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WPT System for Cooperative Robotics

Senior Design Project Proposal

Andrew Terrazas, Blake Janowicz, Jason Knight-Han

Sonoma State University Department of Engineering

Faculty Advisor: Dr. Nansong Wu

Industrial Advisor: Dr. Shun Yao (Skydio)

Client: NASA

05/05/2023

https://knightha4.wixsite.com/my-site-1

terrazasa@sonoma.edu

janowiczb@sonoma.edu

knightha@sonoma.edu

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Overview

Problem Statement, Value Proposition, Existing and Proposed Solution
Marketing and Engineering Requirements
System Overview, Hardware Diagram, Software Flowchart
Alternate Design Matrices, Challenges and Risks
Tests and Results
Budget and Materials
Schedule
Supporting Courses

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The problem we are exploring concerns companies and scientific missions which use Unmanned Aerial Vehicles (UAVs) in collaborative systems, who desire more efficiency in remote operations. The inability to efficiently charge a cooperative UAV with tolerance for misalignment while providing robust charging capabilities reduces the efficiency of scientific missions which leaves mission planners and operators feeling frustrated.

Problem Statement

Oldest: The problem we are exploring concerns companies and scientific missions which use UAVs (Unmanned Aerial Vehicles) in collaborative systems, who desire more efficiency in remote operations. The available battery charging methods for these systems require precise placement of the UAV and charger or use solar panels which are insufficient as most of the gathered energy is used to heat electrical components. The inability to remotely charge UAV systems with robustness and efficiency reduces the progress of these missions leaving mission operators feeling frustrated.

Old:

The problem we are exploring concerns companies and scientific missions which use UAVs (Unmanned Aerial Vehicles) in collaborative systems, who desire more efficiency in remote operations. Limited availability of charging methods that can meet the requirements of these missions narrows the available options for the design and development of collaborative systems. Additionally, the inability to efficiently charge cooperative UAV systems with tolerance for weathering and misalignment at any desired time reduces the efficiency of scientific missions which leaves mission planners and operators feeling frustrated. [last prob stat]

now discusses:

efficiency in charging

misalignment

efficiency of overall mission

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Our wireless charging system gives companies and scientific missions a way to wirelessly charge their UAVs in an efficient manner. The system reduces operator frustration by providing a robust charging method that is tolerant to misalignment and resistant to physical degradation, increasing available flight time.

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Value Proposition

Our wireless power and data transfer system enables companies and scientific missions which use UAVs in their autonomous systems to wirelessly charge their UAVs in an efficient manner. It minimizes the ground time between charges and reduces the physical degradation of components during operation while freeing up resources for air and ground systems and enabling more robust exploration capabilities.

Our wireless power and data transfer system provides companies and scientific missions which use UAVs in their collaborative systems a way to wirelessly charge their UAVs in a efficient manner that allows for variability. It increases the average flight time and reduces the physical degradation of components during operation, enabling more exploration capabilities.

needs to discuss:

now discusses:

efficiency in charging

misalignment

efficiency of overall mission

blakes:

Our wireless power and data transfer system gives companies and scientific missions a way to wirelessly charge their UAVs in an efficient manner. It provides a robust charging method that tolerates misalignment and provides efficiency. Increasing average flight time and reducing physical degradation of components enables for greater efficiency of the overall mission and mission capabilities. fu

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There are currently multiple methods for charging electric UAVs:

Manual battery replacement
Charging Contacts

Skydio Drone Dock™

Solar:

NASA Ingenuity

Inductive Charging

Powermat PMT 300

While these existing solutions provide high charging efficiency, they fall short in providing a robust charging system that can tolerate misalignment and different size UAVs in an autonomous system.

Existing Solutions

Pros

Cons

Method


Manual Replacement	Contact Charging	Solar Charging	Non-Resonant Wireless
Best efficiency	High efficiency, no manual interaction	Moderate efficiency, no manual interaction	No manual interaction, robust
Requires manual interaction	Requires precision, physically vulnerable	Utility only in certain locations, time of day	Low misalignment tolerance, variable efficiency

Strongly coupled systems are able to achieve efficient energy transfer because energy the exchange capability of resonant objects surpass non-resonant objects [10], [11]. Since the four-coil system of SCMR can achieve higher efficiencies and higher quality factor compared with the traditional two coil system usually used for the inductive coupling, the detrimental effects of low coupling coefficients can be counteracted. (Chathuranga et al.)

