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MQ 29365
MQ 29365
James Duffin
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Abstract
This thesis describes the design, construction and testing of RoboRaptor: a petrol engine-
incorporating a flapping-mechanisrn was built, and used t o wind-tunnel test three types of
membrane-wings for optimum performance. Lift and thrust for a triangular wing, a
variable-span wing, and a triangular wing of high aspect ratio were measured at different
The results showed that the variable-span wing produced good lift but inadequate thrust,
while increasing the aspect ratio of the triangular wing improved its lia. Increasing
airspeed, stroke angle and flapping frequency al1 improved lift and thrust performance.
The ornithopter was built by adapting the drivetrain and flapping-mechanism of the test
platform. When completed, flight tests were carried out. RoboRaptor is not yet capable
First 1would like to thank Dr. DeLaurier, for his constant support and advice throughout
RoboRaptor's development, and for continuing to offer his students this type of
construction oriented research work. 1 enjoyed it very much. Thanks must also go to my
colleagues in the subsonic aerodynamics lab: Dino, Stu, Joeleff, Felix, Mike, Lorenzo,
Patrick, Bruce and of course, Dave. They answered questions, rendered advice, held bits
and pieces together while the glue set, and threw RoboRaptor off hills. Finally, 1 thank
both my parents for their unstinting support, and for providing me with three square meals
Il
Abstract
Acknowledgements
Table of Contents
List of Figures
Chapter 1 : Introduction
Chapter 2: Theory
Chapter 4: RoboRaptor
4.1 Design and Construction
4.2 Tcst Flights
Chapter 7: References
List of Figures
Page
Appendix D - Photos
vii
Chapter 1: Introduction
Leonardo Da Vinci
Dr. J. D. DeLaurier for the development of a mechanical raptor for airport wildlife
control. Since then, the role of this radio-controlled 'bird of prey' has been extended to
Collisions between aircrafi and birds are a serious problem in aviation, causing
damage worth thousands of dollars and sometimes causing the aircrafi involved to crash.
Nor is this a rare occurrence: figures of around 850 bird impacts per year have been
reported in Canada. Berry farms, meanwhile, suffer the attentions of small birds that eat
the crops before they can be gathered, reducing the farm's output. A deterrent is
required to keep birds and other animals fiom obstructing flight operations at airports
At present, live raptors are used for this purpose. A falconer releases the bird of
prey, which hunts down any smaller birds and animals nearby. Using these specially
trained hawks, falcons and eagles has several drawbacks, however. They are not under
the falconer's direct control, are somewhat unpredictable, and often the birds they are
supposed to chase away are not their natural prey. Naturally, any birds tliat the raptors
catch are killed. RoboRaptor would supplement this system by providing a reliable, fully
controllable and non-letha1 way to frighten off these pests.
this role, even with noisemakers attached, as the birds eventually become accustomed to
their presence and do not construe them as a threat. RoboRaptor will capitalise on the
theory that it is the flapping wing motion of raptors, coupled with a purposehl
movement towards the target, that smaller birds have been 'programmed' by evolution
to fear. Hence RoboRaptor will be an ornithopter, using flapping wings to stay aloft.
The practicality of this method of flight has been demonstrated in the past by Mr.
These used wings with a leading edge spar supporting a triangutar membrane; inefficient,
but simple and robust. Unfortunately, the details of his design were unobtainable.
Nevertheless, his concept is the model RoboRaptor most closely approaches in terms of
mode1 engines in the last thirty years have made it possible to build RoboRaptor lighter
wing was constructed by Dr. J. D. DeLaurier and Mr. Jeremy Harris in 199 1, but its
design does not lend itself well to mass production. The wings are complicated to build
and dificult to repair. Finally, there are the popular series of small, rubber-band
powered Tim Bird toy ornithopters, also utilising membrane-wings.
RoboRaptor has a wingspan of under two metres, an appropriate size for a bird
designed using wind-tunnel test data. I used the experience gained in the dynamic wind-
tunnel testing of flapping wings as set out in two previous theses, by Mr. Chad J . clark2
system. It is designed to be easy to mass produce and easy to fly. Although this proof-
of-concept mode1 was left unpainted, experiments could be carried out with its colour
Very little theoretical knowledge of ornithopter flight exists. Design data for use
winç flight based on wind-tunnel experiments with Tim Bird toy ornithopters. The Tim
scaled-up Tim Bird with a petrol engine and a rudder. Therefore, Mr. Clark's and Mr.
His results compare well with the average lifi forces measured in my wind-tunnel tests;
however the computed average thrust values does not agree nearly as well. 1 urge those
interested in a more detailed study of flapping wing dynamics to read his thesis.
Chapter 3: Wind-tunnel Tests
3.1 Procedure
This thesis work proceeded in two phases. First, wind-tunnel test data was
gathered for various wing types to determine the configuration producing the optimum
lifi and thrust. Secondly, the fùselage, drivetrain and tail of the ornithopter were
Before data colIection, a test platform was built to support the wings and flap
them. A strain gauge balance was attached to measure the forces exerted by the wings.
The platform (See Figure 1, Figure 2) had the following design features:
The angle-of-attack was configurable at discrete settings: - 1 O", O", 1O", 20"
and 30"
capable of measuring force in one direction oiily (See Figure 3). Although it therefore
required separate orientations to measure Iift and thrust force, this simpler one-axis
Wingspan: 41 inches
G
Side V i e w Front View
Wingspan: 41 inches
al1 dimensions in cm
8
system reduced data errors due to liftldrag interaction (See Figure 4, Figure 5). The
electric signal from the strain gauges was sent via a DAS-8 12 bit successive
which outputs the force exerted in Newtons. The balance was calibrated by applying
The wing stroke angles were derived from the DeLaurier-Harris ornithopter
(+30°/-20") and the Tim Bird toy ornithopter (+4S0/-20"). The low wind-tunnel speeds
were achieved by placing sheets of Fotril fabric stuffing in the tunnel to choke the flow.
One 138 x 92 cm sheet of 114" thick Fotril created a 9.6 m/s flow and three layered
sheets created the 6.9 m/s flow. Figure 6 shows al1 the combinations of variables under
which the wings operated, in flowchart form. 1 selected the best flap amplitude and
frequency using this data and established the probable cruising speed and angle-of-attack
l 1
tunnel speed tunnel speed tunnel speed
O mls 6.9 m l s 9.6 mis
I
I I 1 I 1
1 1
5Vmotor 7Vmolor 9Vmalor llVmotor l3Vmotor
voltage voltage voltage voltage voltage
fibrous plastic, attached to a 46 cm fonvard spar of birch dowel (See Figure 7). The
area of both wings was 1723.9 cm2, the wingspan 104.16 cm, and the Aspect Ratio 5.6.
Variable-span wing: This wing was identical to the ordinary triangular wing except for
one important detail: the spar was hinged at 40% of its length and sprung with elastic so
that the wings folded on the upstroke but remained straight on the downstroke. This
change was adopted in order to reduce the downward force produced on the upstroke
(See Figure 9). The area of the membrane was reduced slightly to accommodate the
hinge: the total wing area is 1716.9 cm2 (See Figure 8). This wing most closely
approximated a bird's wing in flight. Unfortunately, the hinge mechanism was not very
robust, and so these wings were not tested with 13V supplied to the motor because it
Hiah Aspect Ratio wing: This wing had a longer (55.5 cm) spar and a shorter root edge
(27 cm) than the previous two wings which gave it a significantly greater Aspect Ratio
of 9.1, but a smaller area: 1486.9 cm2 (See Figure 10). Its wingspan was 123.16 cm. In
general, increasing the aspect ratio improves the lifting performance of fixed wings, and
1 hoped that this would also be the case for flapping wings.
Figure 7 : Ordinary Wing Membrane
çive a force reading. This procedure was repeated six tirnes, and the six values averaged
to give the final reading. Sampling took place over several seconds, long enough to
ensure that several flapping cycles occurred, so that the average reading represented the
overall force exerted over an entire cycle and not the instantaneous force at any given
Lift and drag tare values were taken for the platform, without the wings
attached, for each angle-of-attack and tunnel speed. Finally, each of the configurations
was filmed with a video camera placed behind the platform in the tunnel. The camera
was set to a high fiame rate, 111000, to capture the motion of the membrane at high
flapping speed.
3.2 Results
Data from the DAS-8 were saved to disk and organised using Microsoft Excel v. 7.0 in
tabular format (See Appendix B). First, the six force values were averaged to calculate
the final lie or thrust figure for that configuration. Second, the tare was subtracted from
this value to eliminate the lift or drag caused by the shrouded platform. The DC motor
voltage setting was converted to a flapping frequency in Hz using the video film of the
wing motion (5V was approximately 2 Hz, 7V=3 Hz, 9V=4 Hz, 1 1V=5 Hz and 13 V
around 5.5 Hz, although these values varied slightly from configuration to
configuration). Lastly, the original six force values were used to determine the standard
Two sets of plots were made to illustrate the trends in the data. The first set
graphed the lifi or drag force vs. tunnel speed for each angle-of-attack setting. The
second set showed the lifi or drag force vs. angle-of-attack, at fixed flow speed, for each
flapping frequency. In each set, separate plots were made for the +30°/-20" and +45"/-
Two trends common to al1 the wings are irnmediately apparent from these graphs
(Figure 1 1 to Figure 50): the larger stroke angle (+45"/-20") produced better lifi and
thrust, and the higher the flappinç frequency, the more lift and thrust was produced (See
Figure 5 1). The wings behave like flat plates in that they produce little lift at zero angle-
of-attack (AOA). The higher the AOA, the more lifi produced; but at high angles the
thrust output drops rapidly. A 1O" angle-of-attack is reasonable for RoboRaptor during
flight, as it optimises the lift and thrust. Also apparent from these graphs is that the
higher the tunnel speed, the better the lift. This indicated that lift and thrust are related:
the higher the thrust, the higher the ornithopter's top speed, and thus the greater the lifi
produced.
