A Morphing-Designed Hexarotor Prototype combining Practical Resilience and Efficiency

Infrastructure maintenance, contact-based inspection, and emergency response can benefit from aerial vehicles that act as a flying human hand with extreme maneuverability, manipulation, and resiliency (MMR): maneuverability to fly in arbitrary orientations to reach remote and tight locations; manipulation to point sensors, turn valves, and press tools at arbitrary orientations; resiliency to maintain accurate motion and force control despite disturbances from arbitrary directions, such as wind, ground effects, and friction. Realizing MMR on aerial vehicles requires not only omnidirectional flight; it also requires (I) vectoring of maximum thrust in any direction, to maximize capacity for contact-force application and disturbance rejection, (II) global stability, to enable control over any orientation/position, and (III) compact, standard designs that build upon platforms such as quadrotors to inherit technological know-how. No current aerial vehicle simultaneously enables I--III, due to structural and control limitations that constrain actuation. We present MorphQuad: a morphable quadrotor that enjoys MMR. Key to our approach is a hardware and control co-design: on hardware, we independently articulate each of the four rotor systems via two-axis gimbals; on control, we introduce globally-stable control, and energy-optimal thrust allocation that permits inter-rotor thrust cancellations only to avoid downwash interference and gimbal lock. With fully-onboard autonomy, MorphQuad demonstrates multi-revolution rotation while translating or hovering, for pipe inspection and target tracking (maneuverability); valve turning, perching, and object pressing and pushing with human-level strengths (manipulation); and wind rejection from any direction, even directed to a single rotor, and push-pull recovery (resiliency).

Abrupt total rotor failures can invalidate nominal allocation despite remaining wrench capability. This paper develops an allocator-layer passive fault-tolerant control (AL-PFTC) scheme for overactuated vector-thrust aerial vehicles. Analysis of convexified attainable force and torque spaces at horizontal hover compares biaxial- and uniaxial-tilt configurations and screens fault cases using prescribed reserve thresholds. Instantaneous wrench loss relative to these reserves characterizes the initial redistribution burden. AL-PFTC adapts the allocation matrix using a virtual error derived from filtered wrench commands and an onboard external wrench estimate, with adaptive parameter bounds constructed from right inverses. Joint analysis including estimator residuals and filter dynamics establishes local uniform ultimate boundedness for position and attitude regulation under the stated conditions. Controller-layer passive fault-tolerant control (CL-PFTC) provides a reference with nominal allocation and observer compensation. Both share a nominal tracking baseline and run at 600 Hz on an STM32H753 without explicit fault identification, fault-mode switching, or online optimization. Comparisons show that AL-PFTC satisfies the recovery criterion in more tested hovering cases than CL-PFTC. Additional experiments using only onboard sensing, including indoor tracking under wind disturbance, outdoor tracking under wind and low-temperature conditions, narrow-frame traversal, and contact-based aerial writing, further validate the robustness of AL-PFTC in complex operational environments.

Aerial manipulation with multirotor platforms enables physical interaction in complex environments, but rotor-induced airflow remains a critical limitation for tasks involving airflow-sensitive targets or surroundings. This paper presents an optimization-based design framework for modular aerial manipulators that jointly considers task wrench feasibility, end-effector placement, and airflow exposure constraints. We first introduce a novel categorization of target-side airflow tolerance and formulate the corresponding exposure requirements as geometric constraints. To efficiently model rotor-induced airflow, we introduce a compact cone-sphere envelope that approximates the spreading structure of a quadrotor's airflow while preserving computational tractability for optimization. Building on this formulation, we propose a reconfiguration optimization that adapts a modular aerial manipulator to diverse task wrench requirements while enforcing both target-side airflow exposure and intra-platform airflow interference constraints. Unlike prior designs that assume a fixed end-effector location, the proposed framework optimizes the end-effector placement together with the platform configuration. Scalability experiments and ablation studies validate the effectiveness of the proposed framework.