Because of its high power density and good orientation features, electromagnetic radiation mode is usually suitable for the long distance transfer applications, especially for the space power generation or military applications. However, its transfer efficiency is severely affected by the meteorological or topographical conditions, and the impacts on creatures and ecological environment are unpredictable. Hence, wireless power transfer based on electromagnetic radiation mode is not appropriate for the civilian use. (Wei)

Wireless technologies which have a range of pitfalls

Far-field technologies using radiated RF Power are impractical
Near-field inductive technologies require coil alignment

Manual replacement - Dronegenuity

Contact charging - Skydio

Solar Charging - NASA’s Ingenuity

Inductive Charging - Powermat

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Proposed Solution

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System Overview

Source	Gain/Loss
50 VDC RF Source + ENI 420L amplifier	+42 dBm [15,800 mW] max(up
Coil Loss (high power)	-0.79 dB @ 83.4%
Rx System Loss	-3.98 dB @ 40%* -0.97 dB @ 80%)
Total:	37.23 dBm [5285 mW] @ rx 40%, 40.24 dBm @ 80%
Requirement:	23 dBm (200 mW)
Margin:	14.23 dB @ rx 40%, 17.24 dBm @ rx80%
End-to-End Efficiency:	33.34%* up to 66.68% efficiency @ Rx80%

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Marketing Requirements

[1] The system shall provide power transfer wirelessly.

[2] The system shall have an efficient charging cycle.

[3] The system shall allow for lateral misalignment while charging.

[4] The receiving module shall supply DC power sufficient for a small UAV battery.

[5] The transmitting module shall require no manual interaction to activate.

[6] The base module shall be able to determine the charge state of the UAV.

[7] The system shall operate in an FCC compliant manner.

[8] The transmitting module shall be contained in a UAV landing pad.

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Engineering Requirements

[1 - MR 1] The system shall transfer no less than 1000 mW power wirelessly between its source and load coil under normal operating conditions.

[2 - MR 2] The power transfer efficiency between coils shall be no less than 70% at optimal alignment and displacement.

[3 - MR 3] The system shall offer lateral forgiveness up to 50mm while maintaining 60% power transfer efficiency between coils.

[4 - MR 4] The receiving system shall provide no less than 200 mW DC power to its load under optimal conditions.

[5 - MR 5] The receiving module shall activate within 50mm of the base station.

[6 - MR 6] The receiving system shall monitor load current with an accuracy of ±5 mA.

[7 - MR 7] System shall emit a specific absorption rate (SAR) and an equivalent radiated power (ERP) no higher than permitted by FCC regulation Part 18 for power transfer.

[8 - MR 8] The receiving system shall reside in an assembly no more than 16 x 20 cm² in area.

2. measured via frequency, power, and separation distance

3. *capacity tbd* RE: 7,8,9: not 100% sure if we should commit to formal azimuth and elevation testing assuming they aren’t impeding the system from working with the standard hovering capability of whatever drone we test. might be unnecessary to triple the test workload for the misalignment beyond lateral forgiveness with everything else that needs to be done, and the powermat resonant charger only advertises the lateral range so at the very least it didn’t prove to be worth emphasizing to them

most important:

ER[3] revise: The power transfer efficiency between the source and load coils shall be no less than 80%.

ER[4] ~power or max output current

ER[10] revise: The receiving module shall turn off at an (minimum) output discharge current of 75 mA... but need to say the exact Ahr value.

Source of Power? HAM radio ~10 W (@DC 5V, 380 mAh, 1.9W needs to be delivered, could be as low as 30% system efficiency)

Link Budget 03/23: 35V ~1.5A the max Vin for our 5V regulator (which feeds into 4100 5V 1S MicroLipo charging module), which has a minimum input dropout of: 2-2.5V (rounded up to 3V) w/6mA quiescent current, so Vout = Vin - Vdrop -> 5V = Vin- 3V = 8V x 6mA = 48mW (16.81 dBm) to turn on and anything else is charge… at full battery charge current 8V @ 100mA = 800 mW (29.03 dBm) but Pmax for simulation coherency [figure below] @ 550 mW (27.4 dBm). Taking this value at 40% efficiency gives us 220 mW or 23.42 dBm i.e., 8V @ 27.5mA that we conservatively expect to supply the load, which will be enough to meet charge requirement, albeit slowly.