1 also compared the performance of each wing type. The variable-span wing
was a disappointment; it produced relatively more lift than the triangular wings at low
speeds and low angles of attack, but these increases were very small, certainly not
h: 0.5N lie as opposed to x -0.8Nfor the ordinary triangular wing (See Figure 45,
Figure 47). They produced significantly less thnist than the triangular wings (See Figure
46, Figure 48). These fmdings agree with the hypothesis of Mr. Tom Jenkyn, who
calculated that most of the thnist in a flapping membrane-wing is produced during the
wing's upstroke. Because the variable-span wing folds on the upstroke, the deformed
membrane produces less thrust. Finally, the design is heavier, more complex, and more
The ordinary triangular wing was the best performer, capable of 6 in/s speeds
and 234 g of lifi at 10" AOA (See Figure 45, Figure 46). The estimated top speed of
RoboRaptor for a particular wing type was taken from the plot of Thrust vs. Tunnel
Speed as the speed at which the plot crosses the horizontal axis (the point of zero
thrust). This is the maximum speed of the wings alone, neglecting the fuselage drag. 1
The higher aspect ratio wing turned in virtually identical lift to the ordinary
triangular wing at IO0 AOA (Figure 49), despite its smalIer area and lower fiequency
(4.5 Hz as opposed to 5.5 Hz). At higher AOAs, however, the performance of the
ordinary triangular wing was superior. The high aspect ratio wing produced lower
values of thrust at 10" AOA, and was again outperformed by the ordinary triangular
wing at 20" and 30" (See Figure 46, Figure 50). 1 concluded that this lower performance
was likely the result of having a shorter average chord. The longer wing spars taxed the
motor more heavily, and the birch dowel spars had to be replaced with fibreglass dowels
to prevent breakage due to the increased loads. Nonetheless, this wing's performance
was good and, with an area and flapping frequency comparable to that of the ordinary
In summary, the variable-span wing proved capable of 2-3 mis top speed,
producing =: 0.3 N of thrust and 1.3 N of lift at I O" AOA and 4.8 Hz flapping frequency.
The ordinary triangular wing was capable of 6 m / s top speed, producing 0.4 N of thmst
and 2 . 3 N of lifl at 1O0 and 5.5 Hz. The high aspect ratio wing was capable of 5 m/s top
speed, 0.4 N of thrust and just over 2 N of lifl at 10' and 4.5 Hz. 1 concluded that, for
best performance, the RoboRaptor wing should have a triangular planform, and combine
the large area of the ordinary wing (for optimum thrust) with a high aspect ratio, since
the high AR wing showed potential for optimum lift at 10" AOA.
Static Ordinary Wing Lift vs. AOA
Figure I l : Static (U=O) Ordinary Wing Lift vs. AOA, +30/-20 stroke
Static Ordinary Wing Thrust vs. AOA
Figure 12 : Static (U=O) Ordinary Wing Thrust vs. AOA, +30/-20 stroke
"
Static Variable Span Wing Lift vs. AOA
+30/-20airokç
O'
a- + ,----]
- 10 -5 O 5 10 15 20 25 30
UTIAS. h r c h 195% AOA (degrces)
Figure 13 : Static (U=O) Variable-span Wing Lift vs. AOA, +30/-20 stroke
Static Variable Span Wing Thrust vs. AOA
a+---
- 10 -5 O 5 10 15 20 25 30
UTlAS. Wrch 13% AOA (degrces)
Figure 14 : Static (U=O) Variable-span Wing Thrust vs. AOA, +30/-20 stroke
Low Speed Ordinary Wing Lift vs. AOA
AOA (degrces)
Figure 15 : Low Speed (U-6.9 mfs)Ordinary Wing Lift vs. AOA, +30/-20 stroke
Low Speeü Ordinary Wing Thrust va. AOA
Figure 16 : Low Speed (U=6.9 m/s) Ordinary Wing Thrust vs. AOA, +30/-20
stroke
Law Spced Variable Span Wing Lift W. AOA
3 --
Figure 17 : Low Speed (U=6.9 m/s) Variable-span Wing Lift vs. AOA, +30/-20
stroke
Low Speed Variable Span Wing Thrust vs. AOA
Figure 18 : Low Speed (U=6.9 mls) Variable-span Wing Thrust vs. AOA, +30/-20
stroke
High Specd Onlinary Wing Lift vs. AOA
10 -r +30/-20s h k e
Figure 19 : High Speed (U=9.6 m/s) Ordinary Wing Lift vs. AOA, +30/-20 stroke
High Speed Ordinary Wing Thrust vs. AOA
-3 1
UTIAS, March 1996 AOA (dc~rccr)
Figure 20 : High Speed (U=9.6 m/s) Ordinary Wing Thrust vs. AOA, +30/-20
stroke
High Speed VariabIe Span Wing Lift vs. AOA
Figure 21 : High Speed (U=9.6 m/s) Variable-span Wing Lift vs. AOA, +30/-20
stroke
High Speed Variable Spiin Wing Thrust vs. AOA
5 tIz
+30/-20stroke
9.6mis
-2.5
Uïï AS. Mÿrch 1936 AOA (degrces)
Figure 22 : High Speed (U=9.6 m/s) Variable-span Wing Thrust vs. AOA, +30/-20
stroke
Static Onfinary Wing Lit vs. AOA
451-20 strokc
"'" T
Figure 23 : Static (U=O) Ordinary Wing Lift vs. AOA, +45/-20 stroke
Static Ordinary Wing Thmst vs. AOA
! A - - 4
- 10 -5 O 5 10 15 20 25 30
UI1AS. i'vbrch 19% AOA (dcgnics)
Figure 24 : Static (U=O) Ordinary Wing Thrust vs. AOA, +45/-20 stroke
Static Variable Span Wing Lit vs. AOA
AQA (degrces)
Figure 25 : Static (U=O) Variable-span Wing Lift vs. AOA, +45/-20 stroke
Static Variable Span Wing T h ~ svs.
t AOA
AOA (degreen)
UTIAS.M:iy 1996
Figure 27 :Static (U=O) High AR Wing Lift vs. AOA, +45/-20 stroke
Static High AR Wing Thmt vs. AOA
+45/-20 dcgrrs
-10 4 O 5 10 15 M 25 JO
LiI'1A.S. N i y 1996 AOA (degrees)
-3
UiïAS. Apd 1W6 AOA (dcgrccs)
Figure 29 : Low Speed (W6.9 m/s) Ordinary Wing Lift vs. AOA, +45/-20 stroke
Low Speed Ordinary Wing Thrust vs. AOA
451-20 strokc
6 . 9 niis
AOA (dcgrccs)
Figure 30 : Low Speed (U=6.9 mls) Ordinary Wing Thrust vs. AOA, +45/-20
stroke
Low Spccd Variable Span Wing Lift vs. AOA
Figure 31 : Low Speed (U=6.9 m/s) Variable-span Wing Lift vs. AOA, +45/-20
stro ke
Low Spccd Variable Span Wing Thrust vs. AOA
AOA (dcgrecs)
Figure 32 : Low Speed (U=6.9 mls) Variable-span Wing Thrust vs. AOA, +45/-20
stroke
Low Speed High AR Wing Lift vs. AOA
Figure 33 : Low Speed (U=6.9 m/s) High AR Wing Lift vs. AOA, +45/-20 stroke
Low Spccd Higli AR Wing Thmst vs. AOA
4 5 1 - 2 0 dsgcrs
69ds
AOA (degrees)
LITIAS. May 1996
Figure 34 : Low Speed (U=6.9 m/s) High AR Wing Thrust vs. AOA, +45/-20 stroke
High Spced Ordinary Winp Lift vs. AOA
-2 1
UTIAS. Wrcli 19% AOA (dcgrws)
Figure 35 : High Speed (U=9.6 m/s) Ordinary Wing Lift vs. AOA, +45/-20 stroke
High Speed Ordinary Wing Thrust vs. AOA
AOA (degrces)
