Integrated Protective Unmanned Aerial Vehicle Control Box

Abstract

This integrated protective drone control box belongs to the field of drone control mechanical design technology. To ensure the reliability of signal input and the integrity of communication functions of the drone control system, this design introduces a radio transceiver module, a signal transmitting / receiving unit, and a 5G communication module as key hardware components. To achieve the aesthetic unity and structural integration of the overall appearance of the drone, a dedicated control box structure needs to be designed. This structure must achieve compact and reasonable internal integration of the above three modules (radio transceiver module, signal transmitting / receiving unit, and 5G communication module) without affecting the process requirements of internal wiring, interface connections, etc.

Description

Technical Field

[0001] This invention designs an integrated protective drone control box, belonging to the field of drone control mechanical design technology. Background Technology

[0002] In existing UAV control systems, core functional modules such as flight controllers, power management modules, communication modules (e.g., data transmission and image transmission), and various sensor connection circuits are typically deployed separately within the fuselage. This distributed layout not only occupies valuable airborne space, increases overall weight and wiring complexity, but more importantly, it leads to lengthy wiring connections and exposed interfaces, posing serious challenges to the system during UAV operation: complex wiring harnesses are susceptible to vibration, resulting in poor contact or breakage; the risk of electromagnetic interference between modules is increased; environmental factors (such as dust and moisture) exacerbate the corrosion of sensitive circuits; and maintenance and upgrades are extremely inconvenient. These problems severely restrict the reliability, stability, and environmental adaptability of UAV control systems. Therefore, a highly integrated, compact, and well-protected mechanical solution is needed to achieve integrated packaging and reliable operation of key functional modules. Summary of the Invention

[0003] (I) Purpose of the Invention

[0004] To ensure the reliability of signal input and the integrity of communication functions in the UAV control system, this design incorporates a radio transceiver module, a signal transmitting / receiving unit, and a 5G communication module as key hardware components. To achieve aesthetic uniformity and structural integration in the overall UAV appearance, a dedicated control box structure needs to be designed. This structure must achieve compact and reasonable internal integration of the three modules (radio transceiver module, signal transmitting / receiving unit, and 5G communication module) without affecting the internal wiring, interface connections, and other process requirements of the box.

[0005] (II) Technical Solution

[0006] 1. General Overview

[0007] The main structure of the control box consists of three parts, from bottom to top: the adapter, the partition, and the control box housing.

[0008] 1) Adapter Design Concept

[0009] The key constraint in the structural design stems from the geometric characteristics of the UAV: ​​the upper surfaces of the battery boxes on both sides are significantly higher than the upper surface of the central fuselage [measured height difference of approximately 20mm]. Preliminary spatial layout analysis, including simple solid modeling in the early stages of 3D modeling, clearly indicates that the width of the control box shell is necessarily greater than the width of the central fuselage. Therefore, if the bottom surface of the shell is directly attached to the upper surface of the fuselage, spatial interference between the two sides of the shell and the raised battery boxes is inevitable. To resolve this interference issue and ensure the overall feasibility of the control box installation, this design introduces an adapter structure. The core function of this component is to raise the installation reference height of the entire control box assembly, ensuring that its final bottom positioning plane is higher than the highest contour surface of the two battery boxes, and enabling the shell and partitions to connect to the UAV fuselage. Furthermore, the design fully considers the ergonomic requirements of the battery box disassembly process, reserving sufficient hand operating space (including the vertical movement of fingers required for operational postures) when setting the reference height. The overall lifting achieved through the adapter effectively avoids interference between the control box and the UAV body [especially the battery box area]. This is the basic principle and core consideration of the structural design of the adapter.

[0010] 2) The partition design takes into account that a large amount of dust will enter the UAV during flight, which will affect the stability of the wiring of the internal control components. The adapter structure cannot guarantee the required sealing of the entire control box structure. Therefore, a partition structure is added to reduce the amount of dust entering during flight.

[0011] 3) Control Box Housing Design Concept: The geometric dimensions of the control box housing directly depend on the specific physical specifications of the core electronic components it houses, including radio transceiver modules, signal transmitting / receiving units, and 5G communication modules. The internal space planning must primarily meet two key constraints: the wiring layout requirements and heat dissipation performance requirements of these electronic modules. Based on this, the core design objective is to achieve compact, high-density integration of these functional modules, while ensuring their stable fixation and structural stability within the housing.

[0012] The following section will elaborate on the specific design concepts, functional characteristics, and key geometric parameters of each structural component [interface, partition, control box housing].

[0013] 2. Detailed Technical Features

[0014] 1) Overall layout of the three hardware modules

[0015] Based on the analysis of measured data and the simulation results of the internal wiring layout of the housing, the optimal component layout scheme is determined as follows: the radio transceiver module with its own housing is placed at the front end of the control box housing (housing feature: the chamfered side is the front end), while the signal transmitting / receiving unit and the 5G communication module are installed side by side in the rear end area of ​​the housing. It should be noted that the signal transmitting / receiving unit and the 5G module themselves do not have external encapsulation housings; the drone control function is achieved solely through their core circuit boards.

[0016] 2) Boss structure

[0017] To accommodate the actual physical thickness of the components on the circuit board and avoid electrical risks or structural interference caused by direct contact between the components and the top surface of the housing, a local boss structure was designed to provide the necessary accommodation space.

[0018] 3) The four-corner connection structure of the three hardware modules

[0019] To ensure the precise positioning and secure installation of the three core electronic components, stud connections were used at the four corners of each circuit board to reliably fix them, based on their specific dimensions.

