DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
(See section 10 and rule 13)

A FLIGHT CONTROLLER SYSTEM FOR UNMANNED AERIAL VEHICLES (UAVs)

TECHNOLOGY INNOVATION IN EXPLORATION & MINING FOUNDATION, a company incorporated in India, having address at 3rd Floor, i2h Tower (Institute Innovation Hub), IIT(ISM) Dhanbad, Jharkhand - 826004

The following specification particularly describes the invention and the manner in which it is to be performed.
FIELD OF THE INVENTION
The present invention relates to a flight controller system for unmanned aerial vehicles (UAVs).

BACKGROUND OF THE INVENTION
Conventional flight controller boards/systems incorporate microcontrollers and intricate assembly of indispensable technologies essential for optimal functioning of unmanned aerial vehicles (UAVs). The array of sensors, gyroscopes, accelerometers, and magnetometers connected to the flight controller board are pivotal for precise attitude determination, orientation control, and overall stability of the UAVs throughout aerial operations.

Further, the flight controller boards/system are designed to incorporate adaptable connectors ensuring seamless connectivity with various peripherals, including receivers for remote control, cameras for visual capturing of the data, and global positioning system (GPS) modules for positioning and navigation. The capacity to accommodate such peripherals significantly amplifies the flight controller board’s/system’s ability and its utilization across diverse applications ranging from recreational drones to sophisticated professional aerial surveying systems.

However, the presently available flight controller boards/systems fail to comprehensively encompass the specialized capabilities required in the mining industry such as:
1. Heightened safety;
2. Precise navigation;
3. Enhanced adaptability within the unique dynamics of the mining industry environment such as resistant to dust, vibration, and extreme temperature;
4. Increased payload capacity;
5. Autopilot compatibility; and
6. Firmware customization.
Therefore, the object of the present invention is to solve one or more of the aforementioned issues.

SUMMARY OF THE INVENTION
This summary is provided to introduce concepts related to a flight controller system for unmanned aerial vehicles (UAVs). The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

A flight controller system for unmanned aerial vehicles (UAVs) is described. The system comprises an enclosure, a multi-layer printed circuit board (PCB), a processing unit mounted on the PCB, and a peripheral unit, connected to the PCB, and operatively coupled to the processing unit.

In some embodiments, the PCB is placed within the enclosure, with dedicated ground planes, and differential signal routing to provide integrated electromagnetic interference (EMI) shielding, electromagnetic conductance (EMC) shielding, and electromagnetic susceptibility (EMS) shielding for stable operation in high-noise environments; wherein the PCB comprises a sensor unit, a power unit, distributed surface-mount device (SMD) capacitors, and a 25 MHz industrial-grade crystal oscillator.

In some embodiments, the processing unit comprises:
a. at least one microcontroller centrally positioned on the PCB to minimize trace lengths to associated components, wherein the microcontroller is thermally isolated from high-power components to prevent performance degradation, wherein the microcontroller comprises:
i. an Extended Kalman Filter (EKF)-based navigation module configured to provide real-time state estimation by utilizing data received from the sensor unit for normal operation as well as operations in failsafe condition by allowing immediate corrective actions during system failures or communication loss in GPS-denied environments;
ii. a failsafe module operatively connected to the Extended Kalman Filter (EKF)-based navigation module wherein the failsafe module being configured to detect failsafe triggering events and operational anomalies to autonomously initiate safety measures to prevent operational failure; and
iii. an adaptive control module coupled to the microcontroller and the sensor unit, wherein the adaptive control module is configured to dynamically adjust flight parameters in response to environmental changes to maintain stable flight and enhance operational reliability;
b. a communication module for communication to and from microcontroller; and
c. a microcontroller memory unit connected to the microcontroller.

In some embodiments, the peripheral unit comprises a port for battery connection, an input-output (I/O) port, a peripheral memory unit, and a plurality of connection ports for connecting peripherals as required by the user.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention disclose a flight controller system for unmanned aerial vehicles (UAVs). The following is a detailed description of embodiments of the disclosure. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.

