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Paper Plane: Towards Disposable Low-Cost Folded Cellulose-Substrate Uavs

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Paper Plane: Towards Disposable Low-Cost Folded Cellulose-Substrate Uavs Proceedings of Australasian Conference on Robotics and Automation, 3-5 Dec 2012, Victoria University of Wellington, New Zealand. Paper Plane: Towards Disposable Low-Cost Folded Cellulose-Substrate UAVs Paul E. I. Pounds University of Queensland, Australia [email protected] Abstract Disposable folded cellulose-substrate micro- Unmanned Aerial Vehicles (UAVs) | paper planes | have the surprising potential to be ef- fective platforms for deploying remote sensors at low-cost. With inexpensive inertial sensors and circuits printed on inexpensive structural material, the cost of a mini-scale aircraft can be reduced to the point that discarding the aircraft post-mission is economical. When launched from high-altitude balloons, paper UAVs ca- pable of navigating jet-stream winds could be guided to land anywhere on Earth with no addi- tional power input. This paper discusses paper Figure 1: Disposable Paper UAV. as a multi-functional electronic-aeromechanical equipment required for stability, navigation and auton- material for use in disposable micro UAVs. A omy. Where an inertial measurement unit suitable for proof of concept paper aircraft with inertial aircraft guidance once cost thousands of dollars, today a sensors and elevons, is presented and it is show similar unit may be had for tens of dollars. In manufac- that glide performance of the aircraft is not turing large quantities of micro-UAVs (MAVs), materials compromised by added mass. processing, fabrication and labour costs may dominate. Consequently, methods identified for reducing the cost of UAV technology are to increase system integration, use 1 Introduction lower-cost components, and reduce manufacturing steps. While substantial progress has been made in reducing Recent advances in micro- and meso-scale aircraft the cost of Unmanned Aerial Vehicles (UAVs), commer- highlight the potential of highly integrated aero- cially available UAV products remain expensive, even mechanical structures. Harvard's robot fly employs at the very low end targeting the consumer toy market. micro-machined folded substrates that assemble from However, there are many applications where a vehicle | laminar sheets [Perez et al, 2011]. Similarly, Berkeley's having completed its mission | may not be recoverable: folded meso-scale running robots are fabricated from where the flight distance exhausts the power supply of composite laminated card stock [Hoover et al, 2010] and the aircraft and it cannot be replenished (e.g. surveying fitted with a drive motor. Both approaches utilise com- the Antarctic, or Amazon rainforest) or where the mis- plex ambulatory motions generated from the structure of sion necessarily involves destruction of the vehicle (e.g. the folded flexure linkages integrated into their assembly. cruise missiles, or delivering sensors into forest fires). The high performance demands of aircraft often drive Contemporary designs are cost-prohibitive for one-way the use of exotic and expensive materials such as carbon- flights, outside of specific military uses. fibre composite and titanium. Unlike larger systems, The concept of a `disposable UAV' is not outlandish. MAVs are able to leverage affordable stock such as balsa The advent of cheap Micro Electro-Mechanical System wood, injection moulded plastics and aluminium. How- (MEMS) devices means that the primary cost driver for ever, while readily available and economical, these ma- micro air vehicles need no longer be the flight control terials require substantial processing to fabricate aero- Proceedings of Australasian Conference on Robotics and Automation, 3-5 Dec 2012, Victoria University of Wellington, New Zealand. dynamic structures. Labour is often the dominant cost to a `stock' paper aircraft, is reported and future direc- driver for product design; even low-cost materials can tions of the technology are discussed. A brief conclusion prove too expensive for disposable devices. Furthermore, completes the paper. any material used in a fuselage that will be discarded where it lands must be inherently biodegradable so as 2 The Case for Paper as an not to pose a risk to the biosphere. Electro-Aeromechanical Material One common material captures all the properties ideal 2.1 Mechanical Properties for use in disposable MAVs: paper. Paper | which con- Paper consists of a matrix of interlinked cellulose fibres sists of biodegradable cellulose fibre sheet | is sturdy, | a knit structure of tangled natural pulp. These fi- extremely low-cost and available everywhere. It has bres give paper good tensile performance and formabil- low processing labour input, and it boasts exceptional ity with low bulk weight. When paper is bent, fibres in strength to weight ratio with desirable aeroelastic prop- the matrix are disturbed and the paper maintains the erties. While origami aircraft fabricated from paper crease. By repeatedly working a crease, a low-stiffness have a long history of use and are regarded as toys, hinge can be