Design of manual aerial docking system
Syam Prasad Ammineni, Sai Pradeep Ayyagari, Sai Shashank Cendepally Muni, Adithya Buddha, Srikar Somanchi · Mechanics Based Design of Structures and Machines · 2025
This paper presents the design, fabrication, and validation of a compact, modular manual aerial docking mechanism enabling mid-air integration between a child-drone and a mother-drone. The mechanism employs a two-stage approach: a centrally placed electromagnet ensures initial magnetic alignment, followed by a servo-actuated iris diaphragm that achieves mechanical locking. The system components were iteratively optimized through CAD modeling and structural simulations using ANSYS Workbench. Prototypes were fabricated via Fused Deposition Modeling (FDM) using PLA, ensuring material efficiency and lightweight construction. The mating probe comprising a stainless-steel bolt, PLA alignment disk, and a precision-machined mild steel billet demonstrated reliable engagement with the docking collar. Finite element analysis confirmed that the stress, strain, and deformation of both the iris diaphragm and docking collar remained well within the mechanical limits of PLA, affirming structural integrity. Ground-based tests validated strong magnetic retention under static and dynamic conditions, while full-scale flight tests confirmed reliable execution of docking and undocking sequences under real operating environments. A detailed weight analysis showed the total mass of the docking assembly to be 254.73 g, making it compatible with commercial UAV platforms rated above 300 g. These results verify the system’s mechanical robustness, functional reliability, and flight compatibility, establishing it as a novel and practical solution for modular UAV docking applications. The outcomes verify structural solidity, reproducibility, and viability for actual deployment. This research lays a groundwork for future autonomous docking systems incorporating computer vision and AI-driven target acquisition toward scalable swarm robot applications.