Author Topic: Inspire 1 Build Documentation  (Read 4535 times)

Offline lunarwukong

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Inspire 1 Build Documentation
« on: March 17, 2017, 05:39:31 PM »
Hello everyone. I'm an 18 year old programmer from NYC. After reading through a few of the threads on this forum I have decided to build my own inspire 1 clone. I am hoping to create an aerial camera comparable to a genuine mavic or phantom. So far I have run into problems at every turn, but that has made the project much more fun! I am going to format this thread in such a way that it is a step-by-step tutorial for making the completed drone, from 3D printing to electronics. And I will also be documenting any issues I run into so future builders can have less of a hard time than i'm having.
« Last Edit: March 21, 2017, 05:38:17 PM by lunarwukong »

Offline lunarwukong

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Re: Inspire 1 Build Documentation
« Reply #1 on: March 17, 2017, 06:08:57 PM »
3D Printing Specs:

Monoprice Maker Select V1 (No Mods)

  • Black PETG Filament
  • 50% Infill Density
  • 235-240 Temp
  • 0.2 MM Layer Height



Offline lunarwukong

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Re: Inspire 1 Build Documentation
« Reply #2 on: March 17, 2017, 07:16:38 PM »
As soon as I started printing the parts I noticed my printer started making a really loud grinding noise. After looking into it I found out that all three of my Y-Axis bearings were completely destroyed. The bearings Monoprice ships their printers with are really short and tend to wear out quickly, so if you have a printer from them I would definitely recommend switching them out.

I ordered 2 sets of LM8LUU 45mm bearings from amazon for around $10. Not only do their ride a lot better, but the longer length makes them less prone to misalignment and grinding.

The new bearings vs the old bearings
http://i.imgur.com/JVgyvHT.jpg

Once I got them I noticed they didn't fit into the metal housing very well because they were so long. There was a huge gap between the C ring indents and the metal housing itself so the bearing would not lock into place. To solve this problem I placed a rubber plumbing ring in between the C ring and the metal housing on one side of the bearing. This ended up filling the gap and made the bearing stay firmly in place. In case anyone was wondering, i used 5'8 Outer C rings, and 11'16 Rubber pluming rings (or "o" rings).

Rubber O Ring on one side, C Rings on both sides
http://imgur.com/Ng1T04j

I had to make a special concession for one of the bearings. On the MakerSelect, the back-left bearing housing also serves as the surface that triggers the Y-Axis endstop. So in order to prevent the endstop from being triggered prematurely, the side of the bearing facing it could not stick out, it had to be completely flush with the metal housing. Since this also meant that one of the C ring indents would not be accessible, and thus wouldn't hold the bearing into place, I used superglue instead.

Superglue used to hold the bearing facing the endstop into place
http://imgur.com/7i3kVmh

After making all the changes, the bottom of my printer looked like this.
http://imgur.com/RCWOpeN

Offline Bioethical

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Re: Inspire 1 Build Documentation
« Reply #3 on: March 18, 2017, 01:29:21 AM »
Pretty cool solution, there are no limits for the inventive. If you saw one of my two home made 3D printers, couldn't believe that I  used two pieces of metal found while walking on the street to attach the cooling fan of the extruder.

Offline lunarwukong

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Re: Inspire 1 Build Documentation
« Reply #4 on: March 21, 2017, 04:21:52 PM »
So I spent a week waiting on parts to arrive so I could get my printer back in order. However, after replacing the parts, a few things more broke down. Luckily my printer was able to print some parts to replace the ones that broke until I can buy more.

I did notice that the XML spreadsheet provided in the build instructions is outdated and has non-functional links, so I have now started to document the links and pricing of everything in my own spreadsheet. So far I have only purchased a few non-electronic parts, but hopefully this will be helpful for you. I will be updating the spreadsheet as I purchase more things.

Spreadsheet for my purchases
https://www.dropbox.com/s/nqx8ekec6ngzg5z/Inspire%20Clone%20Spreadsheet.xlsx?dl=0

There are still a few stragglers, but I managed to finish printing most of the parts. Now i'm just waiting on those screws I ordered to arrive. It took about two weeks and 1 full roll of filament to print everything. For those of you printing in ABS, I would HIGHLY recommend making the switch to PETG. Not only is it oderless and non toxic, but it is just as strong, has PLA level ease of use, refuses to warp, and sticks to the bed insanely well.