Figure 36 : High Speed (W9.6 mls) Ordinary Wing Thrust vs. AOA, +45/-20
stroke
High Speed Variable Span Wing Lift vs. AOA
+45/-20 strokc
4 --
Figure 37 : High Speed (U=9.6 mls) Variable-span Wing Lift vs. AOA, +45/-20
stroke
High Speed Variable Span Wing Thrust vs. AOA
+45/-20 strokç
9.6 mis
Figure 38 : High Speed (U=9.6 mls) Variable-span Wing Thrust vs. AOA, +45/-20
stroke
High Specd High AR Wing Lift vs. AOA
9.7 rnk
4.5 FI;..
6 --
4 --
-z
E
-4 -
AOA (degrees)
W1AS. May lm6
Figure 39 : High Speed (U=9.6 m/s) High AR Wing Lift vs. AOA, +45/-20 stroke
High Specd High AR Wing Thnist vs. AOA
-5 1
WiïAS. m y 1996 AOA (degrees]
Figure 40 : High Speed (U=9.6 m/s) High AR Wing Thrust vs. AOA, +45/-20
stroke
Ordinary Wing Lift vs. Speed at 5.8 Hz
+30/-20 strokr
-3 1
UTIAS. March 1936
+30/-20 strokc
-1 1 -10 AOA
'T
-+451-20~ t r o k z
30 AOA
20 AOA
10 AOA
-,.-.-*----
-___.--- AOA
- - - - - - - - - - -O3
---+----!---
1---t
10
------.--__._____
----__ - - 9 - - _ _
-10 AOA
,--+-1
3 4 5 7 1"
---9---,
1 -10 AOA
20 A 0 A
30 AOA
+451-20 strokc
30 AOA
20 A 0 A
10 dcgrees AOA
6.9 m/s
tnanylar test wing
+45/-20 dcgrcc stroke
O ! a-----
O 2 4 6 8 IO 12 14
UTlAS Decem bcr 1996 Flapping Frcquency (Hz)
After the wing design was determined, the next step was to build the fuselage
and tail assembly. 1 adapted the test platform's drive train and flapping-mechanism for
RoboRaptor in order to take advantage of the lessons learned fiom constnicting and
S~ecifications
Wingspan: 127.1 cm
Length: 72.5 cm
Powerplant: Cox .O74 Queen Bee glow plug engine with throttle and muffler
Estimated power: 122 W
MO01
pad)
Larger wings would be needed for the 700+ g RoboRaptor Mk. la, since the best
wings tested in the wind-tunnel could only support 234 g. 1 therefore made larger wings
with a higher aspect ratio; but 1 wanted to know if they would provide enough lie, and
The larger wings had an area of 2226 cm2, and an aspect ratio of 6.87 (See
Figure 58). 1 made a plot of Wing Area vs. Thrust using data from the Tim Bird and the
ordinary test wings (See Fiçure 59),assurning that zero wing area gives zero thrust. 1
extrapolated the curve to the new wing area and determined that RoboRaptor's wings at
5.5 Hz showed an estimated increase in thrust of 121.4% over the ordinary test wings.
Then, using the graph of Thrust vs. Speed for the ordinary test wings as a
reference (Figure 46), 1 determined that the irnproved thnist of the new wings would
,/-
ordinwy tcst
/-.-
TIM bird
wing
Lifl vs. Speed for the ordinary test wings (Figure 45) predicts 3 - 3.5 N of lift.
However, I now had to calculate and apply the percentage increase in lift due to the
1used data from the Tim Bird and the ordinary test wings to plot Wing Area vs.
Lift (See Figure 60) and extrapolated the curve to the new wing area. 1 assumed that
1 concluded that the new wings should produce an increase in lift of 94.8% over
the ordinary test wings, and applied this increase to the 3 - 3.5 N of lift generated by the
ordinary test wings. 1predicted that the new wings will produce 5.8 - 6.8 N (592 - 694
g) of lift at reasonable flight conditions (10" AOA, +45"/-20" stroke, 5.5 Hz flapping
Although the new wings will operate at 4.3 Hz, not 5.5 Hz, the data for the high
aspect ratio wings operating at 4.5 Hz showed no decrease in lift from the data for the
ordinary test wings at 5.5 Hz under reasonable flight conditions. 1 therefore assumed
that the decrease in flapping frequency would have a minimal effect on RoboRaptor7s
Test wng
TIM bird
O4 I
1 500 1 O00 t 500 2000 2500
-50A
UTlAS November 96 Wing Area (cmh2)
providing enough lie, and afier thirteen test flights these findings were borne out;
greater lie and thmst were needed. 1 designed and built a second set of wings with
longer, uniformly tapered spars and a larger area and aspect ratio (See Figure 61). They
The real problem became apparent after tests with the second wing design: not
enough thmst was being produced. When initially launched, the model could sustain
flight, but soon slowed down and stalled. 1 added compression struts running diagonally
between the wing spar and the root spar to improve the wing's performance (See Figure
62). These braced the wing spar and prevented it from bending in the fore and aft
direction while flapping. 1 assumed that such bending would deform the membrane and
reduce its effectiveness. Initially, 1 used 3/16" birch dowel for the stmt. The wing's
washout was decreased, requiring rebalancing of the model, but no other improvements
were apparent. I believe this could have been because the struts constrained the
membrane's shape on the upstroke, where most of the thmst is generated. I replaced the
dowels with more flexible 118" fibreglass rods, and reduced the constrained area by
moving the struts closer to the fuselage (See Figure 63), but RoboRaptor still produced
insuficient thrust.
1 chose the .O74 CU. in. engine because it provided the optimum balance between
weight and power output. 1calculated the maximum expected power demand from
Figure 61 : RoboRaptor Wing Membrane #2
7/32' Llross tublng
CsoLd~r j o i n t )
RoboRaptor7swings were larger and, because the power required to drive them must
therefore also be larger, 1 doubled this figure to 104 W. Since a 0.45 CU. in. engine
outputs one horsepower, or 746 W, 1 calculated the power outputs of common engine
sizes:
0.1 165.8
.O9 149.2
.O74 122.7
.O49 81.2
1 concluded that the .O74 engine was the optimum choice. This particular engine
1 designed the engine flywheel based on the constraints of the fùselage size. 1ts
maximum possible diameter was approximately 5 cm, so this value was taken as a
starting point for calculations. The flywheel also had to be as light as possible.
Normally, the propeller would act as a flywheel, so a 7-4 propeller (the standard size for
this engine) was used to calculate the minimum moment of inertia the flywheel should
(disk) (ring)
The approximate weight of the flywheel design was calculated using the density of
aluminium. 1 found that the moment of inertia of the lightest flywheel easily exceeded
that of the propeller, and assumed it was adequate to prevent engine strain; the extra
moment of inertia would serve to smooth out the motion of the mechanism whilst
flapping.
Before the engine was installed, it was run up to break it in with a 7-4 propeller
attached in place of the flywheel. The engine was run through three fidl tanks of fuel to
allow the factory-fresh parts to mate with each other. 1 found the engine extremely
dificuit to start initially, but by the end of the breaking-in process, it started on the first
or second try. Next, 1 attached the flywheel and cooling fan, and ran the engine up
again, to see that the flywheel was adequately balanced and that the fan would not
disintegrate at the engine's top speed of 17500 r.p.m. This test was successfbl.
With the engine installed, RoboRaptor was held in a vice whilst the engine was
run to test the flapping-mechanism. 1 started the engine using a high-toque electric
starter, fitted with a rubber wheel that would turn over the flywheel. An electric storage
ce11 was attached to the engine's glow plug, and the flywheel spun counter-clockwise.
The first attempt revealed that the flywheel came unscrewed from the engine
while being rotated counter-clockwise against the compression of the engine. With the
engine driving it, any resistance to rotation would serve to tighten the flywheel;
however, during startup the flywheel loosened. Applications of thread locker to the
screw had little effect on this problem, so 1 drove a 2/56" x 318" screw through the
flywheel into the engine driveshaft to lock the two together. This solution proved
effective, although the torque at startup was so great that a second screw had to be
added later.
The second run up resulted in the successful firing of the engine, but the set-
screws holding the brass drive shafl frorn the gearbox to the flapping-mechanism crank
wheel slipped, and the wings did not flap. 1 retightened the set-screws.
The third run up revealed that the set-screws were still slipping. The brass
tubing forming the drive shaft was removed and found to be damaged: the set-screw of
the crank wheel had gouged a trench in the sofi metal. 1 replaced the tubing with a solid
The fourth run up successfùlly flapped the wings, but only until one of the two
3/16" birch dowel spars acting as the axles for the wing pivots, and the attachment
points for the root edges of the wing membranes, snapped in two. 1 replaced these with
The fifih run up showed that the gear teeth linking the two wing pivots were
skipping, resulting in only one of the wings being driven. 1 replaced the gear teeth with
larger ones.
During the sixth run up, the problem recurred; the twisting of the fkselage under
torque was causing the gears to corne out of alignment and skip. 1 decided to discard
the gear linkage and use the dual strip method 1 had used for the test platform (See
Appendix A). Instead of metal tape, however, 1 used bundies of kevlar thread to link the
wings rnechanicaily. The threads were tied to 2/56" screws set into the acrylic wing
The seventh run up was the most successfùl yet; however, after several flaps one
of the kevlar threads snapped. I thought this fault was due to the cyanoacrylate making
the kevlar brittle and easier to break. 1 installed new kevlar threads with three times as
The eighth run up was completely successful. The engine drove the wings at full
throttle, and no damage occurred. This test was filmed on S-VHS tape at 1/1000 frame
actuate the rudder whilst the engine was running. OAen the mechanical interference
from an operating engine blocks the AM signal. This was not the case here, however,
and the test proceeded successfùlly. This test was also filmed.
By the tenth test, the 2/56" bolts attaching the flywheel to the engine driveshaft
had started to shear through. 1 removed the flywheel, and replaced the central threaded
shaft, discarding the broken bolts. 1 made an aluminium collar to fil1 the space between
the flywheel disk and the engine driveshaft. The central threaded shafi, collar, flywheel
and driveshaft were bonded together with slow curing epoxy. When this had set, 1
threaded two replacement 2/56" bolts through the flywheel and collar and into the
driveshaft. The collar fitted between the fiywheel and the driveshaft reduced the shear
load on the bolts, and provided more support and a greater mating surface between the
two parts.
