Exterior Case: Chosen for its ideal size to efficiently transport the multirotor UAS, 4 propellers, and Jeti Duplex DS-12 controller, the exterior Pelican case provides a tough external shell resistant to impacts and crushing forces (Table 3.1, Figure 3.1).
Base Insert: The base insert cradles the required components in custom-designed slots to hold them still during transport.
Lid Insert: The lid insert provides additional padded support from above to reduce jostling of the required components inside the case.
The final Ground Control Station design consists of a Pelican 1700 Protector Long Case and an arrangement of integrated internally-housed electronics to facilitate seamless command workflows, superior pilot productivity, and enhanced information processing capability during drone missions with autonomous waypoint guidance and tracking (Figure 2.2). The Pelican case serves as a rigid waterproof enclosure around and structural foundation for the mounting hardware securing the electronic components.
Lenovo ThinkStation P3 Mini Computer: Powerful enough to run ArduPilot Mission Planner program smoothly and reliably.
1 TB storage
32 GB RAM
NVIDIA GPU chip
Logitech K845 Mechanical Keyboard: Provides comfortable, tactile feedback with a robust aluminum frame and dedicated numeric keypad.
Elecom Ergonomic Trackball Mouse: Enables seamless user interface and quick navigation across three screens, even on a constrained work surface.
Logitech Backup Mouse: Provides redundant control option in the case of trackball failure mid-flight.
TP-Link 8-Port Ethernet Switch: Enables linking to several different ground radios (Silvus, MicroHard).
Lenovo Docking Station: Enables productivity gains through additional monitor connections.
Lenovo USB Soundbar: Enables auditory alerts (‘beeps’ and ‘boops’) from flight control software to be heard.
Three Brytee Daytime Viewing Monitors: Three 2500-nit screens organize information spaciously and allow for clear, glare-free viewing even in direct sunlight.
StarboardⓇ HDPE: Lightweight, strong, durable, and UV-resistant 12.7 mm (0.5 in) thick high-density polyethylene used commonly in the marine electronics industry.
Lid Panel: Houses and protects monitor assembly inside lid of Pelican case.
Base Panel: Houses and protects mini computer, docking station, ethernet switch, and other electronics inside base of Pelican case.
Sub-Panel: Secured with nuts onto the bottom interior surface of the Pelican case via nine epoxy-bonded flathead screws, providing a modular
The final Pneumatic Launcher design consists of a high-pressure pneumatic system that accelerates a launch cart from which the fixed-wing UAS is launched. The pneumatic system is supported by a frame consisting of a main 8020 aluminum extrusion structural rail and two angled steel bipod feet. The rail serves as the guiding surface for the launch cart’s 8020-compatible linear slider, and hence sits at a launch angle aimable between 10°-20° above the horizontal (Figures 2.7, 2.8).
Pneumatic Power System: Stores and releases necessary energy content to accelerate the ~ 4 kg fixed-wing UAS to final launch speed of 13.5 m/s (30 mph).
Maddox Tire Bead Seater: Inexpensive, reliable, and commercially available tire bead seater acts as compressed air reservoir and energy source for launcher.
Butterfly Valve: Hand-operated valve provides rapid, low-loss release of pressurized air necessary for impulse delivery and launch cart acceleration.
PVC Air Tubing and Pressurized Barrel: 38.1 mm (1.5 in) inner diameter PVC Pipes rated to working pressures exceeding 20 bar (300 psi).
Pneumatic Piston: Delrin construction enables low-friction sliding through pressurized PVC barrel.
PVC Connections: Quick assembly and disassembly enabled through compression fittings.
Launcher Structure: Structurally efficient frame utilized shared component purposes to achieve smooth, usable rail surface at various launch angles.
8020 Aluminum Rail: Single 8020 aluminum extrusion acts as both main structural element and surface for compatible linear slider.
3-tiered rail provides modular, robust design.
Swiveling Steel Bipod Legs: Enable launch angle adjustment.
Pulley Train: Harnesses and transmits pneumatic forces from piston to launch cart, imparting desired acceleration to UAS.
3D-printed pulley from PLA roughly 16cm (6.25”) diameter
Launch cart accelerated via 5 mm DyneemaⓇ SK-78 cable (5400 lb load rating)
3D-printed cable feeder guides airflow for minimal losses
Custom aluminum cuts mount pulley to rail system
UAS-Compatible Launch Cart:
Linear Slider: 8020-compatible linear slider constructed from aluminum with self-lubricating UHMWPE inserts for low coefficient of sliding friction.
Dry Lubricant: WD-40 dry lubricant Further reduces frictional resistance hindering acceleration of launch cart.
Base Plate: Modular aluminum base plate design enables easy changes for payload testing, different airframes, etc.
UAS Mounts: Custom pivoting elements support and accelerate drone until impact, then swing down for easy release, avoiding damage to UAS empennage and propeller.
Forward Launch Ring: Ultra-strong steel anchor shackle swivels on aluminum cam and transmits launch acceleration forces onto reinforced carbon post underneath nose of UAS.
Rear Vertical Support Feet: 3D-printed feet on pivoting aluminum members support UAS fuselage at its center of mass (under wing spars).
Impact Attenuator: Diecast springs provide kinetic energy absorption at the end of the launch cart’s stroke length, with through-bolted fastening onto main aluminum rail for superior impact resistance.
Predicted Launcher Kinematics and Dynamics at 78 psi Initial Input Pressure:
Numerical MATLAB model solved system of 2nd-order nonlinear ODEs.
Actual Test with 75 psi Initial Input Pressure, 3.8 kg Test Mass:
13.44 m/s (30 mph) Final Velocity
The final Recovery Net design solution—submitted as a technical design package based on sponsor input and budget constraints—includes a frame built out of 8020 extruded aluminum, steel Unistrut scissor arms, adjustable bungee cords, nylon cables, and a custom net (Figure 2.9).
Extruded Aluminum Frame: Lightweight, strong, and corrosion-resistant; easily portable due to minimal fasteners and modular 8020 construction.
Quick Assembly and Disassembly: Few fasteners allow the frame to be packed down or set up quickly in the field.
Scissor Arm Mounting System: Arms are attached at 45° angles to the vertical 8020 posts using custom brackets and guides for consistent deployment.
Adjustable Bungee Attachment: Rear overhang on each scissor arm accommodates bungee cords, which stretch to absorb impact energy.
Energy Absorption: On impact, bungee cords extend (up to ~ 66 cm) causing the net to rotate back ~ 25°, safely decelerating the UAS [13].
Locking Mechanism: A safety catch locks the scissor arms post-impact to prevent rebound and secondary motion.
Elastic Nylon Net and Webbing: The net absorbs force via stretchable vertical nylon webbing straps, reducing shock on contact.
Load Distribution: Gaps between vertical struts allow the drone’s nose to pass through while its wings are caught, distributing the load across the entire net frame.