Voyager 2.5 Sailing for 39 hours

 Voyager 2.5 - 39 hours of Ocean Sailing Data 

This article will summarize some the key real world statistics established after 39 hours at sea.

This information is only available because we are able to retrieve the vessel from rocks and read the on-board SD Card.

Voyager sailed well for about 39 hours until she stopped sailing due to water ingress.

Power Consumption 

The Battery was a pack of 14 x 18650 Cells, made up as 7P x 2S.

One of the cells had been tested and verified as having better than 3000mAhr in the voltage range of 4.2Vdc down to 3.0Vdc.

The main battery dropped from 8.30V to 8.12V over the mission.

This corresponds to 0.18Vdc drop over  39hours, or 0.11Vdc drop per day

Assuming a constant rate voltage drop, this would yield 20 days expect life, allowing for a 2.2Vdc drop, from 8.3Vdc to 6.1Vdc .
The actual rate of voltage drop would increase as voltage drops.

The Voyage Controller employs switching regulators to drop the 2S voltage down to 5Vdc for the servo, and 3.3Vdc for the electronics. As the supply voltage drops, the supply current increases to maintain a constant power consumption.

The Wing Sail battery voltage dropped from 4.16V to  4.08V over the mission.

This corresponded to 0.08Vdc drop over  39hours, which is 0.05Vdc drop per day.

This yields 20 days expect life

The Battery consists of 2 x 3Ahr 18650 Cells x 1S

Steering Servo Usage

The steering servo made 67k movements over the mission in 39hours

This corresponds to 1.8k movements per hour.

The Wing Sail Trim Tab made 9,895 movements over the mission, 39hours.

This average out at 250 movements per hour over the mission.

The rate of movement was 10 movements per hours over the first 6 hours.

Pitch

The variation of Pitch over mission was not extreme. The largest value of pitch was 10 degrees, at the start, while on land. The next largest was 9 degrees down, but typical values were less than 4 degrees.

 

Roll

The variation of roll over mission was not extreme. The largest value of roll occurred on land. The next largest was 40 degrees, but generally under 20 degrees.

Temperature

The temperature is measured in Wing Angle Sensor located in the Wing Angle Senor housing located at the base of the mast.

The measured temperature varied in accordance with the diurnal cycle over the 39 hours of the voyage, except for the last half hour where the measured temperature increased dramatically.

This was most likely due to water damage. 

Atmospheric Pressure

The barometric pressure sensor is collocated with the compass sensor.

Link for plot of positions reported via satellite:

https://maps.findmespot.com/s/VG5D

Voyager 2.5 Ocean Voyage

 Voyager 2.5 Two Day Ocean Voyage

Dawn on Monday morning July 11, 2022, Voyager 2.5 was launched from Torquay Beach for a mission through to Western Port, on the eastern side of Melbourne, Victoria.

It is a journey into Bass Strait with distance of around 50nm or around 80km. The mission was made up of around 8 waypoints, expect to take just under 48 hours.

Voyager 2.5 undergoing lake trials in 15 to 20 knots.

Planned course from Torquay heading east to Cape Schanck and into Western Port

Voyager 2.5 on Torquay beach just prior to launch 7:30am 11/7/2022

She sailed well for the first day and a half, but near the 39th hour Voyager stopped sailing. She drifted back out to sea with the tide, and then drifted along the coast of Philip Island for about 20 hours, and drifted ashore on the rocks.

Sailing well past the Cape Schanck waypoint heading into Western Port at 6:30pm 12/7/2022 - 35 hours

Voyager stopped sailing just before reaching the the West Head waypoint 10:59pm 12/7/2022 - 39 hours, then drifted back out to sea.

Voyager drifted east for another day coming ashore on rocks at Redcliff Head, Philip Island at 9pm 13/7/2022

Fortunately we were able to recover the boat from the rocks the next day. This was valuable, and has helped us work out what went wrong.

The onboard SD Card that logs many of the boats operating parameters is intact and can be analysed.

View from Pyramid Rock looking west toward Flinders, showing Redcliff Head, at around the time of coming ashore.

Voyager 2.5 as found on Thursday morning at low tide, perched on  a rock.

The preliminary review of the evidence suggests that the boat stopped sailing because water leaked into the main equipment compartment and damaged the controller.