1 intended the eleventh test to be a trial run for the actuaI launch of RoboRaptor,
to determine the ease of starting. The test was conducted outdoors, with the fibreglass
shell in place and, rather than holding the ornithopter in a vice, it was supported by a
person. The engine started successfùlly, and after some practice the procedure became
easy to accornplish. However, a fùel flow problem caused the engine to cut out after
several seconds. During the subsequent adjustment of the engine needle valve while
running, the mode1 was tipped fonvards causing the engine to run lean for a few
seconds. The engine responded with a burst of power, causing the flapping frequency to
increase markedly. Unfortunately, the strain on the drivetrain was too great and the
brass driveshafi bent and tore upwards through the 1/16" plywood bulkhead directly
behind the wing pivots, causing localised damage. I repaired the bulkhead and
reinforced the area where the driveshafi is supported by gluing a layer of 1/32" plywood
to the rear-facing side of the bulkhead; it was positioned with its grain running
layers of 2 oz. fibreglass attached with epoxy on both sides of the bulkhead. 1 also
replaced the bent driveshaft. During this test. the modified flywheel performed well,
1 noted that during the tests the wings slid fornards along the wing root spars
while flapping, resulting in cmmpling of the membrane. To prevent this, 1 built two
small acryiic collars which clamped the membrane towards the trading edge using set-
The twelflh test was also an outdoor test with the fibreglass shell in place. The
engine was started successfidly, and ran well. However, the positions of the needle
valve for starting and for maximum r.p.m. were not known. Once again I clamped the
ornithopter to the workbench and tested it without the shroud. 1 found that the engilie
started best with the needle valve opened three turns. As the valve was closed slowly
the r.p.m. increased t o a maximum with the needle valve open around 1.5 to 2 turns.
This trial resulted in the highest flapping frequency seen yet and the new driveshaft was
bent out of tme, although the reinforced bulkhead was undamaged. More seriously. one
of the 118" rotary ball-bearing sets on the crank arm was damaged beyond repair.
found that in its current configuration, the system was forced to twist because the
distance between the crank arrn pins was not a constant. At the maximum and minimum
positions during the 360 degree cycle the crank arm length is 2.85 cm, resulting in a
to 3.14 cm, and 90" beyond the maximum the distance was 2.93 cm. CIearly, these
mismatched lengths put the system under undue stress. 1 made a new crank wheel from
aluminium, with a 6 mm long slot rather than a pin joint to allow the Iower bearing of
the crank arm to slide up and down in the slot and adjust its distance according to its
position in the cycle. The pin joint attaching the crank arm to the wing pivot remained
the same.
1 carried out two more tests with the mode1 in the vice to observe the new crank
mechanism. The system worked admirably, with noticeably less stress on the system. 1
transferred video clips of both the old and new mechanisms in operation to an .AV1
computer file, enabling direct, side-by-side comparison when viewed under the Windows
95 operating system.
Unfortunately, the flapping frequency during these tests was quite slow; only
around 1 Hz even at hl1 throttle. I concluded that stretchinç the wing membrane using
the acrylic clamps constrained the mechanism too much. Once the membrane was
allowed some slack, the flapping frequency increased notably. However, high speed
running produced other problems. Once again the brass driveshafi bent, as did the 1/16"
aluminium crank arm. 1 replaced the brass driveshafi with a steel one and made a new
crank arm. 1/16" plywood was reinforced on both sides with two layers of 2 oz.
fiberglass attached with epoxy. The resulting crank arm was strong, lightweight and
immune to deflection. At high frequencies the new crank still produced a lot of shaking
in the fuselage structure, which resulted in the loosening of the horizontal tail hinge
1 carried out the last series of tests with this configuration, and found that back
Ioading on the crank caused the drive gear to the gearbox to corne unscrewed from the
flywheeI; it was secured with thread locker. 1 then deemed RoboRaptor ready for a test
flight.
After six test flight attempts, the Cox engine failed. The piston crank rod was
badly bent and the reed-valve mechanism damaged, probably through contact with the
misshapen piston. Replacing the piston and reed valve using parts from the second
engine only resulted in the same failure, even when running the engine without
significant Ioad: without the crank or wings attached. 1 attributed the Cox engine failure
A P.A.W .O6 diesel was chosen for the new engine. It is a robust, high-quality
settings while spinning a 7-4 propeller. 1 designed a new flywheel to fit the diesel's
larger drive shaft and incorporated a knurled edge to improve the grip for the starter
motor. The only other alteration required to the original design was the replacement of
the silicone clunk line in the fbel tank with neoprene, as diesel fùel causes silicone tubing
to expand.
4.2 Test Flights
Flieht #: 1
Date: 2 1'' A p d
Notes: Engine run at rich starting mixture: needle valve open three turns.
Description: The model was launched nose-down. There was a sudden recovery near
the ground, due either to the effect of the horizontal tail or the tail-heavy balance. The
model pitched up to a 30" angle and turned right, levelled off, lost speed and touched
Damage: Light; most occurred due to the model continuing to flap once it had landed.
The vertical tail broke off on impact, the nylon hinge holding the horizontal tail was
tom, the steel drive shaft was bent, the plywood bulkhead supporting the drive shaft
bearing (second fiom the nose) was worn away around the bearing, and one of the
kevlar strands attaching the wing pivots snapped. The upper fibreglass shell was slightly
cracked, and the drive shaft bearing showed severe signs of fatigue.
Fliaht #: 2
Notes: The mode1 was repaired, and some modifications made. The d i v e shaft was
replaced with a 3/16" steel drill shafl, and the drive shaft bearing was replaced with a
drilled out section of 318" steel threaded shaft. The damaged bulkhead was reinforced
with another layer of 1/8" plywood, and the hole for the bearing enlarged to 3/8". The
threaded shafk was installed and held in place with two nuts on either side of the
bulkhead. Finally, the angle of the horizontal tail was reduced from 10" to 7" to lower
the model's angle-of-attack during flight. The 30"angle assumed by the mode1 during
Description: No flight
Damane: The crank arm had been weakened in the previous flight, and broke before the
Flight #: 3
Date: 2ndMay
Notes: The crank arm was replaced with one made using a 'sandwich' of 1/16" plywood
with a layer of 5 oz. carbon fibre epoxy'd on each side. Model was launched nose up
and with the engine running lean to give more power and a higher r.p.m.
Descriotion: The model maintained level flight for a period, but then lost airspeed and
came to earth. It was noted that just afier launch, the engine 'missed' as the model
pitched up, then picked up again, which may have caused the ornithopter to lose speed.
This was probably caused by fie1 slosh in the tank. Duration: 4.6 seconds
Damage: Minor; the vertical fin broke off again on impact, the foremost bulkhead carne
unghed at the bottom, and the 1/23'' bolt attaching the crank arm to the wing pivot was
bent, probably due to the model flapping against the ground after touchdown.
Flight #: 4
Notes: A piece of plastic scmb pad was placed in the tank to damp out the sloshing
motion. The angle of the horizontal tail was lowered again, from 7" to 5". The mode1
still pitches up too far, and loses speed. The vertical tail fin was redesigned. The new
stabiliser is approximately 2/3 the size of the old one, and the joint between the tail
Description: The model pitched upwards as soon as it was launched. The ornithopter
gained height, turned sharply right and dove towards the ground. From the video taken,
it was clear that the excessive pitch-up was due to the way the model was thrown. The
ornithopter was launched whilst held behind the centre of gravity. This caused a
Damane: Not serious. One of the 3/16" bearings supporting the right-hand wing pivot
was destroyed, and the fibreglass axle damaged. The nose cone was crumpled, but still
useable, and the horizontal tail's nylon hinge was torn apart. Replacing the 3/16"
While waiting for the bearing to arrive, some glide tests were made with the
wings at the mid-dihedral point (1 1.25"). These revealed that the model glides well, in a
stable manner, providing that it is thrown correctly, held as close as possible to the c g .
It was also clear that having the wings flapping did extend the model's flight duration, so
Flight #: 5
Notes: The 1/8" fibreglass spars making up the horizontal tail were reinforced with 2
oz. fibreglass patches and cyanoacrylate where they attach to the model.
Description: Unsuccessfid; the model was not launched with enough fonvard speed for
flight.
Damage: Major darnage to the plywood fiame occurred when the motor continued to
drive the wings against the ground. The keel broke at its thinnest point between the first
and second bulkheads, and the fibreglass axles broke through the second bulkhead. The
Flight #: 6
Date: 6h June
Notes: Both the first and second bulkheads were replaced, and the keel reinforced by a
layer of 1/32" aluminium on each side, wrapped in kevlar. The points at which the axles
pass though the second bulkhead were reinforced with 118" plywood. The nylon hinge
on the tail was replaced by a strip of 1/32" aluminium, bent to the correct angle.
Description: No flight; tùel flow problems prevented the motor from reaching sufficient
r.p.m. to launch.
Damage: None
During the seventh attempt on June 7th, the engine failed before launch and had
to be stripped down and examined. It was found that the piston arm was bent and the
reed valve was damaged, possibly through contact with the deformed piston arm.
