For this, it is aimed to keep the total
this was done by creating slots along the
weight of the quadcopter below 16.67N
surfaces of both arms and plates.
(i.e. 1.7kg by mass). Therefore, adequate
materials should be used for building the
Finally, the design of the central plates is
copter’s body and appropriate electronic
based on the dimensions of the battery and
equipment must be chosen for providing it
other various components that are kept in
power to generate high thrust-to-weight
between the two plates. The 3D geometric
ratio.
model was made using Solid Works.
The aim was to create a design which
would be light in weight, have good
structural integrity and provide a stable
flight. The detailed design for the frame is
discussed in the following section. The 3D
model of the frame was made using Solid
Works, after which its structural analysis
was conducted.
This quadcopter consists of two central
base plates, which act as a housing for
various electronic components such as
battery, power distribution board and the Fig. 3: Assembly of frame using Solid
flight controller, and four arms, which are Works.
attached to these central plates at one end
and have one brushless DC motor at their SELECTION OF MATERIAL
ends each. A Quadcopter’s frame must be designed
such that it is low in weight but has high
After studying the previous literature, it structural strength in order to carry the
was found many different calculations that load of electronic components that would
are required for a safe design of a be mounted on it. To achieve this, slots
quadcopter. Based on that information were made in the arms as well as central
appropriate size of the copter can be

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2

base plates of the copter to reduce its applied to the frame as shown in figure is
weight. shown in Figure 4. The ends of the
quadcopter’s arm that are connected to the
Final step before proceeding for structural base plate have been assigned to be fixed
analysis was to select appropriate supports. A force of 1N is applied to each
lightweight material with high tensile of the free ends of the arms, which is equal
strength. Aluminium, was chosen for the to the force exerted by the motors on the
central base plates to provide safety to the arm. After applying these boundary
components between them. In addition, 3D conditions, the mesh was generated. The
printed plastic material, Acrylonitrile mesh was created using 2D planar plate
Butadiene Styrene (ABS) was chosen for elements and it has 16614 elements and
the arms. Properties of both the materials 43812 nodes.
are given in the table below.

There are many different kinds of 3D

printing material available, such as, Nylon,
Carbon fibre, Polylactic acid (PLA) etc.
ABS has been chosen over all these
materials as it has almost similar
properties compared to these materials and
is economically viable. Although, nylon
and carbon fibre have higher density and Fig.4:-Application of boundary conditions.
strength, they are very expensive which is
not feasible. Moreover, PLA has almost Following conclusions can be drawn from
identical properties as that of ABS, but the results of structural analysis –
ABS is the best material which can be  Maximum deformation of 1.546mm
used where high strength and thermal was observed on the arms of the
stability is needed. quadcopter from Figure. 5(a), which
may not have significant impact on its
Table 1:-Material properties. performance.
Property
ABS
Aluminium  Maximum Von Mises stress value was
Plastic
2
Elastic Modulus (N/mm ) 2410 69000 observed to be 1.15MPa from Figure.
Poisson’s Ratio 0.3897 0.33 5(b) by which it can be concluded that
Shear Modulus (N/mm2) 862.2 27000 the base plate will be able to provide
Mass Density (kg/m3) 1070 2700
Tensile Strength (N/mm2) 40 68.94
required strength in order to support
Thermal Conductivity the frame.
0.2618 200
(W/m-k)  The amount of deformation gradually
increases towards the applied force of
STRUCTURAL ANALYSIS OF the motors acting on the free ends of
FRAME the arms, while maximum amount of
After selecting material for the copter, it stress acts near the area where the
was necessary to conduct a Finite Element arms meet the base plates.
Analysis of the assembled frame to
analyse the impact of the various loads After analysing various parameters on the
acting on it. Hence, static structural arm and the base plate it is safe to say that
analysis was conducted on it using our design is safe and the frame will be
ANSYS 18®. The final CAD model of the able to provide structural stability to the
frame with boundary conditions are quadcopter.

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 Recent Trends in Automation and Automobile Engineering
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(a) Total deformation (b) Von mises stress distribution

Fig.5:-Results of structural analysis.

COMPONENTS OF QUADCOPTER Motors and Propellers - Brushless DC

Battery - Lithium polymer (LiPo) battery, motors and propellers are required to
is selected which is often used for such rotate and generate thrust to fly the
remote controlled projects to power the quadcopter. A 1400kv (where kv =
whole system. It is used mainly because of constant velocity) motor is appropriate for
its high energy density and durability. The the project. It implies that the motor
battery which is optimum for our rotates 1400RPM per volt. In simple
quadcopter is the 11.1V, 2200mAh and 3S words, for a supply of 1V, speed of the
(S, implies that the battery has 3 cells motor will be 1400RPM.
stacked together).
Parihar P. et al [7] recommended that
Power Distribution board – is required to small-sized propellers should rotate at high
equally distribute the power drawn from speed and large propellers with medium or
the battery to other components of the low speed motor. Hence,
quadcopter. The battery is connected to nylon propeller is selected.
this board to which other components such Where, Dia. of propeller = 0.254m and
as the electronic speed controllers are Pitch = 0.114m
attached.
Microcontroller - or the flight controller
Electronic Speed Controller - ESCs are board, as described before acts as the
joined to the power distribution board to “brain” of the copter. It consists of the
control speed of the DC motors connected important sensors such as gyroscope and
to them. The appropriate ESC can be accelerometer sensor. It can be
found using the formula below.[4] programmed easily to control the
( ) quadcopter.
(2)
So, which implies, the Transmitter and receiver – is required
minimum ESC rating should be greater for controlling the quadcopter. The
than 27A. Here, a 30A speed controller transmitter transmits signals to the copter
could be used to control the speed of the to which the flight controller makes the
motors. adjustments and acts accordingly.

