Designers are looking to reduce the cost of drone systems for a wide range of applications but still need to provide accurate positioning data. This however is not as easy is it might appear.

There are several satellite positioning systems, from the U.S.-backed GPS and European Galileo to NavIC in India and Beidou in China, providing data down to the meter. However, these need to be augmented by an inertial measurement unit (IMU) that provides more accurate positioning data that is vital.

Figure 1 An IMU is vital for the precision control of the drone and peripherals like gimbal that keeps the camera steady. Source: Epson

An IMU is typically a sensor that can measure movement in six directions, along with an accelerometer to detect the amount of movement. The data is then used by the developer of an inertial measurement system (IMS) with custom algorithms, often with machine learning, combined with the satellite data and other data from the drone system.

The IMU is vital for the precision control of the drone and peripherals such as the gimbal that keeps the camera steady, providing accurate positioning data and compensating for the vibration of the drone. This stability can be implemented in a number of ways with a variety of sensors, but providing accurate information with low noise and high stability for as long as possible has often meant the sensor is expensive with high power consumption.

This is increasingly important for medium altitude long endurance (MALE) drones. These aircraft are designed for long flights at altitudes of between 10,000 and 30,000 feet, and can stay airborne for extended periods, sometimes over 24 hours. They are commonly used for military surveillance, intelligence gathering, and reconnaissance missions through wide coverage.

These MALE drones need a stable camera system that is reliable and stable in operation and a wide range of temperatures, providing accurate tagging of the position of any data captured.

One way to deliver a highly accurate IMU with lower cost is to use a piezoelectric quartz crystal. This is well established technology where an oscillating field is applied across the crystal and changes in motion are picked up with differential contacts across the crystal.

For a highly stable IMU for a MALE drone, three crystals are used, one for each axis, stimulated at different frequencies in the kilohertz range to avoid crosstalk. The differential output cancels out noise in the crystal and the effect of vibrations.

Precision engineering of piezoelectric crystals for high-stability IMUs

Using a crystal method provides data with low noise, high stability, and low variability. The highly linear response of the piezoelectric crystal enables high-precision measurement of various kinds of movement over a wide range from slow to fast, allowing the IMU to be used in a broad array of applications.

An end-to-end development process allows the design of each crystal to be optimized for the frequencies used for the navigation application along with the differential contacts. These are all optimized with the packaging and assembly to provide the highly linear performance that remains stable over the lifetime of the sensor.

It uses 25 years of experience with wet etch lithography for the sensors across dozens of patents. That produces yields in the high nineties with average bias variations, down to 0.5% variant from unit to unit.

An initial cut angle on the quartz crystal achieves the frequency balance for the wafer, then the wet etch lithography is applied to the wafer to create a four-point suspended cantilever structure that is 2-mm long. Indentations are etched into the structure for the wire bonds to the outside world.

The four-point structure is a double tuning fork with detection tines and two larger drive tines in the centre. The differential output cancels out spurious noise or other signals.

This is simpler to make than micromachined MEMS structures and provides more long-term stability and less variability across the devices.

The differential structure and low crosstalk allow three devices to be mounted closely together without interfering with each other, which helps to reduce the size of the IMU. A low pass filter helps to reduce any risk of crosstalk.

The six-axis crystal sensor is then combined with an accelerometer for the IMU. For the MALE drone gimbal applications, this accelerometer must have a high dynamic range to handle the speed and vibration effects of operation in the air. The linearity advantage of using a piezoelectric crystal provides accuracy for sensing the rotation of the sensor and does not degrade with higher speeds.

Figure 2 Piezoelectric crystals bolster precision and stability in IMUs. Source: Epson

This commercial accelerometer is optimized to provide the higher dynamic range and sits alongside a low power microcontroller and temperature sensors, which are not common in low-cost IMUs currently used by drone makers.

The microcontroller technology has been developed for industrial sensors over many years and reduces the power consumption of peripherals while maintaining high performance.

The microcontroller is used to provide several types of compensation, including temperature and aging, and so provides a simple, stable, and high-quality output for the IMU maker. Quartz also provides very predictable operation across a wide temperature range from -40 ⁰C to +85 ⁰C, so the compensation on the microcontroller is sufficient and more compensation is not required in the IMU, reducing the compute requirements.

All of this is also vital for the calibration procedure. Ensuring that the IMU can be easily calibrated is key to keeping the cost down and comes from the inherent stability of the crystal.

Calibration-safe mounting

The mounting technology is also key for the calibration and stability of the sensor. A part that uses surface mount technology (SMT), such as a reflow oven, for mounting to a board, which is exposed to high temperatures that can disrupt the calibration and alter the lifetime of the part in unexpected ways.

Instead, a module with a connector is used, so the 1-in (25 x 25 x 12 mm) part can be soldered to the printed circuit board (PCB). This avoids the need to use the reflow assembly for surface mount devices where the PCB passes through an oven, which can upset the calibration of the sensor.

Space-grade IMU design

A higher performance variant of the IMU has been developed for space applications. Alongside the quartz crystal sensor, a higher performance accelerometer developed in-house is used in the IMU. The quartz sensor is inherently impervious to radiation in low and medium earth orbits and is coupled with a microcontroller that handles the temperature compensation, a key factor for operating in orbits that vary between the cold of the night and the heat of the sun.

The sensor is mounted in a hermetically sealed ceramic package that is backfilled with helium to provide higher levels of sensitivity and reliability than the earth-bound version. This makes the quartz-based sensor suitable for a wide range of space applications.

Next-generation IMU development

The next generation of etch technology being explored now promises to enable a noise level 10 times lower than today with improved temperature stability. These process improvements enable cleaner edges on the cantilever structure to enhance the overall stability of the sensor.

Achieving precise and reliable drone positioning requires the integration of advanced IMUs with satellite data. The use of piezoelectric quartz crystals in IMUs for drone systems offers significant benefits, including low noise, high stability, and reduced costs, while commercial accelerometers and optimized microcontrollers further enhance performance and minimize power consumption.

Mounting and calibration procedures ensure long-term accuracy and reliability to provide stable and power-efficient control for a broad range of systems. All of this is possible through the end-to-end expertise in developing quartz crystals, and designing and implementing the sensor devices, from the etch technology to the mounting capabilities.

David Gaber is group product manager at Epson.

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