The evidence suggests that the water leaked through the Wing Angle Sensor housing. This is a 3D printed component. It appears to be watertight, but over a period of two days, a small amount of water can leak through the walls of the printed component. In future, this component will be assembled using different methods to avoid the leaking problem.

Voyager 2.5 suffered a lot of damage on the rocks. It is likely that she will patched up yo be able make another ocean voyage to further test the systems.

The next article will discuss some of the overall results from the voyage. A further detailed article will cover the evidence and events surrounding the failure.

Link for plot of positions reported via satellite:

https://maps.findmespot.com/s/VG5D

 Voyager 2.0 returns to sailing as Voyager 2.5

After Voyager made an ocean voyage in May 2021, she was retired, and focus shifted to Voyager 3.0. But after some thought it was decided to refurbish and upgrade Voyager 2.0 to become Voyager 2.5 with aim of completing an ocean voyage.

The main features of the upgrade of Voyager 2.5 are:

• Aluminium mast replaced with Carbon fibre.
• Aluminium fin increased in thickness from 3mm to 5mm, to increase stiffness and strength.
• Sail Plan reduced in height by 100mm to reduce heeling moment, but increased length cord low down. The overall sail area was increased, but heling moment was reduced.
  Overall, its a much better sail plan.
• Updated Wing Sail Controller PCB. Improved design and an improved software increased battery life of Wing Sail from around 8 days to 20 days. The radio link was changed from Bluetooth 4 to Bluetooth 5 (with other methods in between).
• Updated Voyager Controller PCB, with new Teensy 3.6 microprocessor, rather than the Arduino Mega2560. Improved design and an improved software increased battery life of main controller from around 8 days to 20 days.
• Improved fastening of the equipment cases to the hull to prevent them being lost.

Voyager 2.0, with a similar setup used for the ocean voyage in May 2021

Voyager 2.0 refurbished as 2.5, under-going final lake trials prior to going to sea, June 2022.

Voyager 2.5 on Torquay beach, preparing to go to sea

 Wingsail Controller Evolution

The wingsail is mounted on ball bearing races, and must be able to freely rotate. It also has a trim tab that must be controlled.

My solution to this has been to develop a controller to operate a trim tab servo under the command of a radio signal of some type.

The Voyager Sail Controller is visible in the image of Voyager 2.0 sailing, as the green PCB in wingsail.

Voyager 2.0 with Sail Controller V1 fitted in the Wingsail 

The first designs used Bluetooth 4 as the communications link. The Voyager Sail Controller was set up as a Slave Bluetooth 4 device, connecting to the main Voyager Controller which was the Bluetooth  Master.

This worked well but the Bluetooth 4 modules had a continuous current drain of about 9mA while connected.

Prototype Wingsail Controller using Bluetooth 4

Voyager Sail Controller V0 using Bluetooth 4 - August 2018

Voyager Sail Controller V1 using Bluetooth 4 - March 2019

During 2019 we changed the main telemetry link to the vessel to be LoRa radio using the Ebyte devices. 

The Ebyte LoRa devices can be operated in a low power mode, where they wake up at predetermined intervals and check for a signal and then return to sleep. In practice, this yields an average current drain of around 6mA.

It also yielded the benefit that there are less components required on the Main Voyager controller, because the radio link to the wingsail is the same as the telemetry link to shore.

The only problem is the slow data rata rate and high latency. This yielded delays of around 1 to 2 seconds from when the wingsail should be responding.

Voyager Sail Controller V2 using LoRa Radio - May 2019

In 2022 the Bluetooth 5 module JDY-25M became available, and new Wingsail controller V4 was developed.

The JDY-25M Bluetooth 5 module has an idle current of around 1mA.

The low current consumption, combined with high data rate and low latency make a good option.

As of mid-2022, this is best version of the Wingsail controller yet.

When the wingsail is fitted with 2 x 2200mAHour 18650 cells, the wingsail has a projected battery life of at least 2 months.

This compares very well with the original Bluetooth 4 Wingsail controller having a battery life of around 8 days.

Voyager Sail Controller V4 using Bluetooth 5 - February 2022

Self Trimming Wingsail Design 101 (or What I should have known already)

 Self Trimming Wingsail Design - 101

The first sailing trials for Voyager 3 in late 2021 were disappointing.

