Upcycling UAS into modular platforms for Earth science and autonomy research

Abstract:

This reports the results of a multidisciplinary project conducted at the NASA Ames Research Center (ARC) involving a number of student interns over the summers of 2014 and 2015. The project had a goal of applying rapid prototyping techniques, including 3D printing, to unmanned aircraft systems (UAS), and demonstrated that surplus UAS could be repurposed into new configurations suitable for conducting science missions. ARC received several units of the RQ-11 Raven and RQ-14 DragonEye manufactured by AeroVironment Corporation, along with ground stations and spare parts. These UAS have electric propulsion, a wingspan and length ~1m; they are designed to disassemble for transport, have a simple wing design with snap-together interfaces, made from lightweight materials. After removing all ITAR restricted technology these were made available to summer interns that also had access to 3D printing, CNC laser-cutting equipment through NASA’s SpaceShop. The modular nature and simple wing profiles enabled the teams to deconstruct and subsequently reconfigure them into completely new airframes. Two multi-fuselage designs were assembled using Ardupilot-based common avionics architecture (CAA), with extended wingspans, an H-tail and an innovative cambered flap system. After NASA internal design reviews, the students fabricated new control surfaces and subcomponents necessary to splice the RQ-14 subcomponents back together. Laboratory testing was performed on test articles to determine bending modulus and safety factors, and documentation was prepared for airworthiness flight safety review. Upon receiving approval of documentation and flight readiness certification, the repurposed UAS were flown at Crows Landing airfield in Stanislaus County, California, initially under RC pilot control and subsequently under fully autonomous control. The RQ-11 is now being used to expand on the modularity design and the Team has been at work in designing different configurations and a payload pod that will allow flexible modular implementation. This project demonstrated that rapid prototyping combined with modular subcomponents can enable an increase in the rate of design iterations on aircraft optimized for science missions. Field data will be reported for missions at the Salton Sea and Crows Landing, California.