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An accurate mathematical model is indispensable for simulation and control of a micro helicopter. The nonlinear model in this work is based on the rigid body motion where all external forces and moments as well as the dynamics of the different hardware elements are discussed and derived in detail. The important model parameters are estimated, measured or identified in an identification process. While most parameters are identified from test bench measurements, the remaining ones are identified on subsystems using the linear prediction error method on real flight data. The good results allow to use the systems for the attitude and altitude controller design.

The goal of the European project muFly is to build a fully autonomous micro helicopter, which is comparable to a small bird in size and mass. The rigorous size and mass constraints infer various problems related to energy efficiency, flight stability and overall system design. In this research, aerodynamics and flight dynamics are investigated experimentally to gather information for the design of the helicopter's propulsion group and steering system. Several test benches are designed and built for these investigations. A coaxial rotor test bench is used to measure the thrust and drag torque of different rotor blade designs. The effects of cyclic pitching of the swash plate and the passive stabilizer bar are studied on a test bench measuring rotor forces and moments with a 6-axis force sensor. The gathered knowledge is used to design a first prototype of the muFly helicopter. The prototype is described in terms of rotor configuration, structure, actuator and sensor selection according to the project demands, and a first version of the helicopter is shown. As a safety measure for the flight tests and to analyze the helicopter dynamics, a 6DoF vehicle test bench for tethered helicopter flight is used.

The goal of the European project muFly is to build a fully autonomous micro helicopter, which is comparable to a small bird in size and mass. The rigorous size and mass constraints infer various problems related to energy efficiency, flight stability and overall system design. In this research, aerodynamics and flight dynamics are investigated experimentally to gather information for the design of the helicopter's propulsion group and steering system. Several test benches are designed and built for these investigations. A coaxial rotor test bench is used to measure the thrust and drag torque of different rotor blade designs. The effects of cyclic pitching of the swash plate and the passive stabilizer bar are studied on a test bench measuring rotor forces and moments with a 6-axis force sensor. The gathered knowledge is used to design a first prototype of the muFly helicopter. The prototype is described in terms of rotor configuration, structure, actuator and sensor selection according to the project demands, and a first version of the helicopter is shown. As a safety measure for the flight tests and to analyze the helicopter dynamics, a 6DoF vehicle test bench for tethered helicopter flight is used.

muFly EU project started in 2006 with the idea to build an autonomous micro helicopter, comparable in size and weight to a small bird. Several scientific and technological objectives were identified. This spanned from system-level integration, high efficiency micro-actuation, highly integrated micro vision sensors and IMUs and also low processing power navigation algorithms. This paper shows how most of these objectives were reached, describing the approach and the role of each partner during the whole project. The paper describes also the technological developments achieved like the 80 g, 17 cm micro robotic-helicopter, the 8 g omnidirectional and steady-state laser scanner, the uIMU, the highly efficient micro motors, the high power-density fuel-cell and the successful graph-based navigation algorithms