As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

The flight controller system for unmanned aerial vehicles (UAVs) is described. In some embodiments, the system comprises an enclosure, a multi-layer printed circuit board (PCB), a processing unit mounted on the PCB, and a peripheral unit, connected to the PCB, and operatively coupled to the processing unit.

In some embodiments, the PCB is placed within the enclosure, with dedicated ground planes, and differential signal routing to provide integrated electromagnetic interference (EMI) shielding, electromagnetic conductance (EMC) shielding, and electromagnetic susceptibility (EMS) shielding for stable operation in high-noise environments; wherein the PCB comprises a sensor unit, a power unit, distributed surface-mount device (SMD) capacitors, and a 25 MHz industrial-grade crystal oscillator.

In some embodiments, the processing unit comprises:
a. at least one microcontroller centrally positioned on the PCB to minimize trace lengths to associated components, wherein the microcontroller is thermally isolated from high-power components to prevent performance degradation, wherein the microcontroller comprises:
i. an Extended Kalman Filter (EKF)-based navigation module configured to provide real-time state estimation by utilizing data received from the sensor unit for normal operation as well as operations in failsafe condition by allowing immediate corrective actions during system failures or communication loss in GPS-denied environments;
ii. a failsafe module operatively connected to the Extended Kalman Filter (EKF)-based navigation module wherein the failsafe module being configured to detect failsafe triggering events and operational anomalies to autonomously initiate safety measures to prevent operational failure; and
iii. an adaptive control module coupled to the microcontroller and the sensor unit, wherein the adaptive control module is configured to dynamically adjust flight parameters in response to environmental changes to maintain stable flight and enhance operational reliability;
b. a communication module for communication to and from microcontroller; and
c. a microcontroller memory unit connected to the microcontroller.

In some embodiments, the peripheral unit comprises a port for battery connection, an input-output (I/O) port, a peripheral memory unit, and a plurality of connection ports for connecting peripherals as required by the user.

In some embodiments, the PCB comprises:
a. a sensor unit comprises an inertial measurement unit (IMU) configured to provide real-time orientation and acceleration data, a magnetometer for providing heading information, a barometric sensor for altitude measurement, and a GPS unit to provide position and navigation related data.

b. a power unit, to control impedance for optimized power management, comprises a switching voltage regulator, a low-dropout regulator, an inductor, and a schottky rectifier for reverse current protection, wherein low forward voltage drop minimizes power losses and prevents damage to critical subsystems during transient power fluctuations;
c. distributed surface-mount device (SMD) capacitors mounted to sensor unit and the power unit, wherein the surface-mount device (SMD) capacitors is mounted on the sensor unit for noise filtering (decoupling), and precise signal conditioning, and wherein the surface-mount device (SMD) capacitors is mounted on the power unit for power stabilization, and noise filtration; and
d. a 25 MHz industrial-grade crystal oscillator, wherein precise clock stability ensures accurate execution of real-time control loops, high-fidelity sensor sampling, and error-free digital communication.

In some embodiments, the inertial measurement unit (IMU) is an MPU-6050 which comprises of a gyroscope and accelerometer along with Digital Motion Processor, wherein the magnetometer is HMC5883L, and wherein barometric sensor is BME280.

In some embodiments, the power unit is configured to optimize power management and utilises techniques, including EMI suppression, ferrite bead filtering, and PCB trace optimization, wherein the power unit provides minimal power loss, mitigates EMI, and maintains compliance with industrial EMC standards.

In some embodiments, the low-dropout regulator and switching voltage regulator are high-current power components which are physically segregated from low-noise analog and digital signal paths using copper pours and ground separation zones, wherein this structural design prevents cross-talk, enhances sensor stability, and maintains reliable communication in EMI-prone environments.