The boat could not sail a straight course and was uncontrollable.

At first, I thought it was due to turbulent winds caused by the nearby trees, but eventually it became apparent that there was a basic design flaw in the new sail.

The issue relates to the location of Centre of Pressure for a foil.

The Centre of Pressure must be behind the axis of rotation to ensure that the self trimming wingsail will operate correctly and "feather", pointing into the wind.

Various refences indicate that the Centre of Pressure (CP), or Aerodynamic Centre of a foil with established circulation is around 25% back from the leading edge.

Before the circulation is established, the CP will be located close to the centroid of the foil.

Reference: Center of Pressure (nasa.gov)

My sail design has the axis of rotation located 37.5% back from the leading edge. This was chosen, because it seemed reasonable

The image below shows the calculated location of the line of the CP (25%) and the line of the Centroid (50%).

First Wingsail Design for Voyager 3 - CP is too far forward.

The calculated CP is forward of the axis of rotation by about 18mm. That is bad.

The effect of this is that initially the CP will be close to the 50% line (behind the mast), causing the wingsail to feather and commence operating.

Then as the circulation builds, the CP moves forward to the 25% line (forward of the mast). This causes the leading edge to fall away, and foil stalls, and CP moves back to the 50%.

So with these conditions, the wingsail may oscillate back and forth, yielding an uncontrollable boat.

The video below provides examples of unstable behaviour of the sail.





In future, I plan on placing the mast at the 25% line within the foil. Then a tail of almost any size will ensure that the CP is drawn behind the mast, yielding a stable design.

Once the issue of CP being located at the 25% line was understood, a new larger tail could be designed which would draw the CP aft. 

The image below shows the new locations of the CP and centroid with the new tail fitted, which is just over 3 times the size of the original tail.

Updated Wingsail Design - CP remains aft of the axis

Voyager 3.0 - First On-water Trial

Its November 2021 and most lockdown restrictions are gone now.
Today was the first opportunity to get on the local lake for the maiden voyage of Voyager 3.0.
It was good to get the boat in the water for the firs time,  but it was inconclusive due to turbulent winds coming through the nearby trees making course keeping difficult.

I need to pick a day on the lake with north-westerly winds to get the cleanest winds for testing.

Voyager 3.0 Approaches First Sailing Trial

September 2021 in Melbourne is still a time of lockdown with restricted travel.

This has allowed time on the weekends to move forward with Voyager 3.0.

The first sail for Voyager 3 is almost complete and almost ready for the water. 

This is the Lake sail, which is intended to be a fairly large sail for lake use, not in the ocean.

It is expected that the Ocean sail will be about 75% of the size of the Lake sail.

The structure of the Lake Sail is complete, awaiting the plastic covering.

 Voyager 2.0 Last Voyage. What happened ?

Voyager 2.0 was at sea for 32 hours before the failures occurred, leaving the boat adrift for a further 44 hours.

The mast was broken off , and the electronic controller was lost.

Voyager 2.0 shortly after recovery

The mast suffered a brittle fracture at deck level.

The image below shows the fracture.

Remainder of Mast showing the brittle fracture at deck level

A test bend was performed on the remaining part of the aluminium mast.

It displayed the typical ductile bend expected of aluminium tubing.

The aluminium mast had been in use for around 3 years. 

The brittle fracture was probably due to work hardening or a fatigue failure.

This failure was avoidable.

Testing of the remainder of the mast showing ductile failure.

The Electronic Voyager Controller was lost when the lashing failed. The lashing was fixed to the hull using a simple 25mm screw through the fibre glass and into the foam. 

This was fine for trials on a lake, but clearly not suitable for ocean conditions.

Failed Lashing intended to restrain the Equipment Compartment 

The Spot GPS and the controller are housed in a Sistema Brilliance 920ml container. After 76 hours at sea, about 5ml of water had entered the container.

This implies that additional sealing will be required if these containers are used at sea. The containers are watertight for short durations, such as lake trials.

Tests will need to be performed to establish the reason for the water ingress. This could include diurnal heating and cooling, improperly seated seal, possibly due to dirt particles, or simple leaking through the seal.

Brilliance 920ml Container with the 5ml water acquired during the 76 hours at sea.