Replacing these parts and running the engine again only produced the same syrnptoms. 1
believed that the failure of the Cox engine was due to the poor quality of the parts.
Flight #: 8, 9 consecutively
Notes: A new engine was quickly substituted for the .074. This was a P.A.W. .O6
diesel. The new engine was easily fitted to the original fuselage and engine mount. The
only modifications necessary were the machining of a new flywheel and the replacement
of alI the fiiel lines with neoprene o r tygon tubing. AAer breaking in, the new engine
was installed and tested by flapping the wings while stationary on a test bench. These
tests were successfûl and RoboRaptor was prepared for flight. Fuel needle valve setting:
1 1/4 turns open. Durations: 2.15 seconds and 2.79 seconds respectively.
Description: Both flights were comparable with the second test flight. The mode1
pitched up, and this extra drag caused it to slow down and stall. Nose up attitude was
Damage: None
During fùrther tests, the set-screw securing the flywheel came loose and the
stresses whilst starting the engine stripped the threads in the set-screw hole on the
flywheel. The set-screw was enlarged to a size 6-32 screw, and a second hole was
drilled and tapped. The set-screws are located one directly opposite the other on the
flywheel shaft.
Notes: Model was launched without its fibreglass shell, saving 77g but increasing the
Damage: None
Flight #: 2 2, 1 3 consecutively
Date: 1 7LhJuly
Notes: Model was launched without its shell, the receiver and battery. New al1 up
weight: 590g
Description: The mode1 was launched into strong (25 k d h ) winds, and for several
seconds was able to maintain altitude with minimal ground speed. The model then sank
to the ground, possibly due to a lu11 in the wind. Durations: 2.06 seconds and 3.32
seconds respectively,
Damaye: None
Notes: Model was launched with the second, larger set of wings, without the shell. Al1
up weight: 646.2 g
airspeed to sustain flight, however it soon slows down and descends. The wings do not
appear to be producing enough thrust for sustained flight, or the drag on the model is
Damage: None
The new wing spars were reinforced with birch dowel compression stmts. The
dowels run from the centre of each wing spar to the root spar near the trailing edge.
The dowels are hinged about the wing root spars. They prevent any horizontal flexinç
of the wing spar which would deform the membrane during flapping. Similar struts were
Flight #: 16
Notes: Model flown with dowel compression stmts on wing spars. No shell. Al1 up
weight: 666.2 g
Description: The new wing spars restrict the wing's washout angles during flapping.
This reduced twisting resulted in the model pitching up very sharply after iaunch. Stall
Damage: None
The mode1 was re-balanced by rnoving the radio receiver and the battery fonvard
to a position above the drive shaft between the second and third bulkheads. Extension
wires were led back to the servo. Several gliding flights were made to check the new
Notes: Model launched with the C.G.position fonvard, no shell. Dowel compression
Description: Model still does not develop enough thmst. No improvement over
Damage: On the second launch, the mode1 stalled and dove steeply. One of the dowel
Notes: Model launched with C.G. position fonvard, shell attached. Dowel compression
seconds respectively.
Damage: None
Flight #: 2 1
Notes: For this flight, the wings were inverted so that the compression strut was above
the membrane rather than below it. This configuration does not constrain the membrane
on the wing's upstroke, and 1 hoped that more thrust would be produced. The model
Description: There was no visible improvement over previous flights. The ornithopter
appeared to be too heavy and did not produce enough thrust. The model did appear
Damage: None
Flight 21 demonstrated that although the wing design is asymmetric, with the
strut normally on the underside of the membrane, reversing the wings so that the 'top'
became the 'bottom' did not affect the aerodynamic performance significantly.
Chapter 5: Discussion of Results and Recommendations
Disappointingly, RoboRaptor was unable to achieve sustained flight. From
observation of the test flights on videotape, 1 concluded that the wings did not produce
enough thrust to maintain the airspeed necessary for flight. When thrown, the
ornithopter initially rnaintained altitude until the speed dropped and the model stalled.
The stall resulted either in the model diving into the ground or sinking to the ground
while maintaining its slightly nose up attitude. The short flight times allowed no
believe that part of the problem lay with the diesel engine. Although it was completely
retiable and had many advantages over the Cox engine, it produced its maximum torque
at a lower r.p.m. Flapping frequencies with the Cox engine were roughly double those
with the P.A.W. and, as can be seen from Figure 5 1, frequency has a significant effect on
the wings' performance. Flights with the diesel and the large area wings were shorter
than the ones made with the Cox engine and the first set of wings in terms of distance
and duration.
Apart from the wings, I believe that RoboRaptor's final design was good. The
Mk.2 was robust enough to survive heavy landings without sustaining damage. The
procedure for starting the engine and flying was simple and trouble free, and al1
components were easily disassembled for maintenance. Care had to be taken, however,
when launching the ornithopter. If the model was thrown nose down, it produced no lifi
and dove into the ground. If the model was thrown pitched too far up (i.e. above IO0
AOA), the wings acted similar to a parachute brake and caused almost immediate
stalling.
recommendations:
RoboRaptor should be test flown from a large hill to extend the flight times and get
an idea of its long-term stability. Such a test was planned, however, inclement weather
The larger wings should be wind-tunnel tested in order to discover their actual lift
and thrust output. The effect of the compression struts and any subsequent
be made.
Modify the wing design to produce more thrust. 1 suggest copying the wings of the
Spencer ornithopter directly if the information is available, since these wings have
proven successfùl. They also seemed to flap faster than RoboRaptor's wings.
ModiQ RoboRaptor's construction to Save weight. The Iighter the model, the less
lift and thrust it will require to fly. For example, the fibreglass outer shell made from
one layer of 5 oz. and two layers of 2 oz. fibreglass masses 77 g alone. It could be
replaced with a shell made from only two layers of 2 oz. fibreglass. Alternatively, a
Also, the planetary gearbox is one of the heaviest components of the model. Its steel
engine. The Cox .O9 Tee Dee engine is now manufactured by Estes, and the quality may
have improved enough to make it a viable replacement. Decreasing the gear ratio,
however, would entai1 replacinç or severely modi@ingthe gearbox, and would decrease
(1) DeLaurier, J. D., The Development of a Mechanical Raptor for Airport Wildlife
Control, an application to the Charles A. Lindbergh Fund, Inc., Institute for Aerospace
Studies, University of Toronto, (1 994)
(2) Clark, C. J., An Experimental Investigation of the Performance of the Tim Bird and
Cornparison with Other Winged Models, BASc. Thesis, Faculty of Applied Science and
Engineering, University of Toronto, (1994)
The test bed was a platform on which a motor, drivetrain and flapping-
beam strain-gauge balance that measured the forces exerted during testing. The
apparatus was placed in the subsonic wind-tunnel with a set of the wings under study
attached to the flapping-mechanism, and data was output while the tunnel and the device
were active.
The foIlowing guidelines for the test platform design are based on experience
The device should allow the user to easily interchange different types of wing
From these specifications I drew plans and constructed a platform (see Figure 1,
Figure 2). An L-bracket of plywood holds a DC motor, a 68: 1 planetary gearbox from
a cordless screwdriver, a 318" steel drive shafi and an aluminium crank wheel. The
crank wheel was attached to the drive shafl with a set-screw. Laminate bulkheads
supported two 5/32" aluminium rods which formed the axles about which the wings
pivoted, as well as the attachment point for the root edge of the wing membrane.
Acrylic wing root pivots rotated about these rods, and were held in place by acrylic set-
screw collars. An aluminium crank rod connected the left-hand root pivot to the crank
wheel.