In some embodiments, the switching voltage regulator is LM2596, wherein the low-dropout regulator is RT9080-33GJ5, wherein the inductor is a 68µH, and wherein the schottky rectifier is SS34.

In some embodiments, the PCB has dedicated ground loops and differential signal routing to prevent EMI, EMC, EMS, mitigate cross-talk, and ensure compliance with industrial EMC regulations for stable operation in hazardous environments.

In some embodiments, the power unit comprises an intrinsically safe power architecture with galvanically isolated circuits and transient voltage suppressors.

In some embodiments, the microcontroller is configured to communicate with the inertial measurement unit (IMU), the magnetometer, the barometric sensor, and the GPS unit of the sensor unit for sending and/or receiving the data.

In some embodiments, the microcontroller is STM32F4 series, preferably, STM32F411.
In some embodiments, the communication module is configured with optimized pull-up resistor values and clock stretching mechanisms to enable low-latency data transmission based on protocol, including, an Inter-Integrated Circuit (I2C), and a Serial Peripheral Interface (SPI) protocol.

In some embodiments, the processing unit comprises:
a. an integrated Fly-By-Wire (FBW) module comprises a sensor validation submodule that cross-validates redundant sensor data to isolate faults and ensure accurate state estimation; an autonomous mode transition submodule for stable switching between manual and autonomous control upon detecting sensor discrepancies; a failsafe mechanism submodule that overrides manual inputs to maintain stability during critical failures; a priority-based command processor submodule for superseding critical commands over non-essential inputs; a low-latency communication interface submodule for rapid signal transmission; and an integrated stability control submodule that counteracts environmental disturbances for precise flight control;
b. a real-time manual UAV control module having capability of priority override logic; and
c. a low-latency communication module having protocols, including i-BUS, SBUS, PPM, and ExpressLRS for communication through input-output (I/O) port to communicate with unmanned aerial vehicles (UAVs).

An example of working of a Fly-By-Wire (FBW) module is described. The FBW module includes:
a. Triple-Redundant Sensor Validation
i. The FBW module continuously cross-validates IMU, magnetometer, and barometric sensor data to detect inconsistencies.
ii. Faulty sensor inputs are isolated, and redundant data sources are used to maintain accurate state estimation.
b. Autonomous Mode Transition for Flight Stability
i. If sensor discrepancies exceed predefined thresholds, the FBW system autonomously switches between manual and autonomous control modes.
ii. Ensures seamless transition without inducing instability during in-flight anomalies.
c. Failsafe Mode Engagement via FBW
i. If a critical failure is detected (e.g., navigation errors, loss of GPS or control link), the system overrides manual inputs and enters failsafe mode.
ii. Maintains aircraft stability and prevents erratic behaviour during emergency landings.
d. Real-Time Command Processing with Priority Override
i. The FBW system implements a priority-based logic where critical commands (e.g., emergency landing) override non-essential inputs.
ii. Prevents erratic pilot commands from compromising flight safety during system failures.
e. Low-Latency Communication for Rapid Response
i. The FBW module utilizes optimized I2C, SPI, and UART protocols to ensure minimal latency in control signal transmission.
ii. Enables near-instantaneous reaction to pilot commands and system-generated corrections.
f. Integrated Stability Control for Adverse Conditions
i. Actively compensates for environmental disturbances such as wind gusts, turbulence, or sudden attitude deviations.
ii. Maintains precise flight control by dynamically adjusting motor outputs based on real-time sensor feedback.

In some embodiments, the processing unit comprises:
a. a monitoring and feedback module for continuously tracking critical subsystems including power management, communication interfaces, and sensor health, wherein the monitoring and feedback module enhances UAVs operational reliability by enabling predictive maintenance and mitigating potential failures before they impact mission performance.
b. a telemetry module capable of real-time diagnostics and fault prediction;
c. an adaptive thresholding module for proactive anomaly detection; and
d. a remote-control override module for overriding the control of remote control in event of remote-control failure.