 First and Last Ocean Voyage of Voyager 2.0

May Day 2021, a Saturday, at 6am, Voyager 2.0 commenced its first ocean voyage from a beach at Torquay in western Victoria. The course consisted of seven waypoints covering 55nm through to a beach in Western Port, in eastern Victoria.

The course from Torquay to Pt Leo.

Pre-Launch

Sunrise on May Day with Voyager a few kilometres into the voyage, still in range of the LoRa telemetry.

The winds were light to moderate from the north for the majority of the journey.

She sailed well for 32 hours to the waypoint south of Cape Schanck, a distance of approximately 30nm. Voyager successfully round the waypoint at about 1:40pm on Sunday May 2nd.

Voyager 2.0 sailed well for 32 hours in Bass Strait.

The boat successfully rounded the waypoint, and commenced the beat in the north easterly wind, but within about half an hour there was a catastrophic failure of some type which meant the boat was no longer sailing. 

With good fortune, the winds turned to the south east later that night, at around 20 to 25 knots.

The slow rate of drifting, in strong winds implied that wingsail was not present.

Eventually Voyager drifted with the tides and the south easterly winds into Western Port.

It ultimately drifted in to a beach at Shoreham, where I was able to retrieve it, 44 hours after the failure.

It was an extraordinary coincidence that the beach at Shoreham where the boat drifted ashore was just 3km from the intended destination at Pt Leo. 

Once Voyager was retrieved the nature of the failure became apparent.

The wingsail was missing as expected, but also the main controller was missing. 

This contained the electronics including the SD card recording the sailing data.

It was lucky that the GPS satellite tracking  was not lost, and allowed the remainder of the boat to be retrieved.

The remnants of Voyager on the beach at Shoreham.

Voyager 3.0 Emerges

Voyager 3.0 Design Goals

Voyager 3.0 is next in the series of the Voyager sailing drones.

The main aim for Voyager 3.0 is to be able to operate at sea for about 14 days or longer.

Voyager 2.0 can only operate for about 4 days on battery. Voyager 3.0 will include solar charging with the aim of allowing continuous operation. An endurance of 14 days at sea should allow for a rounding of King Island from the Victorian coast and back.

Tests of solar charging rigs have suggested that around 20 solar cells as a minimum are needed for reasonable charging levels for a 2S battery powering Voyager.

The dimensions of Voyager 3.0 have been entirely dictated by the compromise of minimum size for ease of handling, versus adequate deck space to accommodate enough half-size solar cells to support reasonable charging levels.

Overall dimensions of 1800mm length and 350mm beam were chosen to allow possibly up to 23 half-size solar cells to be accommodated.

Proposed Deck Layout with 23 Cells 

Proposed Layout for Voyager 3.0 along side Voyager 2.0 for comparison

Commence Construction of Voyager 3.0 with the Stringer, shown partially completed here

Preparing to glue the first foam sheet on the stringer.

Part way through cutting the foam sheets using a hotwire cutter.

Commence shaping the laminated foam hull.

Part way through shaping of the foam core hull

Voyager 3.0 with glassing finished, ready for fit-out, along side Voyager 2.0

Note: This is part of the ongoing development of a low cost autonomous oceangoing sailing drones, utilising a self-trimming wingsail. This is the Voyager series of sailing drones.

Another Port Phillip Crossing Attempt - Post COVID Lockdown

Melbourne, Australia has come out of the second lockdown recently, so on December 10 2020, I commenced another run across Port Phillip.

In the months since the last run we've been in lock down for weeks at a time and not permitted to either leave home or leave our local area without good reason.

During this time Voyager 2.0 has had some hardware and software updates based on lessons learnt during the last crossing attempt.

The main software issue being addressed was the method of correcting the course as the vessel is steering toward a distant waypoint.

Checks done. Ready to go again.

 Steering to a Waypoint

When waypoints are only a few hundred metres away, it is simple to steer a course representing the Bearing to Waypoint (BTW) and you will typically arrive there, having followed closely along the rhumb line.

When the waypoint is many miles away, and the steering method is to steer the BTW, then it is quite likely that the vessel will deviate great distances from the rhumb line over a period of time.

This was one of the problems encountered during the last voyage across Port Phillip in March 2020.