This flapping-mechanisrn was derived frorn that used in the Thomas ornithopter
described in Mr. Tjengdrawira's thesis. The crank rod could be secured to the wing root
in two places to give either a +45"/-20" or a +30°/-20" wing stroke. The root pivots
were linked to operate in phase by two strips of metal tape. The bearings of the root
pivots and the crank arm were made fiom brass tubing. The spars of the various wings
were reinforced at their roots with lengths of 7/32" brass tubing, and secured by
inserting them into holes in the acrylic pivots. A 2-56 x 3/4" steel countersunk screw
variable angles of attack and which could be bolted to the strain-gauge balance. Finally,
1 constructed a streamlined shroud consisting of a foam nose cone and a plastic cylinder
formed around four plywood hoops. The plastic cylinder was made frorn plastic sheet in
two halves, lefi and right, with slots cut for the wings. The sheets were attached to the
Vel Attack Thmst Coeff Voltage Frequency Average Thmt T ' s t Error
.(m/s> (de@ (NI 03 (Hz) 0 0
O 20 1.374 2.677
O 20 1.395 2.7166
Static Ordinary Wing Lifl, +30/-20 stroke UTIAS,March 1996
Vel Attack Lifi Coeff Voltage Frequency Average Lift Lift Error
(&s> (deg) 0 03 (Hz) 0 0
O O 0.007 0.0067 5 2.1 -0.0725 0.058648
O O 0.124 0.1203
Static Ordinary Wing Lift, +30/-20 stroke UTIAS,March 1996
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Static Ordinary Wing Lift, +30/-20 stroke UTIAS, March 1996
Vel Attack Lifi Coeff Voltage Frequency Average Lift Lift Error
Ws) (de@ (NI 0 W) (NI N
O 30 4.034 -0.0329 5 2.1 0.054666667 0.0134866
O 30 -0.043 -0.0419
Static Ordinaxy Wing Thrust, +45/-20stroke UTIAS, March 1996
Vel Attack Thrust Coeff Voltage Frequency Average Thnist Thnist Enor
(m/s> (del31 O 03 (Hz) 0 O
O O 0.326 0.2115 5 2 0.342 0.0184842
O O 0.325 0.2111
O O 0.324 0.21
O O 0.358 0.0698
O O 0.372 0.0724
O O 0.347 0.0675
O( O 0.691 0.1345 7 3 0.693166667 0.0063879
O O 0.697 0.1357
O O 0.701 0.1366
Static Ordinary Wing Thmst, +45/-20 stroke UTIAS,March 1996
Vel Attack Thrust Coeff Voltage Frequency Average T h t Thmt Enor
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Vel Attack Thnist Coeff Voltage Frequency Average Thmt Thmt Error
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O 20 0.132 0.1286
Static Variable Span Wing Thrust, +45/-20 stroke UTIAS,April 1996
Vel Attack Thrust Coeff Voltage Frequency Average Thmst Thmst Error
(ds) (de@ 0 0 W) (N> 0
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1 1 1 ~UTIAS.March 1996
Vel Attack Thnist Coeff Voltage Frequency Average Thrust M s t Error Drag Tare Tare Error Adjusted Thrust Adjusted Error
(m/s> (dei31 (-1 0 ml 0 0 0 0 0 0
6.91 O -0.139 -0.2457 5 2.1 -0.126833333 0.016506733 -0.40567 0.015051763[ 0.278833333 0.02233892
6.93 10 -0.737 -1.3052 7 3.3 -0.735333333 0.007431 166 -0.5105 0.019024108 -0.224833333 0.020423978
6.93 IO 6.745 -1.3187
6.93 10 -0.722 -1.2783
6.93 IO -0.74 -1.311
6.93 IO -0.738 -1.3062
6.93 10 -0.73 -1.293
6.93 10 -0.668 -1.182 9 4.3 -0.674833333 0.009956851 -0.5105 0.019024108 -0.164333333 0.02 1472204
6.93 10 -0.674 -1.1929
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6.93 10 4.674 -1.1926
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6.93 10 -0.663 -1.1734
6.93 10 -0.695 -1.2305
6.93 10 -0.623 -1.1035 11 5 -0.616666667 0.032304111 -0.5 105 0.019024108 -0.106166667 0.037489628
6.93 10 -0.584 -1.0345
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6.93 10 -0.558 -0.9889 13 5.8 -0.5325 0.024356724 -0.5105 0.019024108 -0.022 0.030905771
6.93 10 -0.568 -1.0059
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6.93 20 -3.586 -6.3506 5 2.1 3.623166667 O. 102449 0.451833 0.013030946 3.171333333 O. 103274446
6.93 20 -3.752 -6.6446
6.93 20 -3.583 -6.3445
6.93 20 -3.699 -6.5508
6.93 20 -3.438 -6.0871
6.93 20' -3.681 4.5177
6.93 20 -3.907 -6.9187 7 3.3 3.834166667 0.0677702 0.451833 0.013030946 3.382333333 0.069011674
6.93 20 -3.818 -6.7615
6.93 20 -3.763 4.6635
6.93 20 -3.785 -6.7027
6.93 20 -3.945 -6.9848
6.93 20 -3.787 -6.706
6.93 20 -4.035 -7.1455 9 4.3 4.029166667 0.0935101 0.451833 0.013030946 3.577333333 0.094413688
6.93 20 -4.046 -7.16451
6.93 20 -4.055 -7.1809
6.93 20 -4.147 -7.3434
6.93 20 -4.055 -7.1799
6.93 20 -3.837 -6.7937
6.93 20 -4.335 -7.6757 11 5 4.4 13 0.0577177 0.451833 0.013030946 3.961 166667 0.059170422
6.93 20 -4.432 -7.8479
6.93 20 -4.4471 -7.8745 1
6.93 20 -4.424 -7.8344
6.93 20 -4.342 -7.6882
6.93 20 -4.498 -7.9645
6.93 20 -4.815 -8.5261 13 5.8 4.786333333 0.07 12967 0.451833 0.013030946 4.3345 0.072477774
6.93 20 -4.779 -8.4625
6.93 20 -4.689 -8.3025
6.93 20 -4.85 -8.5885
6.93 20 -4.703 -8.3273
6.93 20 -4.882 -8.6447
Low Speed Ordinary Wing Thmst, +45/-20stroke UTIAS, March 1 996
Vel Attack Thnist Coeff Voltage Frequency Average Thmt T ' t Error Drag Tare Tare Error Adjusted k s t Adjusted Emor
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t Error
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Vel Attack Lifi Coeff Voltage Frequency Average Lifi Lifi Error Lifi Tare Tare Error Adjusted Lift Adjusted Enor
,(m/s> (del31 O O 0 0 (N> 0 0 0
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Ws> (deg> 0 0 0 0 0 (N> N 0
Vel Attack Lift Coeff Voltage Frequency Average Lift Lift Error Lift Tare Tare Error Adjusted Lift Adjusted Error
(m/s> (dei31 N 03 (Hz) 0 0 0 0 0 0
l ~ o wSpeed Variable Span Wing Thnirt, 4-301-20 stroke 1 JUTIAS, March 1996
Vel Attack Thst Coeff Voltage Frequency Average Thnist T ' t Error Drag Tare Tare Error Adjusted Thnist Adjusted Error
Ws) (de& O 0 (Hz) 0 N (N O 0 0
Low Speed Variable Span Wing Thrust, +30/-20 stroke UTIAS, March 1996
1 I 1 1
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p-pppp Tare Error Adjusted Thmst Adjusted Error
(Hz) 0'0 (-1 0 0 0 0
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'LOW Speed Variable Span Wing Thrust, +45/-20 stroke UTfAS, March 1996
Vel Attack Thnist Coeff Voltage Frequency Average Thmt Thmst Enor Drag Tare Tare Enor Adjusted Thrust Adjusted Error
(m4 (del31 O\T) Cv) (Hz) (N> 09 0 0 09 0
-1.1724
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Vel Attack Thmst Coeff Voltage Frequency Average Thnist Thnist Error Drag Tare Tare Error Adjusted Thmt Adjusted Error
(mfs) (deg) N 03 W) 0 0 0 0 0 0
~ ~
6.911 20 -1.259 -2.2285 5 2 -1.2435 0.026737926 -0.60367 0.006368324 -0.639833333 0.027485855
6.91 20 -1.203 -2.1309
Low Speed Variable Span Wmg Thrust, +45/-20 stroke UTIAS, March 1996
Vel Attack Thmst Coeff Voltage Frequency Average T h s t T h t Error Drag Tare Tare Error Adjusted Thrust Adjusted Error
(m/s> (del31 O (v> (Hz) 0 O 0 0 0 (N>
Vel Attack Lift Coeff Voltage Frequency Average Lifi Lift Error Lift Tare Tare Error Adjusted Lift Adjusted Error
(ds> (deg) O (v> W) 0 0 0 O 0 0
6.87
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W) 0 (N>
Vel Attack Lift Coeff Voltage Frequency Average Lift Lift Error Lift Tare Tare Error Adjusted Lift Adjusted Error
(mJs) (de@ O 03 W) 0 0 (N> O 0 0
Low Speed High AR Wing Thnist, +45/-20 stroke m S , May 1996
1 1 1 I
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.ws> (de@ O 0 W) (N> 0 0 (N> 0 0
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UTIAS, May 1996
0
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0
20 -0.47 -0.833
lLow Speei High AR wing Lifi, +45/-20 stroke l UTIAS, May 1996
Attack Lifi Coeff Voltage Frequency Average Lifi Lift ~rrof Lift Tare Tare Error Adjusted Lifi Adjusted Error
(deg) O 03 (Hz) 0 N 0 0 N 0
k=
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High Speed Ordinary Wing Lifl, +30/-20 stroke UTIAS, March 1996
Vel Attack Lifl Coeff Voltage Frequency Average Lifl Lift Error Lifi Tare Tare Enor Adjusted Lift Adjusted Error
(m.1~) (dei31 O O ml N N N N N 0
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9.57 10 3.294 2.984
9.57 10 3.191 2.8909
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9.6 10 3.342 3.0278
9.6 10 3.357 3.0412
9.6 10 3.468 3.1418
9.6 10 3.401 3.0808
9.6 10 3.327 3.0143
9.6 10 3.767 3.413 9 4.3 3.65 1166667 0.058422075 0.1 10833 0.016526914 3.540333333 0.0607 14725
9.6 10 3.684 3.3378
9.6 10 3.605 3.2664
9.6 10 3.607 3.2682
9.6 10 3.612 3.2728
9.6 10 3.632 3.2905
9.6 10 4.025 3.6465 11 5 4.05 1666667 0.07865254 1 O. 1 10833 0.016526914 3.940833333 0.080370151
9.6 10 4.075 3.692
9.6 10 4.032 3.6529
9.6 10 3.936 3.5656
9.6 10 4.2 3.8047
9.6 10 4.042 3.6622
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Vel Attack Lift Coeff Voltage Frequency Average Lift Lift Error Lift Tare Tare Error Adjusted Lift Adjusted Error
(W (del31 O 0 (Hz) O (N> 0 0 0 0
Vel Attack Lifl Coeff Voltage Frequency Average Lifl Lifi Error Lifl Tare Tare Error Adjusted Lift Adjusted Error
(m4 (dei31 O 0 (Hz) ,O 0 0 (N> 0 N
9.66 30 -7.353 -6.6619 5 2 7.406333333 0.2603092 1.351833 0.039930843 6.0545[ 0.26335406
