Researchers at the University of Southampton have created a new method for designing more efficient propellers used on small drones. Their approach, which uses a specialized computer program called MATLAB, aims to improve the performance of drones, especially the ones used for first-person view operations, where real-time feedback is important. These propellers are smaller in size and often face challenges in how well they work, particularly due to the complex airflow patterns they experience. The study, led by Dr. Stephen Prior and Daniel Newman-Sanders, was published in the Applied Sciences journal in July 2024.
Experts on the team developed an innovative computer program that helps optimize the design of these small propellers. This program carefully adjusts the shape and angle of the blades to make sure they perform as efficiently as possible. A key part of their work was ensuring that the airflow over the propeller stayed above a certain Reynolds Number (Re) level of 100,000, which is essential for maintaining strong performance. “This level is important because it separates low efficiency from high efficiency in the propeller’s performance,” said Dr. Prior. Their improved design showed a noticeable boost in how well the propellers work compared to standard designs.
The MATLAB computer program also lets users see how the force and torque are distributed along the propeller blades. This gives a better understanding of how changes to the design affect overall performance. To test their approach, the researchers compared their results with data from an actual small propeller and found that their predictions were very accurate. The new design could greatly improve the endurance of small drones, allowing them to fly longer while using less energy.
Newman-Sanders highlighted how this research could be applied in the real world: “First-person view drones are becoming more important in many special operations where it’s essential to balance endurance with performance. Our aim is to ensure these drones can achieve that balance more effectively.” He also mentioned that their program could eventually work alongside 3D design software like SolidWorks, which would make it easier to move from the design phase to rapid production.
The results of this research have wider implications, not just for drone technology, but for any situation where small, efficient propellers are needed. While larger aircraft propellers can reach very high levels of efficiency, smaller ones typically don’t perform as well. The advancements made by Dr. Prior and his team push the boundaries of what’s possible, making significant progress in improving the design of propellers for unmanned air vehicles.
The researchers are looking to take their work even further by creating propeller designs that reduce energy loss even more. They’re also exploring options like using overlapping propellers to increase efficiency. Future research will also look at how this method can be applied to other small-scale propellers used in different industries, with the goal of setting a new standard for efficient design.
Dr. Prior added “The war in Ukraine has highlighted the need for efficient first-person view (fpv) drones which have the ability to fly long distances whilst carrying large payloads.”
Journal Reference
Prior, S.D., & Newman-Sanders, D. “Advanced Scale-Propeller Design Using a MATLAB Optimization Code.” Applied Sciences, 2024. DOI: https://doi.org/10.3390/app14146296
About the Authors
Dr Stephen D. Prior holds a Readership in Unmanned Air Vehicles at the University of Southampton. He is also the director of the Autonomous Systems Laboratory, which engages in defence-related research. Dr. Prior is the author of 200 technical publications. His research interests include co-axial rotorcraft, novel UAS and perching techniques. He is an active member of the IMechE and was the general chair of ICICE Conferences in China, and the co-chair of ICMES Conferences in Taiwan. He is also on the editorial board for the Unmanned Systems Journal, International Journal of Micro Air Vehicles and the Journal of Science and Innovation. Dr Prior is the founder and CEO of Hybrid Drones Ltd, a company developing Heavy-Lift Hybrid Drone technology for last-mile resupply and other missions.
Dan Newman-Sanders is currently a software engineer, working at a tech company in Bristol, UK. He has previously worked in the defence industry, where he worked on complex guidance, control and navigation algorithms for missiles and missile systems. He studied at the University of Southampton in the UK, where he achieved a first-class MEng honours degree in his Aeronautics and Astronautics. At university, his passions included computational optimisation, and the design and manufacture of air vehicle systems. Outside of work, his hobbies include football and running.
