Sure!

Here’s a simplified breakdown of the design approach for the AeroTHON UAV project,
along with interview questions and easy-to-follow answers.

---

### Project: Unmanned Aircraft Vehicle (UAV) for SAE AeroTHON 2024

The goal of this project was to design and build a UAV (drone) that could perform tasks like
**surveillance, object detection, counting, and delivering a payload**. Here’s how we
approached the design to meet the requirements and tackle these tasks.

---

### **Design Approach**

1. **Purpose and Mission Goals**:

- We started by understanding the competition theme, which focuses on **surveillance and
disaster management**. Our UAV needed to handle tasks like identifying objects, navigating
obstacles, and delivering payloads safely.
- We planned the design in two main parts: **manual operation** (for tasks done with human
control) and **autonomous operation** (where the UAV works without human input).

2. **Key Design Components**:

- **Multirotor Type**:
- We chose a multirotor design (multiple propellers) for better stability and precise control.
This type is excellent for short-range tasks and can hover in place, which is helpful for
surveillance.

- **Weight and Thrust Calculations**:

- We calculated the weight of the UAV, ensuring it was under 2 kg to meet the rules. Based
on the weight, we figured out the **thrust** needed from the motors to lift it with the added
payload.

- **Motor and Battery Selection**:

- To ensure the UAV could stay in the air long enough for each mission, we selected motors
and batteries that provided a good balance of power and efficiency. We used electric motors, as
required, and tested different battery options to find one that supported longer flight times
without being too heavy.

- **Frame and Structure**:

- We designed a lightweight yet strong frame, using materials like **carbon fiber** to reduce
weight while ensuring durability. This helped the UAV survive small impacts during obstacle
navigation.
 - **Sensors and Navigation**:
- We used sensors and a flight controller to manage navigation. For autonomous missions,
these sensors helped the UAV stay on course, detect objects, and avoid obstacles.

3. **Autonomous Features**:
- **Object Detection and Counting**:
- We programmed the UAV to recognize and count objects using a camera and computer
vision algorithms. This allowed it to perform tasks like spotting and counting different shapes or
colors autonomously.
- **Payload Drop**:
- For the payload drop task, we designed a simple mechanism to release the payload
precisely at the target area. In autonomous mode, the UAV uses GPS to navigate to the drop
point and releases the payload at a set altitude.

---

### **Interview Questions and Answers**

#### **Question 1**: *How did you decide on the type of UAV?*

- **Answer**: "We chose a multirotor UAV because it’s stable and can hover in one place,
which is ideal for surveillance and disaster management tasks. This type allows for precise
control and easy adjustments in confined areas, making it suitable for both manual and
autonomous missions."

#### **Question 2**: *How did you ensure the UAV was able to handle its payload?*

- **Answer**: "We calculated the total weight, including the payload, to ensure the motors
could generate enough lift. By testing different motors and batteries, we found a setup that kept
the UAV lightweight but still powerful enough to carry a 200-gram payload safely."

#### **Question 3**: *How did you prepare for obstacle navigation?*

- **Answer**: "We included sensors that help the UAV detect and avoid obstacles. In manual
mode, we practiced guiding the UAV through a set obstacle course. In autonomous mode, the
sensors work with a programmed path to help it avoid obstacles on its own."

#### **Question 4**: *What methods did you use for object detection and classification?*

- **Answer**: "We used a camera and image processing algorithms to identify objects. This
setup allowed the UAV to recognize different shapes and count them. For example, it could
identify and log how many of each shape it saw, which is useful in tasks like damage
assessment."
#### **Question 5**: *What was your approach to the payload drop mechanism?*

- **Answer**: "We designed a release mechanism that lets the UAV drop the payload
accurately when it reaches the target. In autonomous mode, the UAV uses GPS to get to the
drop area and then releases the payload at a low altitude, so it lands as close as possible to the
target."

---

### **Additional Design Notes**

- **Material Choice**:
- Lightweight materials like **carbon fiber** were used for the frame to keep the UAV durable
yet light. This helped maintain stability and prevented extra strain on the motors.

- **Power and Endurance**:

- We ran several tests to choose a battery that balanced flight duration and weight, giving the
UAV enough power to complete each mission without becoming too heavy.

- **Safety Features**:
- Our UAV includes a return-to-home function, so if it loses connection or battery power gets
too low, it can return to a safe location automatically.

This approach shows careful planning for each competition requirement, balancing the need for
stability, endurance, and precision. Let me know if you need more details on any section!

Here's a breakdown of the work you did in designing and fabricating the 3D-printed chassis and
gripper mechanism for the autonomous quadcopter project. I’ll also provide some interview
questions along with answers to help you explain your process effectively.

---

### **Project Explanation**

#### 1. **Design and Fabrication of the 3D-Printed Chassis**

- **Objective**: You designed a quadcopter chassis optimized for **lightweight strength** and
**stability**, using 3D printing to quickly create and test the physical structure.
- **Process**:
- **Solidworks**: You used Solidworks to create 3D models of the chassis, starting with a
conceptual design and refining the dimensions, material thickness, and other structural details.
Solidworks allowed you to easily adjust the design to achieve an optimal balance between
weight and strength.
- **Ansys Workbench for Structural Analysis**: Once you had the chassis model, you used
Ansys Workbench to conduct a **Static Structure Analysis**. This helped you determine how
well the chassis would hold up under different types of stress, such as take-off, landing, and
minor collisions. You could simulate real-world forces and pinpoint any weak points in the
design, allowing for adjustments before 3D printing.
- **3D Printing**: After finalizing the design, you 3D-printed the chassis. This process let you
rapidly test the physical version of your model, make adjustments as needed, and create a
functional chassis for the quadcopter.