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10

System Overview

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Hardware Block Diagram

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Software Design

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Rx Microcontroller

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Transceiver	weight	HiLetgo HC-05 Bluetooth Transceiver	HiLetgo RC522 RFID Module	HiLetgo PN532 NFC Module
Mass	0.34	0.43	0.32	0.25
Power	0.25	0.20	0.12	0.68
Size	0.23	0.43	0.26	0.31
Cost	0.17	0.34	0.46	0.20
Score	1	0.35	0.28	0.37

Alternate Design Matrices

MCU	weight	Adafruit Trinket MCU	PIC16F877A	Node MCU ESP8266
Mass	0.48	0.49	0.31	0.20
Power	0.24	0.52	0.38	0.10
Size	0.16	0.38	0.52	0.10
Cost	0.12	0.47	0.29	0.24
Score	1	0.48	0.36	0.16

Transceiver

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Challenges

Previous Challenges:	RF signals from coils may interfere with external components	Limited availability of a cost-effective AC power source	Lack of experience prototyping high frequency

Current Challenges:	Different Capacitors Yield Different Results	Achieving High Efficiency with RF-DC Converter	Capacitors are in a Physically Compromised Position

Ripped capacitor

Burnt capacitor

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Summary of Tests Conducted

Test #	Objective	ER addressed	Notes
FT.1 - Power Transfer Efficiency Test	Validate efficiency of power transfer under optimal alignment.	ER.2	Pass 12/06
FT.2 - Lateral Misalignment Test	Validate efficiency of power transfer under lateral misalignment.	ER.3	Pass 12/06
FT.3 - Current Detection Test	Validate ability to monitor current at output of receiving system.	ER.6	Pass 11/30
FT.4 - Data Communication Test	Validate that NFC sensing is compatible with our system.	ER.5	Pass 12/06
ST.1 - NFC Coil Power Switching Test	Validate the system requires no manual interaction to activate.	MR.5	Fail 12/06
ST.2 - Rx System Rectification Test	Validate that our receiving system supplies DC power sufficient for small UAV battery	MR.4	In Progress

Test #	Objective	ER addressed	Notes
FT.1 - Power Transfer Efficiency Test	Validate efficiency of power transfer under optimal alignment.	ER.2	Pass 12/06
FT.2 - Misalignment Test	Validate efficiency of power transfer under lateral misalignment.	ER.3	Pass 12/06
FT.3 - Current Detection Test	Validate ability to monitor current at receiving system output within ±5 mA.	ER.6	Pass 11/30
FT.4 - Data Communication Test	Determine base system can activate within 5 cm of receiving system (w/NFC)	ER.5	Pass 12/7
ST.1 - NFC Coil Power Switching Test	Validate the system requires no manual interaction to activate.	MR.5	Fail 12/8
ST.2 - Rx System Rectification Test	Validate that our receiving system supplies DC power sufficient for small UAV battery	MR.4	Pass 03/02, 03/25
ST.3 Power Characterization Test	Characterize and determine received power across coils vs. power being supplied to the RF power amplifier	ER.1, ER. 4	Pass 03/14
Final System Verification	Validate system integration	ER.1, MR.8	Conditional

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Test Results –

FT.1 - Power Transfer Efficiency Test (Low Power)

FT.1 - Power Transfer Efficiency Test
The power transfer efficiency shall be no less than 70% at optimal alignment and displacement.
ER.2
Pass 12/06

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Test Results –

FT.1 - Power Transfer Efficiency Test (High Power)

Peak power transfer of 41.2dBm [13.2W] was observed with a efficiency of 83.4%

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Test Results –

FT.2 - Misalignment Test (Low Power)

FT.2 - Misalignment Test
The system shall offer lateral forgiveness up to 50mm while maintaining 60% power transfer efficiency between coils.
ER.3
Pass 12/06