The main software design change since then was to continual measure the Cross Track Error  (CTE) and use this to add a proportional course correction to the BTW to encourage the vessel to return to the rhumb line. The amount of course correction to apply is calculated as the ratio of CTE to CTEMax (where CTEMax is defined in the mission as half width of the corridor to the next waypoint), multiplied by gain constant.

Hence the simple course to be steered is: BTW - CTE/CTEMax x Kc

Note: This is all assuming that a course can be laid directly to the waypoint without tacking. If tacking is required, then a whole set of different rules apply which are beyond the scope of this article.

The first 10 hours were good

The vessel sailed from east to west, and for the first 10 hours was perfectly on course, staying very close to the rhumb line.

Unfortunately, at 6am the next morning, it was once again picked up be a fishing boat. A commercial fishing vessel this time.

This can be seen in satellite tracking plots shown in the image below. It was picked up in the middle of Port Phillip, as it was heading eastward, and carried on the remainder of their fishing trip, before the fishing vessel returned to her home port of Port Arlington.  I arranged to meet them there for the handover.

Satellite Tracking Plot 

Shared View: Voyager 2.0 December 2020 - SPOT Tracking (findmespot.com)

Mission in Yellow and actual course in Green. You can hardly separate them

Conclusions

The new method of steering using CTE combined with BTW appears to work well.

I've tried to sail across Port Phillip twice now, and failed both times due to human intervention.

I'll need to add signage suggesting to "KEEP CLEAR" or head out to the open ocean where there's less chance of meeting other vessels.

Port Arlington - Home Port for the last vessel to "rescue" Voyager

This is part of the ongoing development of a low cost autonomous oceangoing sailing drones, utilising a self-trimming wingsail. This is the Voyager series of sailing drones.

Solar Charging Trials during COVID19

Solar Charging Trials - in COVID Times.

It is August 2020 in Melbourne, Australia. We haven't been allowed to travel any distance for many weeks now, so there's no sailing trials permitted for hobbyists. So no chance to test the new sail, or the new LoRa telemetry system now installed on Voyager 2.0.

This allows time to start looking ahead to Voyager 3.0, which will be a scaled up version of Voyager 2.0 at 2m LOA, and about 0.5m in beam.

The intention of Voyager 3.0 is that it has a large enough deck space to accommodate enough solar cells to allow for missions of indefinite duration. Currently the battery capacity of Voyager 2.0 is about 80 to 120 hours (4 or 5 days). The Wingsail battery life is about 200 hours (8 days).

The Solar Cells in use are the Sunpower C60 cells. These are a light weight and flexible (within limits) and can be sliced up. They can provide over 3A at around 0.5V in direct sun. I'm currently slicing them into thirds, which can yield around 1A at 0.5V per cell in direct sun, and of course when connected in series, the three cells can yield 1.5V at 0.5A.

The image below shows a typically test set up for working out the basic parameters of the charging setup.

Preliminary Test Set up for assessing Cell Quantity and Charging Circuits

In order to evaluate different Solar Charging arrangements in the real world, I commenced with the Wingsail by pressing into service the failed (overweight) WingSail #2. This was kitted out with 4 third size slices of Sunpower C60 Cells in conjunction with the LTC3015 Step up DC-DC converter charging a single 18650 Li-ion cell. The load is the current Wingsail Controller board, but without the Bluetooth module, which was replaced with an Ebyte LoRa module instead. The Wingsail Controller was programmed with software primarily intended to read 3 sets of Voltages and currents and transmit them to a monitoring station.

Mock up of the Voyager Wingsail and electronics for trialing Solar Charging

It will be necessary to place cells on both sides of the sail.

The current Wingsail (without Solar Charging) has two 18650 cells. It is expected that only one cell will be required once solar charging is used. This will partially offset the increased weight due to solar cells (but not by much).

The test rig charging circuits and the the test rig software  are still being adjusted, but the aim is to monitor the operation of the solar charged Wingsail over a period of a month or so.

During this time, we'll start on a mock up of the deck of  the future Voyager 3.0 and set up a solar charging test rig for her.

This is part of the ongoing development of a low cost autonomous oceangoing sailing drones, utilising a self-trimming wingsail. This is the Voyager series of sailing drones.