Design, fabrication, and characterization of multifunctional wings to harvest solar energy in flapping wing air vehicles

Currently, flapping wing unmanned aerial vehicles (a.k.a., ornithopters or robotic birds) sustain very short duration flight due to limited on-board energy storage capacity. Therefore, energy harvesting elements, such as flexible solar cells, need to be used as materials in critical components, such as wing structures, to increase operational performance. In this paper, we describe a layered fabrication method that was developed for realizing multifunctional composite wings for a unique robotic bird we developed, known as Robo Raven, by creating compliant wing structure from flexible solar cells. The deformed wing shape and aerodynamic lift/thrust loads were characterized throughout the flapping cycle to understand wing mechanics. A multifunctional performance analysis was developed to understand how integration of solar cells into the wings influences flight performance under two different operating conditions: (1) directly powering wings to increase operation time, and (2) recharging batteries to eliminate need for external charging sources. The experimental data is then used in the analysis to identify a performance index for assessing benefits of multifunctional compliant wing structures. The resulting platform, Robo Raven III, was the first demonstration of a robotic bird that flew using energy harvested from solar cells. We developed three different versions of the wing design to validate the multifunctional performance analysis. It was also determined that residual thrust correlated to shear deformation of the wing induced by torsional twist, while biaxial strain related to change in aerodynamic shape correlated to lift. It was also found that shear deformation of the solar cells induced changes in power output directly correlating to thrust generation associated with torsional deformation. Thus, it was determined that multifunctional solar cell wings may be capable of three functions: (1) lightweight and flexible structure to generate aerodynamic forces, (2) energy harvesting to extend operational time and autonomy, and (3) sensing of an aerodynamic force associated with wing deformation.