Measurement \ Results: \ S_{21} \ = \ -0.46dB \\

Efficiency \ Calculation: \\

S_{21} = 20log_{10}(\frac{V_{2}^{-}}{V_{1}^{+}}) \ dB \\ Where: \\

V_{1}^{+} = Voltage \ from \ Port \ 1 \\

V_{2}^{-} = Voltage \ from \ Port \ 2 \\ \\

S_{21} (ratio) =\frac{^{V_{2}^{-}}}{V_{1}^{+}} = 10^{\frac{S_{21} dB}{20}}= 10^{\frac{-0.46}{20}} = 0.948\\

Power \ Transfer \ Efficiency \ Calculation:\\

|S_{21} (ratio)|^{2} = |\frac{V^{-}_{2}}{V^{+}_{1}}|^{2} = |0.948|^2 = 0.899 \\

Power \ Transfer \ Efficiency \ = 0.899 * 100\% = 89.9 \%

Measurement \ Results: \ S_{21} \ = \ -0.652dB \\

Efficiency \ Calculation: \\

S_{21} = 20log_{10}(\frac{V_{2}^{-}}{V_{1}^{+}}) \ dB \\ Where: \\

V_{1}^{+} = Voltage \ from \ Port \ 1 \\

V_{2}^{-} = Voltage \ from \ Port \ 2 \\ \\

S_{21} (ratio) =\frac{^{V_{2}^{-}}}{V_{1}^{+}} = 10^{\frac{S_{21} dB}{20}}= 10^{\frac{-0.652}{20}} = 0.928\\

Power \ Transfer \ Efficiency \ Calculation:\\

|S_{21} (ratio)|^{2} = |\frac{V^{-}_{2}}{V^{+}_{1}}|^{2} = |0.928|^2 = 0.861 \\

Power \ Transfer \ Efficiency \ = 0.861 * 100\% = 86.1 \%

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Test Results –

FT.2 - Misalignment Test (High Power)

50mm - 80% power transfer efficiency
80mm - 60 % power transfer efficiency

Test Setup

https://latex.codecogs.com/png.image?\LARGE&space;\dpi{110}\bg{white}V_1{}^{+}&space;=&space;Voltage&space;\&space;Signal\&space;&space;to&space;\&space;&space;Port&space;\&space;1&space;\\&space;V_2{}^{-}&space;=&space;Voltage&space;\&space;Signal&space;\&space;from&space;\&space;Port&space;\&space;2&space;\\&space;S_{21}&space;\&space;=&space;\&space;\frac{V_2{}^{-}}{V_1{}^{+}}&space;\\&space;S_{21}&space;(dB)\&space;=&space;\&space;-1.551dB&space;\\&space;S_{21}&space;(ratio)&space;\&space;=&space;\&space;10^{\frac{-1.551}{10}}&space;\&space;=&space;0.6997&space;\\Power&space;\&space;Transfer&space;\&space;Efficiency&space;\&space;=&space;\&space;\left|&space;S21&space;\right|^{2}&space;\&space;*&space;\&space;100%&space;\\=&space;\&space;0.6887^{2}&space;\&space;*&space;\&space;100%&space;&space;\\&space;=&space;\&space;0.4896&space;\&space;*&space;\&space;100%&space;\\=&space;\&space;48.96%&space;\&space;Power&space;\&space;Transfer&space;\&space;Efficiency&space;&space;

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Test Results –

FT.3 - Current Detection Testing

FT.3 - Current Detection Test
Validate ability to monitor current at output of receiving system within ±5 mA.
ER.6
Pass 11/30

RANGE		ACCURACY	RESOLUTION
AC voltage	4V / 1000V	±(1.2%+5) @ 40V	1mV-1V
DC voltage	400mV / 1000V	±(1.0%+3) @ 4-400V	0.1mV-1V
AC current	400µA / 10A	±(1.5%+3)	0.1µA-0.01A
DC current	400µA / 10A	±(1.0%+3)	0.1µA-0.01A
Resistance	400Ω / 40MΩ	±(1.5%+5) @ 400Ω-400kΩ	0.1Ω-10kΩ
Frequency	10Hz / 500kHz	±(1.0%+5)	0.001-100Hz
Capacitance	40nF / 4000µF	±(3.0%+5) @ 400nF-400µF	10pF-1µF
Duty cycle	1% to 99%	±(1.2%+2)	0.1%
Temperature °F	0 / 1500	±(2.0%+9°F)	0.1-1°F
Temperature °C	-18 / 538	±(2.0%+5°C)	0.1-1°C

