Design optimization and robustness analysis of rigid-link flapping mechanisms

Tailless flapping-wing micro-aerial vehicles (FWMAVs) mimic the impressive flight performance of hummingbirds, utilising unsteady aerodynamic effects. However, existing designs are still limited and purpose-built with a restricted flight envelope and poor endurance. We therefore propose an adaptable tiltwing framework enabling bioinspired aerial robots to switch between hovering flight, high-speed directional flight, and energy-efficient gliding flight. The proposed framework utilises thrust vectoring with a wide actuation range via two fully independent propulsion units, each flapping a single wing, for effective control and enhanced manoeuvrability. For this, we developed a hybrid Scotch-yoke-based flapping mechanism that ensures a symmetric motion profile with a modular design guaranteeing an arbitrarily wide flapping angle to exploit the lift-enhancing clap-and-fling effect. Additionally, we implemented a passive wing-rotation mechanism, which, in combination with our dual-wing thrust-vectoring approach, allows unprecedented wing-design freedom, unlocking potential for precise optimisation. A contactless leading-edge tracking sensor provides accurate feedback on the wing's orientation and, in the gliding mode, enables dihedral-angle control, augmenting the active wing-pitch control. Extensive testing of a propulsion unit was conducted with a six-axis force/torque sensor, demonstrating the flapping mechanism's performance while optimising transmission efficiency and the passive wing-pitch mechanism. At full throttle, the average lift force generated by a single wing, flapping with a 188° amplitude, was 21.1 gf for a small 3.1 g 1S BLDC motor. Additional tests covering the full range of the wide-angle tilting capability showed an effective thrust-vectoring control architecture with a linear and symmetric response curve of the moments generated.

Aerobat is a bat-inspired flapping-wing robot with a wing gait generate by the computational structure, a planar linkage of carbon fiber links driven by a single motor. This design minimizes weight but couples both wings to a shared input motor, eliminating independent thrust control and preventing asymmetric maneuvers. This thesis investigates thrust regulation by modifying the effective length of the first radius link $R_1$ in the computational structure. Static experiments using FDM-printed $R_1$ links at three lengths (28.58, 29.33, and 30.08 mm) across 3,4, and 5 Hz flapping frequencies demonstrated that a 1.5 mm length increase produced a 37% increase in peak lift force and shifted peak force timing within the downstroke. An additional experiment using a string-actuated regulator mechanism was performed. Further actuation methods were evaluated: sub-gram micro-servo and piezoelectric slip-stick. After both the string-tension and micro-servo actuation methods failed due to structural member compliance and motor fragility respectively, a TULA-50 piezoelectric slip-stick actuator was selected. Multiple force-amplifying mechanisms were prototyped, resulting in a direct-drive variable-length mechanism. This final mechanism was demonstrated in a preliminary bench-top test, though insufficient force output prevented dynamic testing during flapping. This work establishes linkage-length modulation via embedded slip-stick actuation as a viable approach to independent wing thrust control.

Flapping-wing aerial vehicles (FWAVs) demonstrate remarkable agility but face substantial autonomy challenges due to their high sensitivity to aerodynamic disturbances and limited sensor payload capacity. Current simulation platforms typically rely on oversimplified laminar flow assumptions and idealized sensor models, failing to capture the complex turbulence patterns and perceptual limitations encountered in real-world operation. This simulation-to-reality discrepancy significantly impedes the development of robust autonomy systems for FWAVs. We introduce FWAV-Sim, a high-fidelity Unity-based simulation framework that integrates: (1) a composite aerodynamic model combining quasi-steady blade-element theory with bluff-body drag effects, (2) spatiotemporally correlated turbulence generation through fractal noise synthesis, and (3) realistic sensor simulation including noisy IMU measurements, LiDAR point clouds, and RGB camera feeds. Our platform enables scalable generation of synchronized datasets containing ground-truth vehicle states, aerodynamic forces, turbulent wind fields, and multi-modal sensor streams. Experimental validation demonstrates that autonomy pipelines (including both controllers and perception systems) developed in FWAV-Sim exhibit significantly improved simulation capability, thereby advancing the outstanding performance in simulation-based development for flapping-wing aerial systems.