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(de131 O Pl W) 0 N 0 0 O (N>
9.56 10 -1.513 -1.3704 5 2.1 -1.513333333 0.012512216 -1.009 0.017851237 -0.504333333 0.0217995'
9.56 10 -1.526 -1.3828
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High Speed Variable Span Wing Thrust, +30/-20 stroke 1 1 UTIAS, March 1996
Vel Attack Thmst Coeff Voltage Frequency Average Thnist Thmst Error Drag Tare Tare Error Adjusted Thnist Adjusted I
(m/s> (de&?) (N O W) 0 0 0 0 0 N
9.56 20 -2.581 -2.3386 5 2.1 -2.584666667 0.014325579 -1.284833333 0.023255226 -1.299833333 0.0273 1
High Speed Variable Span Wing Thnist, +30/-20 stroke UTIAS, March 1996
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(ds> (del31 (N) (v> (Hz) 0 0 0 0 0 0
High Speed Variable Span Wing Lift, +30/-20 stroke UTIAS, March 1996
I
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(m/s> (deg) O O W) 0 0 N 0 (N> (N>
Speed Variable Span Wing Lit?, +30/-20stroke UTIAS, March 1996
Vel Attack Lifi Coeff Voltage Frequency Average Lift Lift Error Lift Tare Tare Error Adjusted Lin Adjusted Error
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Ws> (deg) O (v> 09 0 0 09 0 0
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Vel Attack Force Coeff Voltage Frequency Average k tk t Error Drag Tare Tare Error Adjusted Thmst Adjusted Error
.(&s> (de& (-1 03 W) 0 0 0'0 (N> (N> 0
9.66 O -0.304 -0.2688 13 4.5 -0.2615 0.044932357 -0.8115 0.010062306 -1.073 0.046045268
9.66 O -0.281 4.249
9.66 O -0.318 -0.2813
9.66 O -0.253
9.66 O -0.189
9.66 O -0.224
Kgh Speed High AR Wing Tfinist, +45/-20 stroke (UTIAS,May 1996
I l l I I I I I l
Vel Attack Thrust Coeff Voltage Frequency Average Thrust Thmt Error Drag Tare Tare Error Adjusted Thmst Adjusted Error
(m/s> 0 0 W) 09 ml (NI 0 (N>
High Speed High AR Wing Thrust, +45/-20 stroke UTIAS, May 1996
Vel Attack T h t Coeff Voltage Frequency Average T h t Thnist Error Drag Tare Tare Error Adjusted Thmst Adjusted Error
(ds) (W 09 0 W) 0 (N> (NI O\J> (N> (N>
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High Speed High AR Wing Thrust, +45/-20 stroke UTIAS, May 1996
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Frequency Average Thmst T h m t Error IDrag Tare 1 Tare Error l~diusted~hnist1 ~diustedError
9.7 -10 2.756 2.8918 13 4.5 -2.843833333 0.13 1835019 -0.16133 0.023292822 -2.6825 O. 133876913
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9.7 -10 2.635 3.1931
9.7 -10 3.057 3.0359
Figure 52 through to Figure 57 show the side, top and front views of the
RoboRaptor Mk. la and Mk.2. The fùselage interna1 support structure was built out of
plywood, with seven bulkheads of 1/8" and 1116" plywood al1 held in place by the main
structural members: a keel and spine of %" plywood. The keel is the component that the
ornithopter lands on, so it must be robust. Small hardwood gussets helped to brace the
bulkheads where they attached to the keel and spine. The bulkheads were lightened as
much as possible by drilling holes in them. This also allowed the free flow of air down
the fùselage, and the passage of wires and tubes between fuselage sections.
In the RoboRaptor Mk. la, a section at the very rear of the fuselage housed the
microservo actuating the rudder, a battery pack, and a 2-channel receiver. A 'floor' of
bluefoam insulation provided a flat area to mount the battery pack and receiver using
velcro strips. The microservo was attached to the rearmost (#7) 118" bulkhead with
screws. The receiver's antenna was routed through a hole in the 1116" #6 bulkhead
immediately fonvard, and into the graphitelepoxy tailboom. The antenna wire ran down
this tube and hung freely out the back of the ornithopter. In the RoboRaptor Mk.2, the
battery and receiver were attached to a small 1116" aluminum plate using velcro, and
positioned above the driveshafi between the #2 and #3 bulkheads. Extension wires
1/16" #6 bulkhead, and was attached by velcro to a bluefoam 'floor'. The &el line was
routed from the tank, through the 118" #5 bulkhead to which the motor was attached,
The Mk. 1a's engine was a .O74 CU. in. gIow-plug engine with a muffler and
throttle. In order to fit it into the fùselage with enough clearance to avoid the wings, the
exhaust manifold was rotated 90°,the muffler was mounted backwards, and the engine
mount was attached at a 24" angle. The drive shaft of the engine was modified to permit
during operation any resistance to the engine's rotation served to tighten this screw,
starting the motor against the resistance of compression caused the flywheel to Ioosen.
To solve this problem, an aluminium collar was epoxy'd between the flywheel and the
engine driveshafi, and two 2/56" screws were driven through the flywheel and the collar.
into the drive shaft. This solution permanently linked the flywheel and driveshafi. A
plastic six-bladed fan was fitted to the shafi of the flywheel to cool the engine during
operation. The gearbox was driven via a gear fitted to the end of the flywheel shaft.
The Mk. II's engine was a P.A.W. .O6 diesel, mounted at the same angle and
using the same engine mount. Tts flywheel disk had a knurled edge to provide the starter
wheel with better grip. The flywheel hub was designed 41nin longer than that of the
Mk. 1a to accommodate the larger engine drive shaft and to coinpensate for the diesel's
shorter length. The new flywheel was secured more simply than the old, using a 6-32
set-screw set in a dimple drilled into the engine's drive shafi. The fùel line was yellow
tygon tubing, which is resistant to diesel fùel. Similar tubing was used to conduct the
muffler exhaust to a hole in the bottom of the fiiselage shell, so as to direct the spray of
unburned &el outside the shell and away from the wings.
The gearbox was placed ahead of the engine, sandwiched between two 1116"
bulkheads (#4 and #3). It was a cordless screwdriver planetary gearbox with a 68: 1
reduction ratio; the same gearbox used on the test platform. The screwdriver hexagonal
attachment on the front was removed and repiaced with a 3/16" set-screw shaft coupling
to Save weight. Plywood rings held the circular gearbox steady, and removable
aluminium strips held the fonvard plywood ring in place, facilitating removai of the
entire gearbox assembly. The fonvard #3 bulkhead was reinforced with carbon strips
attached with cyanoacrylate to both sides. The gearbox was lubricated with moly-slip
From the shaft coupling, a 3/16" 0.d. steel drill shafi ran fonvard to the flapping-
mechanism through the 1/16" #2 bulkhead. Following damage sustained during a test
flight, the #2 bulkhead was rebuilt and reinforced with layers of 118" plywood around
the area of the drive shaft, and where the fibregIass root spars passed through it. A
bushing, made by drilling a 3116" hole down the centre of a 318" threaded shaft,
supported the drive shaft at this point. The 2 cm long section of threaded shaft was held
in place with 3/8" nuts on either side of the bulkhead. Originally, a hollow brass drive
shaft was used to Save weight, but it proved inadequate to sustain the large torque
exerted on the drivetrain. It was replaced with a solid steel rod, and dimples were
drilled into it to give the set-screws a better grip. The section of the keel between the
first and second bulkheads was later reinforced with a layer of 1/32" aluminium on either
An aluminium crank wheel was attached to the fonvard end of the steel shafi and
secured with a set-screw, The Mk. la's wheel used a 118" boit as a pin joint to link it to
the crank arm. The Mk.11'~crank wheel had a 6 mm long slot to allow a 5/32" brass
tube to slide freely back and forth in it. The tube acted as a bushing for a 1/8" screw
that passed through it. Nuts were used to hold the screw and bushing in position. A
fibre on either side was attached to the screw, and rotated at its opposite end about a
118" bolt with a 5/32" brass tube bushing. The bolt connected this end to the right-hand
acrylic wing pivot. The crank was attached at the correct points which gave a +45"/-24"
stroke angle.
Only one pivot was driven; the other was linked using two bundles of kevlar
thread tied to 2/56?' screws. This mechanism was analogous to that used for the test
platforrn, except that kevlar thread was used instead of steel strips. Originally, the
pivots were linked with gear teeth made from rubber timing belts, but the twisting of the
fùseiage under torque caused the teeth to skip. Larger gear teeth failed to solve the
problem. I decided to revert to the dual strip method, as this system mechanically links
the pivots and twisting bas no effect. The knots in the kevlar thread were secured with
small amounts of 5 minute epoxy, as cyanoacrylate glue caused the kevlar to becorne
brittle.