In some embodiments, the remote-control override module comprises:
a. a signal capture submodule that utilizes hardware interrupts and timers to receive and measure pulse-width modulation (PWM), SBUS (Serial Bus), or iBUS signals with microsecond precision;
b. a control arbitration submodule configured to switch between autopilot and manual control based on RC signal validity;
c. a direct memory access (DMA) submodule to enable low-latency processing of RC signals without CPU polling;
d. an input smoothing mechanism submodule having an extended Kalman filter (EKF) to ensure stable actuator transitions during control mode switches;
e. an error detection submodule having cyclic redundancy checks (CRC) to validate and discard corrupted RC signals; and
f. a failover submodule having a watchdog timer to detect signal loss and trigger failsafe actions including return-to-home (RTH) or controlled landing.

An example of working with the remote-control override module is described. The remote-control override module includes:
a. Hardware Interrupt-Driven Signal Capture
i. The microcontroller utilizes dedicated hardware timers and external interrupts to capture PWM, SBUS, or iBUS signals from the RC receiver.
ii. Timer Input Capture (TIC) registers measure pulse width with microsecond precision, ensuring low-latency signal processing.
b. Priority-Based Control Arbitration Using Multiplexing
i. A real-time software multiplexer within the flight control firmware continuously switches between autopilot and manual control based on RC signal validity.
ii. Conditional branching in the control loop checks for active RC inputs and overrides flight computer commands when necessary.
c. Direct Memory Access (DMA) for Low-Latency Processing
i. DMA channels are configured to handle high-speed serial protocols like SBUS and iBUS without burdening the CPU.
ii. This allows immediate command execution by bypassing processor-intensive polling methods.
d. EKF-Based Input Smoothing for Transition Stability
i. The Extended Kalman Filter (EKF) integrates real-time sensor fusion to dampen abrupt attitude changes when switching from autonomous to manual control.
ii. A transient damping algorithm adjusts actuator outputs gradually, preventing sudden motor response spikes.
e. Error Detection & Signal Validation via CRC Checking
i. Cyclic Redundancy Check (CRC) verification is applied to digital RC signals (SBUS/iBUS) to detect transmission errors.
ii. Invalid or corrupted packets are discarded, ensuring only stable control inputs affect the UAV’s behaviour.
f. Failover Logic for Signal Loss Detection and Recovery
i. A watchdog timer monitors RC link status and triggers automatic reversion to failsafe mode if signal dropout is detected.
ii. The system switches to pre-programmed return-to-home (RTH) or landing procedures based on the last valid flight state.

In some embodiments, the peripheral memory unit comprises a high-speed NOR Flash memory with error correction code (ECC) support for telemetry buffering and secure firmware storage.

In some embodiments, the failsafe module comprises:
a. a detection submodule for monitoring power, communication, and sensor status to autonomously trigger controlled landing upon anomalies;
b. a response submodule configured to conserve power during battery anomalies, execute return-to-home (RTH) or landing procedures based on the last valid flight state or auto-land mode based on last known GPS coordinates, maintain position during radio loss and land if reconnection fails, and isolate faulty sensors and stabilize excessive drift;
c. a power-fault tolerance submodule ensuring essential control during power disturbances;
d. a telemetry submodule enabling predictive failure mitigation; and
e. a redundancy submodule with firmware rollback to ensure continuous failsafe operation.

