Experimental and numerical analysis of an optimized flapping wing mechanism for flapping wing robots

Abstract Flapping Micro Aerial Vehicles (FW-MAVs) offer remarkable features such as compact size, lightweight structure, high manoeuvrability, stealth capabilities, and hovering ability, making them highly suitable for applications like surveillance, reconnaissance, search, and rescue [1–7]. However, vibrations generated by their flapping wing mechanisms can significantly impact structural rigidity, stability, performance, fatigue life, and operational safety. This study presents a comprehensive investigation into the structural performance of both optimized and non-optimized flapping wing drone mechanisms aimed at enhancing structural rigidity and overall stability. The research methodology integrates Finite Element Method (FEM) simulations, precision fabrication of optimized components, and seamless integration into the existing FW-MAV system. The simulations accurately determine natural frequencies, mode shapes, and deformation behaviour of critical components, particularly the motor holder. Experimental validation using high-precision displacement sensors confirmed that the optimized gearbox effectively reduces vertical displacement to less than half of that observed in the original system across five different flapping frequencies. The improved design successfully minimizes detrimental vibrations, thereby enhancing fatigue life, stability, and safety during high-frequency flapping. These findings provide valuable insights for developing more robust, reliable, and efficient FW-MAVs capable of performing effectively in complex and demanding operational environments.