[0020] 4) External structure design of the shell

[0021] The left and right sides of the housing are axially connected by six M3 screws, ultimately securing it to the bottom adapter for reliable overall fixation. Different heat dissipation solutions are designed for different modules: the radio transceiver module, due to its built-in heat sink, features a perforated structure in its corresponding housing section, directly utilizing its own heat sink for heat exchange and achieving natural convection cooling. In contrast, the signal transmitting / receiving unit and the 5G communication module rely on a heat sink structure integrated into the housing for heat dissipation. This heat sink uses a 2mm wide parallel stripe pattern, significantly increasing the heat dissipation surface area. When the drone is in flight, the high-speed airflow across the housing surface flows into the gaps between the heat sinks, efficiently carrying away the heat generated by the modules through forced convection, thus collaboratively ensuring the thermal stability of the system.

[0022] 5) Interface and instruction component layout structure

[0023] Functional openings are provided on the upper and rear sides of the control box housing for mounting key components that work in conjunction with the internal circuit board. Specifically, these include:

[0024] SMA type RF adapter: provides an external interface for radio signals.

[0025] LED status indicators: used for visual indication of system operating status.

[0026] J30J series aviation connectors: enable electrical connection and data / power transmission between the device and the outside world.

[0027] The layout (top / rear) of the aforementioned interfaces and indicator elements is determined comprehensively based on the overall structure optimization of the housing and the requirements of human-computer interaction.

[0028] 6) Partition

[0029] To address dust protection requirements during flight operations, an isolation baffle structure was designed at key locations inside the control box to prevent excessive dust intrusion and potential wiring contact problems. The baffle has a circular through-hole of a specified size in its center, specifically for wires to pass through, ensuring a reliable connection between the electronic modules in the upper control box housing and the circuit board of the lower adapter.

[0030] 7) Adapter

[0031] The adapter incorporates internal ribbed supports to enhance overall rigidity, ensuring structural stability and reliability while reducing the risk of deformation. For example, the rib layout optimizes stress distribution and improves compressive strength. Four slots on both sides are specifically designed to accommodate the drone's battery box latching mechanism, preventing structural interference, ensuring free movement of the latches, and maintaining a compact shape. In similar designs, these slots often mate with external component bayonets, simplifying assembly and disassembly. The 12 holes at the lower end precisely align with existing holes on the upper fuselage; during connection, the original screws must be removed, and seamless assembly is achieved directly with new screws. This design emphasizes the concentrated distribution of holes, enhancing stress balance at connection points and preventing loosening.

[0032] (III) Beneficial Effects

[0033] This integrated structure effectively accommodates three core functional units, including the core flight control module, mission payload control module, and data link communication module, as well as other necessary auxiliary control systems. By integrating multiple systems into a single, compact shell, it not only significantly optimizes the spatial layout of airborne equipment but also ensures the aesthetic unity and structural integrity of the overall UAV design, avoiding visual clutter and aerodynamic interference caused by exposed cables and equipment accumulation. This provides a solid guarantee for continuous and precise operations in complex mission environments. Attached Figure Description

[0034] Figure 1 Overall structure diagram of adding a control box to a drone

[0035] Figure 2 Image of the drone's upper fuselage and battery box

[0036] Figure 3 Diagram of the adapter structure for connecting the upper fuselage of a drone

[0037] Figure 4 This is a mechanical structure diagram of the adapter of the present invention.

[0038] Figure 5This is a mechanical structure diagram of the partition plate of the present invention.

[0039] Figure 6 This is a structural diagram of the back of the control box housing of the present invention.

[0040] Figure 7 This is a front structural view of the control box housing of the present invention.

[0041] Figure 8 This is a diagram of the boss structure in the control box housing of the present invention.

[0042] Figure 9 This is a diagram of the stud connection structure at the four corners of the present invention.

[0043] Figure 10 This is a complete assembly structure diagram of the control box of the present invention. Detailed Implementation

[0044] First, remove the 12 screws that were originally located between the two antennas on the upper fuselage of the drone. Figure 3 As shown, use 12 M3 screws of appropriate length to connect to the upper body first. The second step is as follows... Figure 6 As shown, the required control modules are first installed in the control box housing using... Figure 9 The stud connections shown are complete, and the internal wiring is finished. The SMA adapter, J30J interface, LED indicator, and other modules are also installed on the control box housing. After completing the above steps, the control box housing is inverted, and the wires of the three modules inside the control box housing are connected to the wires of the circuit board in the adapter through the through hole in the center of the partition. Finally, as shown... Figure 10 As shown, the control box housing, partition, and adapter [from top to bottom] are fixedly connected by 6 M3 screws.

Claims

1. An integrated protective unmanned aerial vehicle (UAV) control box, characterized in that: The system consists of a radio transceiver module, a signal transmitting / receiving unit, and a 5G communication module as key hardware components. The signal transmitting / receiving unit and the 5G communication module are installed side by side in the rear area of ​​the housing. The three hardware modules are connected at the four corners, and the left and right sides of the housing are axially connected by six M3 screws. The housing has a hollow structure. It is connected to the upper body with 12 M3 screws of appropriate length, and the control module is connected with studs. The SMA adapter, J30J interface, and LED indicator module are installed. The wires of the three modules in the control box housing are connected to the wires of the circuit board in the adapter through the through hole in the center of the partition. The control box housing is fixedly connected with 6 M3 screws.

Images