AVDASI 2 · Avionics & Mechanisms

Avionics & Mechanisms

AVDASI 2 · Introduction

Dr. Steve Bullock

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Today

Who we are, and where things happen

Part 1 — Avionics
What it does in your aircraft · what the requirements ask for · integration · the workshops, and how to get ready

Part 2 — Mechanisms
What has to move · the design task · where it meets avionics · the sessions



Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Who's who


Steve Bullock
Avionics
Mechanisms


George Burns
Avionics


Tim Ward
Avionics


Robin Carter
Avionics


Mark Graham
Mechanisms


Vince Maes
Mechanisms

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Where things happen

Space Room What for
Stack Room QB F.05 Avionics workshops, Friday mornings
Avionics lab QB M.003 Kit issue and return, supervised tool use
Design Suite QB 1.59 Mechanisms sessions, Thursdays
The Hangar QB L.080 Main lab, open access
Here QB PLT Pugsley Lecture Theatre

Room numbers link to the map. All of these are in Queens Building.

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

The model is only as good as what moves it


Last year's fuselage in the 7×5 tunnel


Photos: Ross Dewar

  • Your model has control surfaces, and something has to move them repeatably
  • Your test campaign needs data — measured, time-stamped, logged
  • Your aerodynamicists need the angle you asked for, not the one you got
  • Avionics and mechanisms turn foam and carbon into an instrumented test article
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Flight-grade kit, off-design

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

What the spec asks of avionics

"Aircraft control systems shall comprise a flight control system (FCS), radio control system (RCS), telemetry system (TMS), and ground control station (GCS), with associated power, wiring harnesses, antennae etc."

Provided to you

  • The flight controller
  • The radio control system
  • The telemetry system
  • Servos, from a set list

Yours to design

  • Power distribution and harnesses
  • Mounting and installation
  • Logging, calibration, evidence
  • Everything that connects them
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

What it has to do

  • Every surface — elevator, rudder, aileron, flap — commandable from both the radio and the telemetry link, to specific angles
  • PID stability augmentation in pitch, tuned on the provided flight controller, switchable on and off
  • Log flight data: 5 Hz minimum, 20 Hz preferred — pitch angle and rate, servo demand, and whatever else your Company needs
  • Everything removable, fixed with mechanical fasteners, for maintenance and recycling
  • Nothing above 15 V, anywhere on or connected to the aircraft
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

What "done" looks like — for now

"A bench-top prototype of full FCS, RCS, TMS, GCS, and associated systems shall be demonstrated working at Gate 2a."

  • The step-by-step guide takes you there: kit, autopilot, telemetry, power, servos, sensors, logging
  • Mechanism prototypes are demonstrated with servo testers, not the flight controller
  • This is done for this teaching block only — integration comes next. A bench that works is not an aircraft that works
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Avionics depends on integration

With You need to agree
Aerodynamics Surface sizes and deflections, and so hinge moments, and so servo torque
Mechanisms Where the boundary sits: they own torque, servo choice and kinematics; you supply the PWM
Structures Mounting, access, cable routes, mass
Test Power, comms, what's logged, how it's handed over
  • Avionics is not only an integration job, but it depends on integration more than most
  • This table is a starting point, not the answer — read the spec for your own remit, then agree each interface with the division opposite
  • Interfaces agreed late are the ones that fail
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Interfaces to pin down early

  • Torque and travel: what the surface needs, and what the servo gives with margin when it is stalled — servo stall, not aerodynamic stall
  • Power: what each component draws, at what voltage, from which supply
  • Connectors and cables: which plug, which route, and who crimps it
  • Data: what's logged, at what rate, in what units, and who uses it
  • Command: who moves which surface in the tunnel, and how you stop it
  • Most of these depend on other teams' work that hasn't happened yet. Start with a rough number — theirs, or your own gut — and track what has to be firmed up, and by when
  • This list is not exhaustive. Yours will be longer
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

The system on the bench

center

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Avionics workshops

Week When Where Focus
1 Friday, 09:00–11:00 Stack Room + M.003 Kit issue; Cube, Mission Planner, telemetry, power
2 Friday, 09:00–11:00 Stack Room Servos and Lua scripting
4 Friday, 09:00–11:00 Stack Room Sensors: ADC and I²C
5 Friday, 09:00–11:00 Stack Room To be confirmed

No session in week 3 — Company Day. Full schedule on SharePoint.

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Friday: kit day

  1. 09:00 A short taught intro in the Stack Room: the kit, and the requirements in more depth
  2. From 09:30 Groups go up to M.003, one at a time, to collect a kit
  3. While you wait Read the guide's first pages (Kit, Cube), with no hardware yet
  4. Kit in hand Work through the guide to the Friday checkpoint
  5. To finish How not to break each component

Friday checkpoint: Cube on Plane firmware, buzzer quiet, connected over Wi-Fi, running on bench power.