An example of working of the failsafe mechanism by the failsafe module is described. The failsafe module includes:
a. Failsafe detection and autonomous triggering
i. The failsafe module continuously monitors critical parameters, including power status, communication integrity, and sensor functionality.
ii. If an anomaly is detected, the system autonomously initiates a controlled landing sequence.
b. Failsafe Conditions & Response Mechanisms
i. Battery Anomaly or Voltage Reduction:
1. The power management system detects undervoltage or abnormal discharge rates.
2. Non-essential subsystems are disabled to conserve power while ensuring stable descent.
ii. Ground Station Control Loss:
1. If telemetry link failure is detected, the UAV enters a pre-configured return-to-home (RTH) or auto-land mode based on last known GPS coordinates.
iii. GPS Signal Loss:
1. The Extended Kalman Filter (EKF) uses IMU, magnetometer, and barometric sensor data for dead reckoning-based position estimation.
2. If sustained loss occurs, the system initiates a controlled descent using relative altitude estimation.
iv. Radio Signal Loss (RC Link Failure):
1. If command input is lost, the flight controller holds the last known stable position and attempts reconnection.
2. If the signal is not restored within a set timeout, the UAV autonomously lands at the safest estimated location.
v. Sensor Malfunction:
1. Redundant sensor validation identifies faulty readings, isolating defective inputs to prevent erroneous control commands.
vi. Severe Flight Instability (Excessive Drift or Angular Deviation):
1. The system detects excessive deviation beyond predefined thresholds and engages emergency stabilization and landing procedures.
c. Power-Fault Tolerance for Continuous Operation
i. The power unit features galvanically isolated circuits, transient voltage suppressors, and EMI shielding to prevent system shutdown during transient power failures.
ii. Essential flight control functions are prioritized to ensure a safe descent in case of power anomalies.
d. Telemetry-Based Predictive Failure Mitigation
i. The telemetry module continuously tracks sensor diagnostics and system health.
ii. Predictive failure detection ensures failsafe activation before critical failures occur.
e. Multi-Boot Redundancy for Fail-Safe Execution
i. Firmware rollback prevents execution failures due to corruption, ensuring continuous failsafe operation.
The failsafe module ensures the UAV can autonomously provide a controlled landing under multiple failure scenarios, enhancing operational reliability and safety.

In some embodiments, the adaptive control module comprises:
a. a real-time sensor-driven submodule that adjusts flight parameters based on data from the IMU, magnetometer, barometric sensor, and GPS to optimize stability;
b. an environmental response mechanism submodule that modifies control gains and motor outputs to counteract atmospheric pressure changes, wind disturbances, and acceleration anomalies;
c. an EKF-integrated control submodule that enables predictive trajectory corrections through multi-sensor fusion;
d. a nonlinear compensation submodule that applies proportional corrections to mitigate flight deviations;
e. a thrust vector optimization submodule that dynamically adjusts motor signals for payload variations; and
f. a predictive fault mitigation submodule that preemptively adapts control strategies to maintain stability under subsystem degradation.

An example of the working of adaptive control module is described. The adaptive control module includes:
a. Real-Time Sensor-Driven Flight Parameter Adjustment
i. Continuously processes data from IMU, magnetometer, barometric sensor, and GPS.
ii. Adjusts roll, pitch, yaw, and thrust dynamically to optimize flight stability under varying conditions.
b. Environmental Response Mechanism
i. Detects atmospheric pressure fluctuations, wind disturbances, and acceleration anomalies.
ii. Modifies control gains and motor outputs in real-time to maintain stable flight dynamics.
c. EKF-Integrated Adaptive Control
i. Utilizes Extended Kalman Filter (EKF) outputs to refine navigation accuracy.
ii. Enables predictive adjustments based on multi-sensor fusion for smooth trajectory corrections.
d. Nonlinear Control Compensation
i. Identifies deviations from expected flight behaviour using adaptive thresholding.
ii. Applies proportional corrections to mitigate undesired oscillations or drifts.
e. Low-Level Thrust Vector Optimization
i. Dynamically adjusts motor PWM signals to compensate for center-of-mass shifts or payload variations.
ii. Ensures consistent thrust distribution for stable hover and maneuverability.
f. Predictive Fault Mitigation
i. Monitors system health to pre-emptively adjust control strategies before failures impact flight stability.
ii. Ensures controlled operation even under partial subsystem degradation.

