Self-excited actuation enables adaptive and resilient flapping-wing flight

Sub-gram flapping-wing flying insect robots (FIRs) are challenging to model because of mechanical complexity in their wings, unsteady aerodynamic flow, and the difficulty of making precise measurements at a small scale. Coupling effects between roll and pitch torque actuation have not previously been measured because a two-axis sensor that is sensitive enough has not been realized. To address this shortcoming, we introduce a microfabricated gimbal design capable of precisely and simultaneously measuring roll and pitch torques as well as thrust. We then used it to measure the extent to which a pitch torque command affects roll torque and vice versa on a 180 mg piezo-actuated flapping-wing flying platform. Our results show a high coefficient of determination in the linear regression for both pitch (0.95) and roll (0.98) and low cross-correlation coefficients (-0.001 and -0.085, respectively) across the full range of simultaneous torque commands, indicating negligible cross-axis coupling. Similarly, thrust force deviates by a maximum of only 5.8% from the mean thrust value. These results validate the assumption that pitch and toll can be considered independently in control and will inform future models of how inputs affect the aerodynamics of resonant flapping-wing systems.

Due to the system's scale and complex fabrication, the model describing the dynamics of a flapping-wing insect-scale aerial robot is subject to parameter uncertainty; for example, in the inertia matrix and the actuator mapping of the flier. Furthermore, due to its low inertia, this type of robot is greatly affected by stochastic and systematic disturbances during flight, including power-wire tension, gusts, and undesired aerodynamic forces produced by wing misalignment. Therefore, the high-performance execution of complex maneuvers at the subdecigram scale requires the robot to adapt its behavior to counteract disturbances and model uncertainty. Toward this objective, we introduce a model-reference adaptive control (MRAC) architecture for high-performance position control of flapping-wing robotic insects that can be modeled as rigid bodies in the three-dimensional (3D) space. In addition, we demonstrate how the implementation of a hybrid multiplicative extended Kálmán filter for estimating current and desired angular velocities during flight significantly dampens attitude vibrations, especially along the roll and pitch degrees of freedom (DOFs), and also improves flight performance. To show the suitability, functionality, and high performance of the proposed approach, we conducted real-time hovering and trajectory-tracking 6-DOF flight control experiments with a 95-mg insect-scale aerial robot.

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.