Acoustic Signature Optimisation for Bioinspired Flapping-Wing Micro Aerial Vehicles

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.

Rigid link flapping mechanisms remain the most practical choice for flapping wing micro-aerial vehicles (MAVs) to carry useful payloads and onboard batteries for free flight due to their long-term durability and reliability. However, MAVs with these mechanisms require significant weight reduction to achieve high agility and maneuverability. One approach involves using single-DOF planar rigid linkages, which are rarely optimized dimensionally for high lift and low power, considering their sweeping kinematics and the unsteady aerodynamic effects. We integrated a mechanism simulator based on a quasistatic nonlinear finite element method with an unsteady vortex lattice method-based aerodynamic analysis tool within an optimization routine. We optimized three different mechanism topologies from the literature. Significant power savings were observed up to 34% in some cases, due to increased amplitude and higher lift coefficients resulting from optimized asymmetric sweeping velocity profiles. We also conducted a robustness analysis to quantify performance sensitivity to manufacturing tolerances. It provided a trade-off between performance and reliability and revealed the need for tight manufacturing tolerances and careful material selection. Finally, the analysis helped select the best mechanism topology, as we observed significant variation in sensitivity to manufacturing tolerances and peak input torque values across different topologies for a given design lift value. The presented unified computational tool can find application in flapping mechanism topology optimization, as it can simulate any generic single-DOF planar rigid linkage without supplying kinematics manually.

Spatial single-loop mechanisms such as Bennett linkages offer a unique combination of one-degree-of-freedom actuation and nontrivial spatial trajectories, making them attractive for lightweight bio-inspired robotic design. However, although they appear simple and elegant, the geometric task-based synthesis is rather complicated and often avoided in engineering tasks due to the mathematical complexity involved. This paper presents a bird-inspired flapping-wing mechanism built from two coupled spatial four-bars, driven by a single motor. One linkage is actuated to generate the desired spatial sweeping stroke, while the serially coupled linkage remains unactuated and passively switches between extended and folded wing configurations over the stroke cycle. We introduce a simplified kinematic methodology for constructing Bennett linkages from quadrilaterals that contain a desired surface area and further leverage mechanically induced passive state switching. This architecture realizes a coordinated sweep-and-fold wing motion with a single actuation input, reducing weight and control complexity. A 3D-printed prototype is assembled and tested, demonstrating the intended spatial stroke and passive folding behavior.