Design, Construction and Finite Element Analysis of a Hexacopter for Precision Agriculture Applications

Agriculture drones face important challenges regarding autonomy and construction, as flying time below the 9-minute mark is the norm, and their manufacture requires several tests and research before reaching proper flight dynamics. Therefore, correct design, analysis, and manufacture of the structure are imperative to address the aforementioned problems and ensure a robust build that withstands the tough environments of this application. In this work, the analysis and implementation of a Nylamid motor bracket, aluminum sandwich-type skeleton, and carbon fiber tube arm in a 30 kg agriculture drone is presented. The mechanical response of these components is evaluated using the finite element method in ANSYS Workbench, and the material behavior assumptions are assessed using a universal testing machine before their implementations. The general description of these models and the numerical results are presented. This early prediction of the behavior of the structure allows for mass optimization and cost reductions. The fast dynamics of drone applications set important restrictions in ductile materials such as this, requiring extensive structural analysis before manufacture. Experimental and numerical results showed a maximum variation of 8.7% for the carbon fiber composite and 13% for the Nylamid material. The mechanical properties of polyamide nylon allowed for a 51% mass reduction compared to a 6061 aluminum alloy structure optimized for the same load case in the motor brackets design. The low mechanical complexity of sandwich-type skeletons translated into fast implementation. Finally, the overall performance of the agriculture drone is evaluated through the data gathered during the flight test, showing the adequate design process.