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Getting ready

  • Install Mission Planner on a Windows laptop before Friday — one working laptop per group

  • Bring that laptop, charged

  • Read the guide's index, Kit and Cube pages

  • Everything you need: avdasi2.github.io → Avionics → Getting ready

  • The Cube setup, scripts and guidance are being revised this month — a more robust version is coming, with a one-step settings file

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Part 2: Mechanisms

From servo to surface

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

What mechanisms have to deliver

Every moving surface needs a mechanism designed, built and proved:

  • Flap — plain, slotted or Fowler, 0° to 30°

  • Aileron, elevator, rudder — four-bar linkages, ±40° to ±45°

  • Leading edge device — droop or slat, starboard wing

  • Landing gear — deployable, behind a door

  • Each holds its angle under aerodynamic load, to a stated tolerance, within a stated time

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

The design task


The parts of a 4-bar linkage


A flap mechanism drawn and simulated in the Linkage app

  • Kinematics: four-bar linkages, mobility, function generation
  • Drawn and checked in the Linkage app
  • Then the real world: bearings, slop, backlash, friction
  • Materials, failure modes, and taking it apart again
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Where mechanisms meets avionics


Standard servos — HJ and Parallax. The kit also has blue micro servos


Inside one: motor, gear train, board — and a pot reading the output shaft


Proved on a servo tester before the flight controller

  • The boundary is the servo cable
  • Mechanisms own torque, servo selection, kinematics — and sensor integration
  • Avionics own the PWM, servo rail power, commanding angles, logging
  • Sensor selection is joint: readable as well as mountable
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Learn from what broke last year


Actuator cable-tied and glued to the false rear spar


Weak linkages, no washers, nothing to reduce friction


Threaded rod as a pivot, into an oversize hole and into the foam

  • Start simple, prototype early, design for disassembly
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Mechanisms sessions

Week When Where
3 Thu, 11:00–13:00 QB 1.59 Design Suite
4 Thu, 11:00–13:00 QB 1.59 Design Suite
5 Thu, 11:00–13:00 QB 1.59 Design Suite

Install the Linkage app before week 3 — Windows only; the macOS version is in early beta.

Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Mechanisms — design realisation

  • From kinematics to practical geometry
  • Transferring torque and motion
  • Design of pivots and joints
  • Standard parts and their uses
  • Precision machining and metrology
  • Functional tolerancing and tolerance analysis
  • Examples and non-examples
Dr. Steve Bullock · Introduction
AVDASI 2 · Avionics & Mechanisms

Questions

Avionics: Friday, 09:00, Stack Room

Mechanisms: week 3

Dr. Steve Bullock · Introduction

Full cohort, 1.40 Pugsley, 12:00-13:00. HARD STOP 12:50. FDAC control lecture 1 is 13:00-15:00 in this room, and the TSRs set the Quanser rig up during this hour. 25 minutes each half. (That FDAC slot is two 50-minute lectures with a break, not one 110-minute block, so if the rig setup needs longer there is a second break inside it to borrow from. Steve's call, and not a reason to plan on overrunning here.) Top-level bullets are fragmented - they appear one at a time on a click.

CHECK BEFORE TUESDAY: the four supplied photographs were assigned in the order they were sent - Burns, Ward, Graham, Maes. Swap the files in docs/assets/people/ if any of them is wrong. Robin Carter starts his PhD on 1 Oct and has flown these autopilots on the MSc Aerial Robotics project - worth saying so when you introduce him.

MazeMap share links, also kept in teaching/rooms.md so other units can reuse them. The Hangar (L.080) is in Queens Building too.

Video starts at 23s, muted. In the PDF this is a still image linked to the video, because Marp's PDF export cannot carry an iframe. The Cube Orange+ runs ArduPilot and is the Flight Lab's standard research autopilot - flown for volcano monitoring, conservation and search and rescue. In AVDASI 2 it is bolted into a wind tunnel with no GPS, and you command surfaces directly. That is deliberately off-design: much of the avionics work is getting a flight controller to behave usefully on the ground.

Requirements Spec section 2.2, Electronics. Point at the word "shall": this is a customer document, not advice. Almost none of the hardware is a choice, and almost all of the engineering is in what joins it together.

Sections 2.2, 2.3, 2.4, 3.3 and 4.4. The logging rate is the one students underestimate: it rules out the slow-and-simple approaches.

Section 2.2 for the gate, 2.3 and 2.4 for the servo-tester route. Say plainly that TB1 ends with two halves that each work on a bench, and that putting them together is the harder job which starts in TB2 - that is the thing groups leave too late.

Servo stall means the servo is driving against a stop or a jam and drawing its maximum current - amps, from a rail sized for milliamps. Nothing to do with the wing stalling, and the double meaning catches people every year.

Handover point. Steve on theory and design tools; Mark and Vince on implementation. Sessions start in week 3.

Drawing is DRG A2 from the requirements spec. Tolerances: 2 degrees for elevator and rudder, 5 for flap and aileron.

The cutaway: demand in on the signal wire, the pot measures the output angle, the board drives the motor until the two agree. The loop is inside the servo - which is why the cable, not the shaft, is where we draw the interface. Photo credits: standard servos by Kborer (public domain); servo internals by Jstapko, CC BY-SA 3.0; micro servo by Suyash Dwivedi, CC BY-SA 4.0 - all from Wikimedia Commons. The tester is drawn. No openly licensed photograph of an HJ or Parallax servo, or of a tester, exists - the tester is drawn. A lab photograph would be better than both.

Worth saying out loud: a hobby servo is itself electromechanical, with its own closed loop inside - a potentiometer on the output shaft, compared against the commanded pulse width, driving the motor until the error is zero. So the real interface arguably sits *inside* the servo, and the cable is just where we agreed to draw the line. Every interface is a choice like that.

TODO(Steve): session content and who leads each - to be confirmed with Mark and Vince.

Mark delivers this one. Seven clicks, one per topic, in the order of his own slide: kinematics, torque and motion, pivots and joints, standard parts, machining and metrology, tolerancing, then the examples. The torque and motion sketch is redrawn from Mark's original: a flap carried on a support at each end, driven from one end only, so the drive has to reach across the whole span. The frowning face is his. Source: Mark's "Mechanisms - Design realisation" slide, September 2026.