#### 2. **Design and Fabrication of the 3D-Printed Gripper Mechanism**

- **Objective**: The goal of the gripper was to allow the quadcopter to perform tasks that
require interacting with objects (like picking up and placing items).
- **Process**:
- **Design in Solidworks**: You modeled the gripper mechanism in Solidworks, considering
factors like weight, movement range, and the ability to securely hold objects. The design
needed to be lightweight enough for the quadcopter to carry but strong enough to function
reliably.
- **Integration with the Chassis**: You ensured that the gripper mechanism could be
attached securely to the chassis and would not interfere with the quadcopter’s flight stability.
You also considered how the gripper’s weight distribution would affect the overall balance.
- **3D Printing**: You used 3D printing to create the gripper mechanism, allowing for quick
iterations and improvements. By printing it in components, you could adjust specific parts
without redoing the entire mechanism.

---

### **Interview Questions and Suggested Answers**

#### **Question 1**: *Can you explain your design process for the 3D-printed chassis?*
- **Answer**: "I began by designing the chassis in Solidworks, where I focused on creating a
structure that was both lightweight and durable. The main objective was to ensure it could
support the quadcopter’s components and withstand minor impacts. After creating the initial
design, I used Ansys Workbench to simulate the stresses that the chassis might experience
during flight, like landing forces and vibrations. This analysis allowed me to refine the design
before printing it, ensuring that the final product was both efficient and structurally sound."

#### **Question 2**: *Why did you choose 3D printing for this project?*
- **Answer**: "3D printing was ideal for rapid prototyping. It allowed me to test the physical
design quickly and make adjustments without the long wait times of traditional manufacturing.
For a project like a quadcopter, where weight and shape directly impact performance, 3D
printing enabled me to experiment with different designs and materials affordably and
effectively."
#### **Question 3**: *What challenges did you encounter with the chassis design, and how did
you address them?*
- **Answer**: "One challenge was balancing strength and weight. Using Ansys, I found that
certain areas were prone to stress, especially around the motor mounts. To address this, I
adjusted the thickness in these regions without adding unnecessary weight elsewhere. Another
challenge was ensuring the chassis was balanced with the gripper mechanism attached, so I
made design adjustments to maintain the quadcopter’s center of gravity."

#### **Question 4**: *How did you design the gripper mechanism to integrate with the chassis?
*
- **Answer**: "I designed the gripper in Solidworks, focusing on keeping it lightweight while
ensuring it could securely hold objects. I considered the mounting points and ensured the
gripper would attach smoothly to the chassis without impacting the quadcopter’s stability. I
tested multiple attachment methods to find one that was both secure and easy to modify as
needed."

#### **Question 5**: *What role did Ansys Workbench play in this project?*
- **Answer**: "Ansys Workbench was crucial for simulating the forces acting on the chassis
and gripper. By performing static structure analysis, I was able to see how well the design would
handle various stresses, like the impact of landing. This allowed me to adjust weak areas and
confirm the design’s durability before moving to 3D printing, saving time and materials."

#### **Question 6**: *What did you learn from the 3D printing process during this project?*
- **Answer**: "I learned the importance of iteration in design. 3D printing gave me the flexibility
to test different design versions and make improvements quickly. It taught me how small
adjustments in thickness, material, or geometry can significantly affect the strength and stability
of the final product, especially in a lightweight structure like a quadcopter."

---

### **Key Skills Highlighted**

- **Solidworks**: Used for designing the 3D model, fine-tuning structural features, and ensuring
that the chassis and gripper integrated well.
- **Ansys Workbench**: Conducted static structure analysis to simulate real-world conditions
and adjust the design for maximum durability.
- **3D Printing**: Enabled rapid prototyping, allowing you to test, modify, and finalize both the
chassis and gripper efficiently.

Based on the design details provided for your quadcopter gripper, it sounds like it is relatively
straightforward, likely focusing on **opening and closing** to pick up and release objects. Here’s
what the DOF breakdown might look like:
### **Degrees of Freedom (DOF) for Your Gripper**

1. **Opening and Closing** (1 DOF):

- This primary function allows the gripper jaws or fingers to move toward each other to grasp
an object and move apart to release it. This movement alone gives the gripper **1 DOF**.

2. **Additional Rotational or Pivot Motion** (Optional):

- If your gripper design includes a **pivot or rotation** feature (such as being able to rotate or
tilt), this would add another DOF. However, from the description provided, if the gripper is fixed
in place on the quadcopter without additional rotation or pivoting, it would remain with just **1
DOF**.

### **Final DOF Estimate for Your Gripper**

- If it only has an **opening and closing mechanism**, then it has **1 DOF**.
- If it also includes a **rotational or pivot feature**, then it would have **2 DOF**.

For most basic quadcopter applications where weight and simplicity are priorities, **1 DOF (just
opening and closing)** is common, as it effectively fulfills the purpose of picking up and
releasing objects without requiring complex movements.