Phase-1: Integrated Heavy-Lift Systems
HEAVY-LIFT
ENGINEERING.
This document outlines the design, technical specifications, and component breakdown for “The Drom”. The primary goal is balancing payload capacity with flight endurance using a Hexacopter configuration for stability, redundancy, and lifting power.
Multi-Rotor
High stability / Precise hover. Vertical take-off/land with heavy lifting capability.
Fixed-Wing
Airplane structure focus. High endurance, no hover capability.
Hybrid VTOL
Dual-system complexity. Efficient cruise with VTOL takeoff.
Mass Capacity & Endurance
Calculated Thrust Metrics
Hover Thrust Calculation
Required Hover Throttle: ~45-50% on 6S LiPo configuration.
Total Available Thrust
Thrust-to-Weight Ratio: 19.2 / 8.5 ≈ 2.25:1 Performance: High
Software Operations & Flight Modes
Mode A
LOITER
GPS-locked position and altitude hold. Precise to ±0.1m.
Mode B
AUTO
Fully autonomous waypoint navigation and mission execution.
Mode C
ALT HOLD
Manual stick control with automated altitude maintenance.
Mode D
RTL
Return to Launch. Emergency failsafe or manual home return.
4. Component Breakdown
A. Airframe
B. Propulsion
C. Power Systems
D. Avionics
I/O Mapping & Critical Tuning
Wiring & Pin Config
PID Stabilization Matrix
System Verification: Autotune recommended with 50% payload attached for mass-inertia calibration prior to first mission deployment.
Functional Component Logic
Flight Controller
The “brain” of the UAV. It utilizes three sets of IMUs (Accelerometers, Gyroscopes, Magnetometers) for triple redundancy. It processes sensor data at 400Hz to calculate real-time orientation and adjust motor RPMs to maintain stability.
Speed Controllers
Acting as the “nervous system,” these bridge the FC and motors. They convert DC battery power into 3-phase AC power. Using the DShot600 digital protocol, they communicate motor health and RPM back to the FC.
Here3+ RTK GPS
Beyond standard GPS, RTK (Real-Time Kinematics) provides centimeter-level positioning accuracy. Essential for precision landing and automated delivery paths where drifts are unacceptable.
6S LiPo Battery
The energy source. 22,000mAh capacity provides the massive current draw required for lifting. It uses high-discharge cells capable of delivering over 500A in short bursts for emergency corrections.
5. Technical Workflow & Concepts
Initialization: Power sequence, ESC health check, and GPS lock verification.
Arming: Safety toggle, pre-arm sensor health check, and voltage verification.
Takeoff: Idle spin-up, throttle lift to hover, and PID stabilization engagement.
Payload: Sling Load engagement via servo hook or rigid Cargo Box mounting.
Failsafes: Automatic Return-to-Launch (RTL) on Low Battery or Radio Loss.
8. Crucial Design Concepts
Thrust Ratio (2:1) System produces 17kg total thrust for 8.5kg AUW. Vital for emergency maneuvers and heavy wind recovery.
Thermal Exchange Aluminum heatsinks on ESCs positioned directly in propeller downwash for maximum heat dissipation.
Redundancy Loop “Motor-Out” emergency logic allows the FC to maintain level flight with only 5 operational rotors.
Moment of Inertia Centralizing battery mass at the Z-axis intersection to reduce torque required for agile maneuvers.
Advanced Technical Specification
Optical Payload
- Sony IMX 4K/60fps Gimbal
- 3-Axis Active Stabilization
- 30x Optical Zoom Capability
- Low-Latency Digital Link
Spatial Awareness
- 360° LiDAR + Ultrasonic Array
- 15m Omnidirectional Range
- Real-time Voxel Mapping
- Autonomous Braking Logic
Environmental
- LWIR Thermal Radiometry
- Atmospheric Pressure Baro
- Pitot Static Airspeed Hub
- Humidity Resistance (IP54)
6. Estimated Cost Analysis $400- $3000
| System Group | Component Specs | Cost (USD) |
|---|---|---|
| Airframe | 900mm Carbon Fiber Hexacopter Frame | $180 – $300 |
| Propulsion | 6x MN5008 Motors, 6x 80A ESCs, Props | $500 – $700 |
| Avionics | Pixhawk Cube Orange+ Set w/ Here3+ GPS | $350 – $450 |
| Optical/Sensors | Sony 4K Gimbal Camera + Lidar Array | $400 – $1,200 |
| Power System | 2x 22,000mAh 6S Tattu LiPo Batteries | $300 – $450 |
| Control Link | Radiomaster TX16S + ELRS/TBS Reciever | $150 – $200 |
| Miscellaneous | Wiring, Copper PDB, Nylon Hardware | $100 |
| Total System Estimate | ~$2,600 – $3,400 | |
11. Assembly Concept Checklist
Solder Integrity 60/40 Grade Rosin Core on power pads (High Temp)
Mechanical Security Blue Loctite 243 on all motor & frame screws
Sensor Calibration Open-field Compass & Triple IMU leveling
Vibration Damping Damped FC plate with custom isolation alpha-gel
9. Safety & Environment
Regulatory Status
FAA/CAA Registration required. Remote ID broadcast modules must be powered at all times during flight operations.
Climate Limits
Wind max: 12 m/s. Temperature floor: 0°C. 30% battery capacity loss in freezing conditions. Operational Ceiling: 4,500m ASL.
Moisture Shield
All electronics require silicone conformal coating for humidity and light rain protection. Sealed motor bearings recommended.