The wing spars were 3/16" fibreglass rods, with 7/32" brass tubing at the root
end to reinforce the area where the spars join the pivots. The spars fitted into holes
drilled in the acrylic pivots, and were held securely by 2/56" screws running through the
pivot and the spar. This was the same method used to attach the spars to the test
platform, except that the screws were mounted horizontally, not vertically. Two 3/16"
fibreglass root spars ran the length of the fuselage, acting as axles for the wing pivots
and attachment points for the root edge of the wing membrane. 3/16" rotary ball-
bearing sets, two to each pivot, were used to reduce friction as the wings rotated about
the axle. 1 tried birch dowels instead of fibreglass to Save weiçht, but they were unable
to withstand the torque and broke. The pivots were held in position by 311 6" set-screw
wheel collars, and similar collars prevented the root spars froin sliding out under load.
The longer wing spars for the second set of wings were sanded top and bottom to
produce a tapered profile in order to reduce the weight of the spars and the loading on
the drive mechanism. These spars also had a length of 118" fibreglass rod running
diagonally between the wing spar and the root spar, forming a triangle (See Figure 63).
The rod was attached to the wing spar with epoxy, reinforced with a balsa gusset and
wrapped with kevlar thread. 9/64" and 7/32" brass tubing was soldered together at a
45" angle to create a hinge at the root spar. The 118" rod slotted into the 9/64" tube,
while the 7/32" tube rotated about the root spar. The rod acted as a compression strut,
The drivetrain, fuel and radio components were designed to be removable from
the tùselage with a minimum of effort; the fuselage could be stripped down to its
plywood frame in under half an hour to repair and maintain the components.
membrane horizontal stabiliser. Both were attached t o a tail boom made from a length
of 318" graphite-epoxy kite spar tubing. The vertical tail was made from 3/32" balsa
with the grain mnning horizontally. 1cm wide balsa strips were glued cross-grain to the
mdder and fin to straighten and strengthen the sheet balsa. The rudder hinges and
control horn were commercially available radio-controlled aircraft parts. Piano wire was
used as the controi link between the microservo and the rudder horn. To firther
strengthen the joint between the vertical tail and the boom, a length of carbon fibre was
fastened along the leading edge of the fin with epoxy and two lengths wrapped around
The horizontal tail was a triangle of membrane Iield in place by two l/8"
fibreglass spars. The tail was hinged at its apex with a strip of 1 /32" aluminum, secured
with kevlar thread and epoxy and bent to the correct angle. A 118" bolt raised the tail to
give it an angle-of-attack that was variable depending on the length of the bolt. Finally,
the tail was tied down with thread just aft of the boIt to prevent it from pivoting under
load.
The outer streamlined shell of the ornithopter was made from three layers of
fibreglass, an innermost of 5 oz., with two 2 oz. top layers. I built up a male mold from
bluefoam insulation, using a series of 1/16" plywood bulkheads spaced along the length
of the mold as guides to maintain the correct shape. The foam was sanded to shape, the
gaps were filied with Poly-Filia, and the outside was covered in packing tape. The tape
was cut into small patches in order to conform to the compound curves of the mold.
Lastly, the mold was coated with PVA mold release agent.
The layers of fibreglass were impregnated with epoxy and laid over the mold.
Two sections were made in separate layups: a top and bottom half with some overlap
along the sides of the fùselage. After the epoxy had set, the two halves were placed in
an oven to cure for eight hours. The oven was made from sheets of bluefoam insulation
and heated by hot air supplied by a hair dryer. The curing teinperature was inaintained
at about 80°C by monitoring the teinperature with a therinometer. The halves of the
shell were trimmed to shape once they had cured, and holes were cut for the muffler,
engine needle valve, rudder control wire and wings. Further holes were cut to access
the engine glow plug and flywheel for startup. A small length of piano wire was used to
hold the engine throttle lever in the Fully open position. The rectangular access hole for
the flywheel was closed with a 'hatch' of fibreglass conforming to the fuselage shape and
butting up against two wooden tabs. A third tab protruded from the bottom of the
Seen fiom above, the fùselage appears pinched inwards where the wing
membranes are attached to the fuselage root spars. This shape allowed clearance for the
wings when they flap and was adopted based on experience with the test platform.
There, the streamiined shroud was so large, to accommodate the oversize wing pivots
and interna1 mechanics, that it constrained the wing membrane's movement and reduced
The nose of the ornithopter was made of bluefoam cut to shape using a hot wire
and a sanding block, and coated in epoxy to improve its resistance to damage. Two
leading-edge wing fairings were created from an inner layer of 5 oz. and an outer layer
of 2 oz. fiberglass using a balsa male mold. These were glued to the acrylic wing pivots
and provided a smooth taper to streamline the wing's leading edge where it joined the
fuselage.
-4 .- c
F r o n t View S i d a View
RoboRaptor M k l a
RoboRaptor M k l a
RoboRaptor M k l a
RoboRaptor M k l a Tai1
RoboRaptor M k l a Drivetrain
RoboRaptor M k 2 Tai1
RoboRaptor Mk2 Drivetrain
'* *
'* PARA.BAS - - - - DATA SAMPLING PROGRAM A PARALLEL BEAM BALANCE *
'* *
'* T.J.M. Nov 11/94 *
'* *
'* Programined by T. Macliacek to acquirc data for a singlc channcl *
'* parallel beain balancc. *
'***********************************************************************
DIM A%,(IOOO, 2)
DIM Avcs(2)
DIM Zero(2)
DIM Lt%(2)
DIM Dit!40(2)
DIM loads(2.2)
DIM coeff(2)
DIM Incoef(2. 2)
DIM Suiti(1000)
COMMON SHARED Lt%(). Di%(), Sum(). Aves(), A%(), scan%. vel, q, density. Batvolt. dcscrip$
COMMON SHARED loads(), Incoef(). Zero(). File$, Delay%. chan, attack. coeff(), s
CLS
5 PRINT
scan% = 1000
10 CALL zcros
PRlNT
INPUT "Would you like to tr&c anotlier zcro rcading @ln) ":Ans$
15 PRINT
IF s'% = 1 THEN
CALL Calibration
ELSEIF s%«= 2 THEN
SAMPLE DATA
PRINT
INPUT "Input thc local barometric pressure (inHg): ": prcss
PRTNT
P U T
q = betz * 249.098
CALL samplc(2)
IF Fileflag% = O THEN
Filcflag'X~= 1
CALL Datatodisk(2)
END IF
ELSE
PlUNT
CALL Appenddata(2)
END IF
END IF
SUB Appcnddata 0)
PRINT # 1, USING "##.## ###.# ###.### ##.####"; vcl; attack; loads(i. 0): cocff(i)
NEXT i
CLOSE #1
END SUB
SUB avcragcs
FOR i = O TO clian - I
Suiii(i) = O
FOR j = 1 TO scaii'X,
Suiii(i) = Sum(i) + A%(i. i)
NEXT j
END SUI3
SUB Calibration
PRINT
FOR j = 1 TO scan%
CALL inode4Q)
NEXT j
CALL averagcs
FOR i = O TO chan - 1
NEXT i
FOR i = O TO cl~aii- 1
END SUE?
SUI3 Datatodisk 0)
PRINT # 1.
P R N ï # 1.
FORi=OTOj
PRINT # 1. USING "##.## ###.# ###.### ##.####": vcl; attack; loads(i, 0 ) ; coeff(i)
NEXT i
CLOSE #1
END SUI3
Incocf(0, O) = 36.1033
Incocf(0, 1) = 0
Iiicoef(0, 2) = 0
1iicocf( 1 , 0) = 0
1 ncocf( 1. 1 ) =0
FOR i = O TO chan - 1
loadsc. i) =O
NEXT i
FOR i = O TO chan - 1
FOR j = O TO chan - 1
NEXT j
NEXT i
PRINT USlNG "##.## ###.# ###.### ##.####": vcl: aitack: loads(L. 0); coefT(L)
END SUB
SUB ModcO
Md% = O
Basadr?? = &H300
Flag% = O
IF Flag% 0O THEN PRINT "ERROR #": Flag%; "IN DAS8 INITIALIZATION (Modc O)"
END SUB
SUB Modc 1
Md% = 1
Lt%(O) = O
Lt%(l) = chan - 1
Flag% = O
IF Flag% <> O THEN PRINT "ERROR #": Flag%: "IN DAS8 INITIALIZATION (Modc 1)"
END SUB
SUB Modc 19
Md%= 19
Lt%(O) = 14
Flag% = O
IF Flag% 0O THEN PRINT "ERROR #"; Flag%; "IN DAS8 INITIALIZATION (Modc 19)"
END SUB
SUB iriodc4 0)
Md% = 4
FlagYh= O
FORi=OTOchan- 1
FOR k = 1 TO Delay%
NEXT k
IF Flag% <> O THEN PRiNT "ERROR#"; Flag%: "IN DASS SAMPLING (Mode 4)"
A%(j. i) = Di%(i)
NEXT i
END SUB
FORi=OTOk
FOR j = 1 TO scan%
CALL inodc4Ü)
NEXT j
C ALL avcragcs
CALL influcncc(i)
NEXT i
END SUB
SUB zeros
FOR j = 1 TO scan%
CALL mode40)
NEXT j
CALL averages
FOR i = O TO chan - 1
Zero(i) = Aves(i)
NEXT i
PRINT
FOR i = O TO chan - 1
NEXT i
END SUB
A IMAGE. lnc
APPLIEO -
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