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 Recent Trends in Automation and Automobile Engineering
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Fig.6:-Arrangement of various components.

SOLAR-HYBRID SYSTEM will stop current from flowing in this

For boosting the overall flight time of reverse direction and help protect our solar
quadrotor, instead of powering it only by cells. The final weight of the quad copter
using solar energy, one must consider was observed to be 1.4kg (without solar
creating a hybrid system of LiPo battery panels) and approximately 1.5kg with
and solar energy. This is because if copter solar panels.
is made to run only using solar energy,
very large solar panels will be required to RESULTS AND DISCUSSION
fly it, which will lead to increase in its After testing the quadcopter, we arrived at
weight. So by going for a hybrid system, following results –
large solar panels will not be needed. 1. The total weight of the quadcopter
Rather, just a few small solar cells will was 1.4kg, with solar panel, and 1.5kg
help in achieving our objective. with solar panels, which is below our
anticipated weight of 1.7kg.
Since, the battery is of 11.1V, three small 2. The design is stable with a maximum
solar cells can be used, which can provide deformation of 1.546mm and
6V each and upto 100 mA of current at a maximum stress of approximately
given time. This is done so that the input 1.15MPa, which will not have any
voltage to the battery is more than significant impact on the structural
battery’s own voltage to prevent flow of strength of the quadcopter.
current from battery to solar panels. 3. An estimated flight time of 4.5mins
can be achieved by using the
Sometimes, due to low radiation or on a electronic components mentioned
cloudy day, their might be an issue of low above without the solar cells and their
power being generated by the cells. This certainly will be an increase in the
could lead to reverse flow of current from flight time if one succeeds in creating
the battery to the cells which will fry them. the solar – hybrid system.
Therefore, to avoid such problem, a solar
assist or a zener diode should be used. This

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2

From this, it can be concluded that, the U. (2013, March). Design and
amount of stress and deformation development of a quad copter
occurring on the frame is within the (UMAASK) using CAD/CAM/CAE.
permissible limits. Therefore, our design is In 2013 IEEE Aerospace
safe. The slots made while designing the Conference (pp. 1-10). IEEE.
quadcopter helps in reducing its overall 2. Haque, M. R., Muhammad, M.,
weight. The use of composite ABS Swarnaker, D., & Arifuzzaman, M.
material also proves to be a good step for (2014, April). Autonomous
reducing the copter’s weight. The use of a quadcopter for product home delivery.
solar hybrid system will help us to increase In 2014 International Conference on
the flight time of the system. Moreover, Electrical Engineering and
using solar energy will help in making the Information & Communication
quadcopter environment friendly. Technology (pp. 1-5). IEEE.
3. Park, J. J., Orozco, R., Rodriguez, A.,
More research can be conducted in order & Gugiu, I. Quadcopter Analysis.
to find which type of solar cell will be the 4. Javir, A. V., Pawar, K., Dhudum, S.,
best for increasing the overall flight time. Patale, N., & Patil, S. (2015). Design,
We also recommend that copter must be analysis and fabrication of
designed in such a way that its centre of quadcopter. Journal of Advance
mass is at the centre of the system. The Research in Mechanical & Civil
frame should be more aerodynamic. While Engineering (ISSN: 2208-2379), 2(3),
designing the arm, make sure that there is 16-27.
enough tolerance for holes of the motor. 5. Jadhav, A., Khapre, A., Khadase, J., &
Nipanikar, R. S. Quadcopter for
CONCLUSION Traffic Surveillance.
The main objective of this project was to 6. Ononiwu, G., Okoye, A., Onojo, J., &
familiarize ourselves with the whole Onuekwusi, N. (2016). Design and
design process, from basic design to final Implementation of a Real Time
assembly of the components. Our research Wireless Quadcopter for Rescue
was focused on preparing a novel design Operations. American Journal of
for a quadcopter using lightweight Engineering Research, 5(9).
composite material and evaluate how solar 7. Parihar, P., Bhawsar, P., & Hargod, P.
power can be used to increase its overall (2016). Design & development
flight time. After exhaustive design and analysis of
analysis process, the results were achieved. quadcopter. Compusoft, 5(6), 2128.
It was a new design made out of 8. Kingry, N., Towers, L., Liu, Y. C.,
lightweight ABS plastic and aluminium. Zu, Y., Wang, Y., Staheli, B., & Dai,
We see that the estimated flight time of R. (2018, May). Design, modeling and
this newly designed copter would be control of a solar-powered quadcopter.
4.5minutes, which would surely increase In 2018 IEEE International
on using a hybrid solar powered system. Conference on Robotics and
Quadcopters will be seen taking important Automation (ICRA) (pp. 1251-1258).
roles in various fields. They will be used IEEE.
for delivering products once we figure out 9. Rahman, K. S., Rokonuzzaman, M.,
how to increase their payload capacity. Xue, G. B., Thakur, R. I., Kabir, K.
M., Matin, M. A., ... & Amin, N. A
REFERENCES Light Weight Solar Powered Mini
1. Manarvi, I. A., Aqib, M., Ajmal, M., Quadcopter for Environmental
Usman, M., Khurshid, S., & Sikandar, Monitoring.

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 Recent Trends in Automation and Automobile Engineering
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10. Goh, C. S., Kuan, J. R., Yeo, J. H., Photovoltaics: Research and
Teo, B. S., & Danner, A. (2019). A Applications, 27(10), 869-878.
fully solar‐powered quadcopter able to
achieve controlled flight out of the
ground effect. Progress in

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