formed. Thus, simple bending and forging cellulose has a bright future as a serious engineering operations are sufficient to make permanent deforma- material. Recent developments in inkjet printing of tions to the shape of a paper structure, greatly reducing UV-cured and microwave-sintered dielectrics on paper processing cost. substrates promise highly integrated, single-fabrication The tensile strength of paper can be as high as aeromechanical-avionic structures [Polzinger et al, 2011; 30 MPa, and comparable to low-end carbon fibre and Mei et al, 2005; Allen et al, 2011]. Siegel et al found some aluminium alloys [CUMG, 2012]. While variable, that paper-laminated circuits could be creased repeat- the stiffness of paper is very similar to that of oak and edly, and formed into three dimensional shapes with- medium-density-fibreboard, at 2.5 GPa [CUMG, 2012]. out compromising circuit function [Siegel et al, 2009]. The density of paper is given in \grams per square me- By leveraging traditional PCB manufacturing technol- ter" (referred to as `gsm'); paper is available in a wide ogy, the cost of fabricating the airframe is subsumed by variety of gsm stocks. Typical office paper is 90 gsm, the fixed-cost of circuit board manufacturing set-up | with a thickness of 0.11 mm. The specific strength of paid once, and then amortised over thousands of units. paper (tensile strength per unit mass) is 30 kNmkg−1, However, the true potential for paper-substrate MAVs superior to that of some aluminiums. lies in the incredible ability for passive paper aircraft The density-cubic specific modulus of paper | to travel long distances. In 2011, Project Space Planes which dictates bending performance | is approximately released 200 paper aircraft, each carrying an onboard 3.4 m8kg−2s−2, very close to the 3.5 m8kg−2s−2 of alu- memory chip, from a balloon 23 km above Germany [Pa- minium [CUMG, 2012]. The very high bending perfor- per Space Planes, 2011]. Some were eventually recovered mance of carbon fibre reinforced plastic (CFRP) clearly from around Europe and | by traveling the jet-stream makes it a superior material for cantilever fuselage con- | North America, India and even Australia. Other ef- struction, but its very high labour requirements make forts by Shinji Suzuki at Tokyo University aim to launch it unsuitable for disposable aircraft. A summary of the a paper plane from the edge of space, to be recovered principal material properties of paper and comparable on the ground [Funuyo, 2008]. By adding light-weight aircraft structural materials is given in Table 2.11. avionics and GPS sensors to miniature disposable air- In comparison with these other popular UAV materi- craft, the author aims to develop a completely passive als, paper weighs less, has comparable tensile strength UAV to traverse the atmospheric jet-stream `highway and specific strength, and is competitive in bending system', and land small sensor payloads anywhere on strength. Paper clearly outperforms polystyrene, a com- Earth for under $100. mon light-weight UAV and radio-controlled aircraft ma- This paper discusses the merits of cellulose sheet as terial. The major weakness of paper is in its low stiffness. an engineering material for fabricating extremely low- Importantly, in the application of micro-UAVs the struc- cost robot aircraft for deploying sensors in environmental tures to be assembled are small. The bending stress σ monitoring applications, and its application as a multi- of a cantilevered wing is given by: functional electronic-aeromechanical component. Sec- tion 2 describes the mechanical, aerodynamic and elec- L · l σ = z (1) tronic aspects of paper and paper aircraft, and antici- 2J pated practical tradeoffs. Section 3 presents a proof-of- 1. Materials property data drawn from Cambridge University concept platform, and describe its aeromechanical fea- Materials Group Interactive Charts [CUMG, 2012]. Here only tures and avionics. The aerodynamic performance of isotropic random-fibre paper is considered, although anisotropic the system laden with avionics package, in comparison paper, such as newsprint, may have properties useful for airframes. Proceedings of Australasian Conference on Robotics and Automation, 3-5 Dec 2012, Victoria University of Wellington, New Zealand. Table 1: Mechanical Properties of Selected Aircraft Structural Material Families Material Density/kgm−3 Tensile Strength Stiffness/GPa Specific Strength Density3 Specific /MPa /kNmkg−1 Modulus/m8kg−2s−2 Isotr. Paper 900 20{30 2{4 15{30 3.4 Polystyrene 1000 30 2 25 2.8 CFRP 1300 30{60 60{200 200{350 44.5 Aluminium 2700 80 70{80 7{110 3.5 Titanium 5000 400 100 20{250 1.2 where z is the vertical deflection distance at the wing leading edge of the wing with a fold line, gain the ad- tip, L · l=2 is the lift force L times half the wing length l vantage of a robust, sharp leading edge. (applied bending moment), and J is the second moment This is important, as a substantial fraction of lift is of area. In the case of a rectangular wing cross-section derived from vortex lift generated by the highly-angled approximation: delta shape of most paper aeroplanes [Bing Feng et al, c · h3 2009].
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