All the parts
http://imgur.com/quB5Ods
http://imgur.com/dX7PInl
« Last Edit: March 21, 2017, 04:35:30 PM by lunarwukong »

Offline Bioethical

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Re: Inspire 1 Build Documentation
« Reply #5 on: March 21, 2017, 04:31:03 PM »
Those parts look great. No doubt that Inspire is going to be a great piece of engineering. I think that more than money it requires a lot of patience, but the satisfactions come at every movement when something works fine during the process.

Offline lunarwukong

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Re: Inspire 1 Build Documentation
« Reply #6 on: March 21, 2017, 05:39:08 PM »
Thanks Bioethical. If I could create something half as great as what you did I'll be happy  :)

Offline Bioethical

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Re: Inspire 1 Build Documentation
« Reply #7 on: March 21, 2017, 08:31:33 PM »
I'm sure you will and probably better.  8)

Offline lunarwukong

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Re: Inspire 1 Build Documentation
« Reply #8 on: March 25, 2017, 07:05:31 PM »
I have been waiting on some M3 threaded rods so I can assemble the frame, but for now I wanted to focus on the arm lifts because I thought that would be the hardest thing to do. School and work have been preventing me from working on the drone as much as I want to, but here is the progress I have made.

My Carbon fiber tubes collectively cost me about $60 on amazon prime. They came in 500MM lengths. For the 22mm I cut them into segments of 290mm and 210MM. For the 8mm tubes I cut them at about 2 8/12 inches or about 67MM.

Carbon Fiber Tubes for the feet
http://imgur.com/a/8eRNt

Carbon Fiber Tubes for the legs and arms
http://imgur.com/a/NrXqd

The arms were a bit tricky to get right. Metal brushings for the outer arms are too expensive for me, so I decided to use the Nylon Outer Brushings in the 3rd party build thread. However, instead of using Nylon, I used PETG. The PETG is definitely flexible and won't break, but im a bit confused on what the brushings are supposed to accomplish. Inside the arms I clamped the brushings onto the tubes and held it in place with tape so the arms are now firmly in place. However I'm wondering if the tube supporting the feet is supposed to twist when the arms lift up. If so, should I loosen the brushings so the arm can twist but not slide? If the arm is supposed to stay rigid wouldn't that mean the motors would be pointed slightly inward once you lift the arms, rather than completely vertical?

Tubes, Arm Links, and Feet Rough Fitting
http://imgur.com/a/VKjEh

And finally, the arm lifts. I'm not exactly sure how the lifting mechanism is supposed to work, but im figuring it out as I go along. I can't really start assembling it until the inner brushings and the threaded rods come in, but I started assembling things separately while I wait.

Bearings inside of the housings, lead screw with block
http://imgur.com/a/d1mOR


Offline Bioethical

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Re: Inspire 1 Build Documentation
« Reply #9 on: March 25, 2017, 07:47:05 PM »
Great! You just arrived to the exciting part.  Now go carefully while assembling. It should work fine. There are a lot of info here regarding the servo motor, connections and stuff. check from everyone. I posted a pic of a physical diagram. Is not a drawing but an actual composite of all the electronics, including end stops and the arduino nano card.

Offline lunarwukong

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Re: Inspire 1 Build Documentation
« Reply #10 on: May 01, 2017, 11:20:58 PM »
I have been super busy with schoolwork lately, so I have been working less at my part time job. That meant I had very little money to put into the Quad. But Allas! Finals are over and I'm backing to working on it.

Most of my time has been spent waiting on the final bits and pieces for the frame and arm lifts to arrive. I have decided to forgo any of the flight components (ESCs, Motors, GPS, Flight Controllers) until the arm lifting mechanism is completed. I figured it would be best to get the hardest part out of the way first.

Frame WIP
http://imgur.com/a/QFDBz

Offline Bioethical

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Re: Inspire 1 Build Documentation
« Reply #11 on: May 02, 2017, 03:01:53 AM »
I think that's a good idea so you can concentrate all of your mental energy on the critical part. That's the way I did it.

Offline lunarwukong

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Re: Inspire 1 Build Documentation
« Reply #12 on: May 02, 2017, 03:26:36 AM »
To anyone who has completed this quad, what kind of flight times are you getting and what battery setup are you using?

Offline primigen

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Re: Inspire 1 Build Documentation
« Reply #13 on: May 08, 2017, 08:07:09 PM »
i'm currently building one and the most common answer that i've found is about 10 mins. i'm also going to fit a big battery for longer flight times lol