MM700 SPECS

N = 30

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Test Results –

FT.4 - Data Communication Test

FT.4 - Data Communication Test
Validate that NFC sensing is compatible with our system.
ER.5
Pass 12/06

MM700 SPECS

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Test Results –

ST.1 - NFC Coil Power Switching Test

ST.1 - NFC Coil Power Switching Test
Validate the system requires no manual interaction to activate.
MR.5
Fail 12/06

MM700 SPECS

Future:	Experiment with code for two Modules, only one Module, implement Backscatter through coils

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Test Results –

ST.2 - Initial Rectification Test

ST.2 - Rx System Rectification Test
Validate that our receiving system supplies DC power at our desired operating frequency
MR.4
Pass 03/02

Conclusion:	Max available power pre-amplification (up to 25 mW) of AC signal rectified into rippled DC at desired frequency.

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Test Results –

ST.2 - Final Rectification Test

ST.2 - Rx System Rectification Test
Validate that our receiving system supplies no less than 200 mW DC power to its load under optimal operating conditions
MR.4
Pass 03/25/23

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Test Results –

ST.5 - Communication Test

Backscatter Communication Test
Receiving Module Shall be able to provide modulated backscatter to the Base Station Module
ER.3
Pass 01/23

https://latex.codecogs.com/png.image?\LARGE&space;\dpi{110}\bg{white}V_1{}^{+}&space;=&space;Voltage&space;\&space;Signal\&space;&space;to&space;\&space;&space;Port&space;\&space;1&space;\\&space;V_2{}^{-}&space;=&space;Voltage&space;\&space;Signal&space;\&space;from&space;\&space;Port&space;\&space;2&space;\\&space;S_{21}&space;\&space;=&space;\&space;\frac{V_2{}^{-}}{V_1{}^{+}}&space;\\&space;S_{21}&space;(dB)\&space;=&space;\&space;-1.551dB&space;\\&space;S_{21}&space;(ratio)&space;\&space;=&space;\&space;10^{\frac{-1.551}{10}}&space;\&space;=&space;0.6997&space;\\Power&space;\&space;Transfer&space;\&space;Efficiency&space;\&space;=&space;\&space;\left|&space;S21&space;\right|^{2}&space;\&space;*&space;\&space;100%&space;\\=&space;\&space;0.6887^{2}&space;\&space;*&space;\&space;100%&space;&space;\\&space;=&space;\&space;0.4896&space;\&space;*&space;\&space;100%&space;\\=&space;\&space;48.96%&space;\&space;Power&space;\&space;Transfer&space;\&space;Efficiency&space;&space;

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Estimated Budget

REVENUE
Income (NASA Minds)	$1,500.00
Donation (RF Diagnostics LLC)	$40.00
Total Exp Income	$1,540.00
EXPENSES
Part/ Quantity	Qty#	ER/MR#	Test	Description	Link	Price
Capacitors - various types/values	1	All (ER.1)	All (ST.3)	Capacitors used in resonant circuit, modulation circuit, rectifying circuit, etc.	N/a	$77.00
80/20 Rods	1	All (ER.1)	All (ST.3)	Rods used for device housing.	Link	$157.35
Copper Rods [4mm diameter]	1	All (ER.1)	All (ST.3)	Copper wire used for charging and communication coils.	Link	$52.49
Copper Tape	1	All (ER.1)	All (ST.3)	Tape Used for Prototyping RF components	Link	$14.50
HiLetgo PN532 NFC NXP RFID Module	3	ER.3	FT.4, ST.1	Used for the Rx system to communicate with the Tx system	Link	$8.99
Adafruit Trinket M0	2	ER.6	ST.1, FT.4	Lightweight MCU for Rx system	Link	$11.82
INA219 Current Sensor	2	ER.7	FT.3	Current sensor for Rx System	Link	$4.25
4410 Adafruit MicroLipo Charge Controller	4	MR.4	FT.4	Module to feed DC to the battery for the Rx system (post-rectification)	Link	$5.95
TP4056 LiPo Charger Modules	3	MR.4	FT.4	Module to feed DC to the battery for the Rx system (post-rectification)	Link	$6.99
Various Schottky Diodes (1N5817, SB550A)	26	ER.4	ST.2	Used in rectification circuit for Rx system	Link	$0.48
Various Zener Diodes	6	ER.4	ST.2	Used in rectification circuit for Rx system	Link	$0.66
RFD199A-PCB RF-DC Converter	1	ER.4	ST.2	Backup module to support RF-DC rectification - low power but can be modified	Link	$40.00
ZX60-100VH+ Low Noise Amplifier	1	All (ER.1)	All (ST.3)	36 dB 150kHz-300MHz 10W	Link	$254.41
SMA Cable	1			Used for RF conections	Link	$60.00
PLA 3D Printer Filament	3			Used for coil mounts and device enclosure	Link	$18.99
Resistors - various types/values	20	All (ER.1)	All (ST.3)	Resistors used in resonant circuit, modulation circuit, rectifying circuit, etc.	N/a	$3.00
Inductors	1	All (ER.1)	All (ST.3)	Inductors used in resonant circuit, modulation circuit, rectifying circuit, etc.	N/a	$50.00
SMA Jack	1			Used for RF connections	Link	$20.00
Protoboard	5	All (ER.1)	All (ST.3)	Used for circuit prototyping	Link	$30.00
MISC Tools	1	All (ER.1)	All (ST.3)	Tools used for making product	N/a	$100.00
Terminal Blocks	1			Used for circuit prototyping and supplying power to circuits	Link	$5.00
Total Cost	$1,214.19
Difference	$325.81

