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Lighter Than Air Surveillance Drone (LTASD)

The LTASD project was started back in 2017 in collaboration with Sheffield University, funded through Innovate UK. The challenge was to create technology capable of remote access into a nuclear facility to characterise defects, debris, objects and layout. The task was further restricted by the need to access the nuclear facilities (like those found at Sellafield) through 6” ports in the wall.

It was decided that the to maximise flight time and prevent kicking up a lot of dust and debris that the best solution would be to develop a lighter than air drone. This drone could be inserted into the facility, inflated and then deflated once the mission was accomplished. FIRMA started conducting trials using scaled prototypes to work out the best means of wrapping the collapsed envelope after deflation. It was this early prototype work which started FIRMA’s ongoing research into 3D printing.

The envelope for the drone was a unique design created by the FIRMA team. Different adhesives and materials were researched and a bespoke set of tools created in order to make consistent and high quality envelopes.

The experts at Sheffield University came up with a bespoke flight control system which would give the LTASD the fine control needed to navigate the, often tight, confines of nuclear facilities. This system required the use of 6 motors and incorporated accelerometers and barometric sensors. Forward and underside cameras with LED lighting were integrated into the drone, giving real time data back to the user.

The FIRMA team pushed the limits of our Prusa printers to prototype the delivery tube and capsule. This design created a docking station which enabled a capsule, containing the LTASD, to be inserted and inflated from outside the facility using helium. Docking clamps could then be removed and the drone could fly its mission. Cameras on the underside allowed the drone to then land back in the capsule. The capsule incorporated charging points, enabling the drone to be charged up for another mission.

The FIRMA team pushed the limits of our Prusa printers to prototype the delivery tube and capsule. This design created a docking station which enabled a capsule, containing the LTASD, to be inserted and inflated from outside the facility using helium. Docking clamps could then be removed and the drone could fly its mission. Cameras on the underside allowed the drone to then land back in the capsule. The capsule incorporated charging points, enabling the drone to be charged up for another mission.

The end of the mission is quite critical for ensuring that the inspection program leaves no further litter in the facility. The docking, deflation and wrapping aspects of the design were therefore given much thought and time. The final flight test day proved this work paid off as the whole system worked seamlessly, with successful reengagement of the landed drone, deflation and remote wrapping and extraction.

The intellectual property secured, UK Patent application number GB1813512.9.

External Link to the Innovate UK application:

https://gtr.ukri.org/projects?ref=132931

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