1 hour fly on foam board plane

by Pedro Albuquerque | December 13, 2015 | (11) Posted in Challenges

My name is Pedro Albuquerque and I live in Lisbon - Portugal.

A year has gone since I started reading Flitetest forum and building it's planes (swapables).

You have really taught me a lote and allowed me to evolve with a very limited budget. Thak you so much for your share and inspiration.

After bilding a few of FT models and crashing my Bix2 (my first plane), I decided it was time to build one acording to my specifications.

The Pelican was born 2 weeks ago, based on FT Guinea Pig, and it revealed to be exactly what I expected.

Hope Peter does not get upset with this renaming. Its a big and heavy bird, yet tremendously versatile.

After my first fly with the tis plane with a 5000mAH batery, my budyes challenged me to have it fly for at least one hour.

One of them even offered a 10000mAH batery to try it.

I first thoughted it could fly with this big batery, its 10400mAH 4S with over 950gr .

So I accepted the challenge and they all brought their chair to assist the show

 

The flying weighwas 2.2Kg

As a twin engine  it has lots of engine power and an incredible lift power that allow for FPV gear (my passion), and heavy battery load for long fly.

I have made the body thinner, with an upper deck for Controller and FPV gear, an adjustable batery tray that allow CG adjustment with and without FPV gear and many batery configurations, and finaly the wing is split in two for easy transportation and storage.

Peter, your design can fly with at least 2.2Kg, and that its hardly the limit.

fly started at 12:01:27 , almost lunch time,but never realy beliebved it woud fly 1 hour

The plane was equiped with and APM 2.5 with Arduplane 3.4 installed.

So I had some degree of freedom not only to fly bit to monitor the fl, excepted that I din not install the power sensor, so no batery voltage or current consuption. For that I only had a batery alarm set for 3.6V

 

For the first minutes we all standed loking at it, and I made some tests on autopilot funcions like stabelized fly and RTL were when plane arrives the launch point it starts doing circles.

It worked just fine, so I left it runnig RTL mode most of the time

 

Even though we have brought chairs to seat, we could not keep looing to the plane the hole time.

After about 16:00 minutes flying some one shouted " the plane is flying away!"

It was a panic moment.

I even had the remote control away from me as I was assiting one of my friends with his plane. 

It was a short moment as the plane regained its course again arround Home position.

 

half-hour later I almost forgot I had a plane in the air.

Its a very looong time.

All the sudden my radio started saying "batery low".

It was time to test the radio failsafe function.

I sitched off the radio to replace bateries and it was fine. Plane remained on its RTL mode. Perfect

 

 

It was lunch time and the seamed that the batery was endeless.

We staryed doughting the batery alarm was working.but the plane was still very energetic,

 

61min after take off finally the alarm fired. Mission acomplished 1 hour fly!!!

There was still more than enough energy for a perfect landing

 

 

As the fly took so long, I had time to imagine new chanladges, and they became real imediatly, but that is theme for my next post.

 Thank you FT crew and all the comunity, you have all been an inspiration to me through all your wonderful videos .

 

Pedro Albuqueque (PA)

COMMENTS

The-One-Who-Never-Crashes on December 25, 2015
Sweet design!
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Pedro Albuquerque on December 27, 2015
Yes in deed "The-one..."
I have just made some minor variation to the original design to adjust for its new funtion, and renamed it as it proved to be so capable of carrying that much load.

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PeterGregory on December 25, 2015
Really great, congrats. Good name since it was carrying such a huge payload, i.e. the weight of the battery. Amazing you'all are doing with a few $1 sheets of foam.
Now waiting for your next creation.
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Pedro Albuquerque on December 27, 2015
Thanks PeterGregory , this is a base platform for some experiment I have in mind that demand some lift power.
They are already on the bench. Soon there will be another article I believe.

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Plattenwerk on January 2, 2016
Could you give details how you managed to fit the wing in two?
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Pedro Albuquerque on January 3, 2016
Hello Platternwerk for the moment I don't have good fotos to details the wing,but as sson as I can I'll try to add that detail. Meanwhile here is how (in words :) ).

Just picture the wing section.
I used a 8mm carbon tube as spar reinforcement.
I feetted it inside the foamboard spar. The foaboard spar has a U share , right?
so I cutted a few stripes of foam board to fill the inside of the U shape. It would become a block of foamboard, yet I cutted the middle layer 8mm narrower, so the carbon spar could fit.


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Plattenwerk on January 3, 2016
Thnx for the quick info. So you use only one spar - sounds like it causes only little weight penalty? For netter snug fit I would try square carbon tube... on the other hand round tube takes probably more forces. Especially if you pull out of a dive.
Does the wiring need some mods?
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Pedro Albuquerque on January 3, 2016
I used round asit was that I had at hand.
I used an icecream stick to align the two wings, is making any force except to align the wing, but what actualiy keeps them in place are the ruber bands against the fuselage.

Concerning cable I had in mibd that I want to take them apartso the power cabe have a Y connector, and also the control cabes both for the ESC and for the aileron servos.
So they all break apart.
But have in mind that by doing this I'm adding more failure points, so this is something I have to double check every time I fly.


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Lines on December 26, 2015
Nice! i believe you could gain a lot of flight time if you were to simplify the body, shrink it down to reduce the amount of air pushing on the frame. try transforming it from a guinea pig style plane to a bit of a slimmer design, the large body frame near the tail of the design is absolutely useless. Overall, i believe you can reduce the plane's weight by around half a kg, and gain around 20 mins of flight time.
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Pedro Albuquerque on December 27, 2015
Thanks Lines for your comment, I will certaintly take that in consideration in my next builds.

I have already slimmed quite a bit the original design to reduce the exposed area. Still need some space there for the next evolution. (i'll do my best to make an article on that too)
This load test proved I can do some abuse on the equipment I can carry, but fly time/eficency will always be a concern.
The foam board plane without batery or FPV gear weighs about 1200gr and part of that is due to wing reinforcement to allow it to break in two for transportation.
Still not sure if the wing is strong enough to resist the stress of assembling and desassembling and still carry 950gr of batery/fpv payload.
I may come to a nicer design for the wings to keep them detachable, strong and reduce weigh.

My biggest surprise was that each motor is just consuming 5A (average for 1 hour)
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Lines on December 27, 2015
That's an immense amount of weight to carry around. the battery can be a lot lighter, of course that would reduce flight time but if you do your math right you can find the optimal weight for the battery versus the efficiency of the plane. more weight just pulls it down faster, while provides more power for a longer time. At some point the weight of the battery will outweigh the actual gain of energy, so stuffing in a bigger battery is not always the solution to a longer flight time. the more the weight the more the motors need to work to keep the craft up in the air. try to find a battery that is not only lighter than your original battery (950 g) but also reduces your weight so greatly that you can keep your plane in an extremely slow glide. Also, to reduce power consumption, add little tips to the ends of the wings to reduce the distortion of air around the wing. it also reduces the need for ailerons quite a lot, as it helps correct the plane to a horizontal position. check out my plane, I take into consideration all these factors when constructing, and found ridiculous ways to reduce weight and distortion around the wing.
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hman123467 on February 18, 2018
Did you use the power pack C for it? or some different motors? will definitely be trying this!
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Pedro Albuquerque on February 18, 2018
Hi hman123467, I am using some motors from HK NTM2830 900KV with a 4S cell bakery.
O both some for a quad build and as I burned one of them I got another 4 used ones. They are not bad, bot not good either :)


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1 hour fly on foam board plane