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Schedule

Gantt Chart

On Track

Delay

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Future Considerations

This project is still early in development and ripe for improvement.

Improvements in design mainly concern the efficiency of various subsystems:

Coil System:

Increase number of resonant coils to increase efficient bandwidth
Explore PCB Coil Designs
EIRP Measurements

Communication System:

Implement a more robust backscatter communication system
Explore different modulation schemes

Power Harvesting System:

Incorporate additional power-handling features including load-sharing

Build:

House system in a proper unit and attach receiving system onto a UAV

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Microprocessors and System Design (EE 310)
Microelectronic Circuits (EE 334)
Linear Systems Theory (EE 400)
Electromagnetic Theory and Applications (EE 430)
Analog and Digital Communications (EE 442)
RF and Microwave Design (EE-444)

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Supporting Courses

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Questions/Comments?

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Questions

Thank you:

Dr. Wu, Dr. Salem, Shahram Marivani, All other faculty members and industry advisors at SSU, Dr. Shun Yao, Asher Robbins-Rothman, and Chris with Skydio, Chris Stewart, Danny at Aerowest, Pawan at Dronegenuity, Starr Ginn with NASA’s Advanced Air Mobility Strategy, Paul Secor with NASA’s MINDS program, Dr. Tom Budka with RF Diagnostics LLC.

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Demonstration

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References

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References

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Input Power (dBm)	Input Power (mW)	Vpp_in (mV)	Vrms_in (mV)	Vpp_out (mV)	Vrms_out (mV)	n_pp	n_rms
0	1	12.6	4.3	4.5	1.7	35.71%	39.53%
5	3.16	35.8	12.4	6.3	2.7	17.60%	21.77%
8	6.31	55.4	19	9.6	5.1	17.33%	26.84%
13	19.95	101	35	11.1	5.6	10.99%	16.00%

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35V ~1.5A the max Vin for our 5V regulator (which feeds into 4100 5V 1S MicroLipo charging module), which has a minimum input dropout of: 2-2.5V (rounded up to 3V) w/6mA quiescent current, so Vout = Vin - Vdrop -> 5V = Vin- 3V = 8V x 6mA = 48mW (16.81 dBm) to turn on and anything else is charge… at full battery charge current 8V @ 100mA = 800 mW (29.03 dBm) but Pmax for simulation coherency [figure below] @ 550 mW (27.4 dBm). Taking this value at 40% efficiency gives us 220 mW or 23.42 dBm i.e., 8V @ 27.5mA that we conservatively expect to supply the load, which will be enough to meet charge requirement, albeit slowly.

Backup slide on why 200mw load:

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[1, pg.16]

Backup slide on safety, SAR

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WPT for Cooperative Systems 2023

Communication Demonstration:

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WPT for Cooperative Systems 2023

Power-Harvesting Demonstration: