Neeraj Kumar Singh, Porselvan Muthukrishnan and Satyanarayana Sanpini
Industrial System Engineering for DronesA Guide with Best Practices for Designing
Neeraj Kumar Singh
Bangalore, India
Porselvan Muthukrishnan
Bangalore, India
Satyanarayana Sanpini
Bangalore, India
ISBN 978-1-4842-3533-1e-ISBN 978-1-4842-3534-8
https://doi.org/10.1007/978-1-4842-3534-8
© Neeraj Kumar Singh, Porselvan Muthukrishnan, Satyanarayana Sanpini 2019
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Dedicated to my sons, Anant and Atulya, for filling my life with joy and inspiration

—Neeraj

Dedicated to my teachers and mentors

—Satya

Dedicated to my teachers and mentors

—Porselvan

Acknowledgements

We would like to express gratitude to the people who helped us through this book; some of them directly and many others indirectly.

It’s impossible to not risk missing someone, but we will attempt anyway.

First and foremost, we would like to acknowledge Vinay K C and Balachandar Santhanam for their guidance and time in review. Vinay and Bala, your detailed review helped the book significantly in terms of structure, content, and quality; thank you very much!!

We would like to thank Intel management for the support and encouragement.

Above all, we thank our families and friends for their understanding, support, and being continuous source of encouragement.

Table of Contents

Chapter 1:​ Introduction 1
What Is a Drone?​ 2
Military 2
Industrial 3
Commercial 3
Parts of a Drone System 4
Hardware 4
Software 10
Mechanical 12
Ground-Based Controllers and Accessories 14
Summary 15
Chapter 2:​ Drone System Design Flow 17
System Design 17
Requirement Specification 18
Architecture 19
Implementation 23
Specifications for Our Drone, “Crop Squad” 23
Mechanical Design 24
Definition 26
Purpose 27
Requirements 28
Dependencies 32
Hardware Design 32
Hardware Requirements 33
Electrical Ingredients Selection 35
PCBA Design 37
Floor Plan 43
Power Architecture 44
Software Architecture 58
Logistics and Operations Management 60
Board and System Assembly 61
Summary 62
Chapter 3:​ Key Ingredients and Selection Considerations 63
System on a Chip 64
Categories 65
Key Considerations 66
Solutions 66
Memory 67
Categories 67
Key Considerations 70
Solutions 71
Storage 73
Categories 73
Key Considerations 81
Solutions 82
Communication Module 83
Categories 84
Key Considerations 86
Solution 87
Camera 88
Categories 88
Key Considerations 90
Solutions 90
Display 92
Categories 92
Key Considerations 93
Flight Controllers 94
Categories 94
Key Considerations 95
Solutions 95
Battery 95
Categories 96
Key Considerations 97
Solutions 98
Thermal Solution 99
Categories 99
Key Considerations 100
Solutions 101
Interconnects 101
Categories 102
Key Considerations 105
Solutions 106
Mechanicals 106
Categories 106
Key Considerations 107
Solutions 108
Summary 108
Chapter 4:​ Drone Hardware Development 111
PCB Library Development 112
Symbol Creation 112
Schematics Design 116
Schematics Capture 117
Design Rules Checking 118
Generating a Netlist 119
Bill of Materials 119
Symbol Attributes 121
BOM Generation 122
Material Readiness 123
Layout Design 123
Board Outline 124
Layer Stack-Up 124
Electrical Constraints 125
Mechanical Constraints 130
Netlist 134
Summary 138
Chapter 5:​ System Assembly, Bring-Up and Validation 139
PCB Fabrication Process 140
Fabrication Steps 140
PCB Assembly Process 142
Surface Mount Assembly Process 144
Through Hole Assembly Process 148
Final Inspection and Functional Test 149
Post Process 149
Board Power-On 150
Basic Inspection 151
Short-Circuit Checks 151
Power Check 152
Sequencing and Reset Check 153
Board-Level Testing 154
BIOS Flash Programming 154
OS and Application Installation 155
Functionality Check 155
Design Validation Testing 156
Power Validation 157
Electrical Validation 161
Drone Assembly 163
Drone System Validation Testing 163
System Pilot Build 164
Summary 165
Chapter 6:​ Software Development 167
Software Development and Deployment 167
Software Development Life Cycle 168
Software Stack 173
Key Considerations of Drone Software Design 180
System Software Integration and Bring-Up 202
System Bring-Up 202
Verification, Validation, and Maintenance 208
Conclusion 213
Chapter 7:​ Drone Product Certification 215
Regulatory Certification 216
Safety 216
Emission 219
Immunity 220
Environmental Certification 222
Temperature 223
Humidity 223
Altitude 224
Drop, Shock, and Vibration 224
Reliability 225
Service and Support 225
Pilot Distribution 225
Device Software Upgrade 226
Technical Service 226
Product Ecology 226
Prohibited Substances 226
ROHS 228
EU REACH 229
California Proposition 65 229
WEEE 230
ISO 230
Product Certification Centers 230
Device Costing 230
Production Cost 231
Accessories Cost 231
Drone Regulations 231
Regulations 232
Drone Registration 232
Summary 232
Appendix I:​ Schematics Basics 233
Reading Schematics 236
Layout Basics 237
Electronic System Design Communication interfaces 238
High Speed Interfaces 241
Pulse-shaping 243
Reliability/​durability 245
Low Speed Communication Interfaces 245
Appendix II:​ References 247
Epilogue 249
Index 251

About the Authors

Neeraj Kumar Singh

has been a Platform Architect for Intel Client platforms for more than 12 years. His areas of expertise are hardware/software co-design, SoC system/platform architecture, and system software design and development. Neeraj is the author of System on Chip Interfaces for Low Power Design and The Impact of Loop Unrolling on Controller Delay in High Level Synthesis .

 
Porselvan Muthukrishnan

has been a Hardware/System Design Engineer for Intel IOT platforms for over 10 years. His area of expertise is hardware/system design. Porselvan is currently working on system designs for connected home, connected cars, and other IoT devices.

 
Satyanarayana Sanpini

has been working in the fields of low-power embedded systems architecture, SoC definition, architecture, and design for the past 17+ years. He has contributed in various technical positions at start-ups Ittiam, Beceem Communications, and MNCs Broadcom, and also Qualcomm and Intel. He is currently based out of Bangalore, India and works at Intel India Center. Satya obtained his M.Tech degree in Electronics Design from Indian Institute of Science (IISc), Bangalore, India. Apart from a passion for technology, Satya likes to spend time with his young kids and explore nature’s grandeur through travel and trek.

 
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