Aerial Ice Dam Control & Removal Major Qualifying Project Report Project: JMS-1604 Submitted to the Faculty of the WORCESTER POLYTECHNIC INSTITUTE in partial fulfillment of the requirements for the Degree of Bachelor of Science in Mechanical Engineering By: Stephen Arata Riley Shoneck Mitchell Weeks Advisor: Professor John M. Sullivan Jr. 25 March 2015 i Abstract Ice dams can cause serious damage to homes during the wintertime. A multirotor mounted solution was sought to drop salt on these ice dams, allowing backed-up water to flow through and prevent water damage. Two mechanisms were developed and prototyped. The prototypes had rapid interchangeability and a unified static multirotor mount. They were created with rapid prototyping technology for quick assembly and repair, with the majority of parts composed of lightweight laser-cut acrylic and 3D-printed PLA. One mechanism carries and deploys 0.7 kg of standard calcium chloride throw-able ice pucks, while the other carries drops 1.239 kg of granular pet-safe ice melt. They are both controlled manually by the same transmitter/receiver system (tested to a line-of-sight range of over 450m), which is independent of the multirotor flight control system. Both mechanisms perform as intended, and jams are clearable using the transmitter. ii Acknowledgements Firstly, we would like to thank our advisor, Professor Sullivan. He kept us on-task and always cognizant of the practical considerations we may have otherwise overlooked. Secondly, Joseph St Germain in the Robotics Engineering department proved instrumental in helping with the multirotor aspect of the project. The feasibility of many multirotors and the workings of our electronics (specifically, the transmitter and receiver) went through him first. He also assisted in the procurement of motors and miscellaneous other hardware that we incorporated into the final designs. Finally, Gregory Tighe, an undergraduate in the Robotics Engineering department, kindly allowed us to survey the S1000+ multirotor that his MQP used as a vehicle. We were able to obtain measurements and a working components list with his assistance. iii Authorship All sections were written and edited jointly by all members. iv Contents Abstract....................................................................................................................................... ii Acknowledgements .................................................................................................................... iii Authorship .................................................................................................................................. iv Contents ..................................................................................................................................... v Table of Figures ....................................................................................................................... viii Table of Tables .......................................................................................................................... ix Executive Summary .................................................................................................................... x Terminology ............................................................................................................................... xi 1.0 Introduction .......................................................................................................................... 1 2.0 Identification of Need ........................................................................................................... 4 3.0 Background Research .......................................................................................................... 5 3.1 Ice Dams and Their Effects............................................................................................... 5 3.2 Ice Dam Prevention, Control, and Removal ...................................................................... 6 3.2.1 Ice Dam Prevention .................................................................................................... 6 3.2.2 Ice Dam Mitigation ....................................................................................................10 3.2.3 Ice Dam Removal ......................................................................................................13 3.3 Multirotors ........................................................................................................................15 3.3.1 DJI Phantom 3 ..........................................................................................................16 3.3.2 3D Robotics X8+ .......................................................................................................17 3.3.3 DJI S900 ...................................................................................................................18 3.3.4 DJI S1000+ ...............................................................................................................19 3.3.5 Feasibility of Select Multirotor Modifications ..............................................................20 3.3.6 Legality of Multirotor Use ...........................................................................................21 4.0 Goal Statement ...................................................................................................................23 5.0 Task Specifications .............................................................................................................23 6.0 Development of Preliminary Designs...................................................................................24 6.1 Preliminary Designs .........................................................................................................24 6.1.1 Design 1 - Vertical Tube with Shelves .......................................................................24 6.2.2 Design 2 - Swivel Arm ...............................................................................................26 6.2.3 Design 3 - Crank-Slider .............................................................................................27 6.2.4 Design 4 - Rack and Pinion .......................................................................................28 v 6.2.5 Design 5 - Turntable ..................................................................................................29 6.2.6 Design 6 - Turbo Puck Release .................................................................................30 6.2.7 Design 7 - CD Changer .............................................................................................31 6.2.8 Design 8 - Granular Funnel .......................................................................................33 6.2 Weighted Design Matrix ...................................................................................................34 7.0 Selection of Final Designs ...................................................................................................37 7.1 Constraints ......................................................................................................................37 7.2 Selection of Materials and Fasteners ...............................................................................41 7.2.1 Material Selection ......................................................................................................41 7.2.2 Rapid Prototyping ......................................................................................................42 7.2.3 Fastener Selection ....................................................................................................42 7.3 Inclusion of Motors and Electronic Components ..............................................................42 7.4 Mounting Mechanisms to the Multirotor ...........................................................................43 7.4.1 Design of the Multirotor Mounting Units .....................................................................43 7.4.2 Design of the Generic Rectangular Mounting Plate ...................................................44 7.4.3 Finite Element Analysis of the Mounting Units ...........................................................45 7.5 Development of the Puck Mechanism Final Design .........................................................48 7.5.1 General Description of Purpose ................................................................................48 7.5.2 Determining a Mass Limit for the Mechanism ............................................................48 7.5.3 Design Development/Construction ............................................................................49 7.5.4 How the Puck Mechanism Works ..............................................................................55 7.5.5 Customization of the Mounting Plate .........................................................................58 7.5.6 Description of the Motor ............................................................................................59 7.5.7 Ensuring an Optimal Center of Mass .........................................................................59 7.5.8 Overall Mass and Height Check of the Final Design ..................................................63 7.6 Final Design of the Granular Mechanism .........................................................................65 7.6.1 General Description of Purpose ................................................................................65