In some embodiments, the system comprises a multi-layer printed circuit board (PCB), a processing unit mounted on the PCB, and a peripheral unit, connected to the PCB, and operatively coupled to the processing unit.

The system of the present disclosure provides high-precision, real-time navigation, sensor fusion, and autonomous flight stability, particularly in challenging environments like mining sites, industrial zones, and disaster response areas. The integrated system leverages cutting-edge hardware and software, with a focus on resilience, adaptability, and operational efficiency in GPS-denied or dynamic conditions.

In the preferred embodiment of the subject of the present disclosure, STM32F411CEU6 microcontroller is used. STM32F411CEU6 microcontroller (ARM Cortex-M4) orchestrates the entire flight controller system. This high-performance microcontroller processes flight algorithms, including state estimation and failsafe protocols, in real-time. The system employs an Extended Kalman Filter (EKF) for precise sensor fusion, enabling accurate positioning even without GPS signals. With a floating-point unit (FPU) and Direct Memory Access (DMA) controller, the microcontroller handles sensor data integration, PID control, and trajectory planning while minimizing CPU overhead. The inclusion of an integrated watchdog timer (IWDG) and clock security system (CSS) ensures autonomous fault recovery, enhancing the system's reliability in adverse conditions.

In the preferred embodiment of the subject matter of the present disclosure, the system integrates multiple sensors for robust state estimation and autonomous flight stabilization. The MPU-6050 IMU offers 6-axis motion tracking with an embedded Digital Motion Processor (DMP), which offloads sensor fusion tasks from the microcontroller, ensuring faster data processing and lower latency. The HMC5883L magnetometer corrects heading errors caused by magnetic disturbances, while the BME280 barometric pressure sensor contributes to accurate altitude estimation by combining pressure and accelerometer data. These sensors communicate via high-speed I2C and SPI interfaces, allowing seamless data aggregation and synchronization for efficient flight control.

In the preferred embodiment of the subject matter of the present disclosure, a high-speed memory subsystem critical for data logging, firmware resilience, and telemetry buffering is disclosed. The W25Q32JVSSIQ NOR Flash memory provides 32 Mbit of storage, supporting secure firmware updates, multi-boot functionality, and post-flight diagnostics, which ensures reliable operation even in dynamic or harsh conditions. The memory also aids in ensuring that data remains intact and accessible during mission-critical flight scenarios.

In the preferred embodiment of the subject matter of the present disclosure, the power unit employs a dual-stage voltage regulation strategy, optimizing power delivery and system stability. The LM2596ADJ buck converter steps down the UAV battery voltage to 5V to power high-current components, while the RT9080-33GJ5 LDO regulator provides an ultra-clean 3.3V supply for noise-sensitive subsystems. A schottky diode (SS34) protects against reverse voltage, and a 68µH inductor ensures smooth voltage fluctuations, reducing noise and enhancing electromagnetic compatibility (EMC). This advanced power architecture is critical for maintaining the performance of the UAV's sensitive electronics in noisy industrial environments.

In the preferred embodiment of the subject matter of the present disclosure, the system includes a novel real-time EKF-based state estimation, sensor redundancy, and intelligent failsafe mechanisms. These features ensure that the system operates effectively even in GPS-denied and interference-prone environments. The flight controller system can prioritize IMU and magnetometer data in such conditions, dynamically adjusting sensor weightage to ensure stable navigation and preventing drift. Collision avoidance algorithms leverage motion tracking and barometric data to trigger preemptive maneuvers, mitigating the risk of terrain collisions. In emergency scenarios, the system automatically triggers failsafe descent modes for controlled landings, ensuring a safe return to the ground.

The subject matter of the present disclosure provides that communication with external devices is handled by multiple receiver interfaces (i-BUS, SBUS, PPM), which ensure low-latency, secure connections to ground control systems or manual overrides. The Type-C USB interface allows for easy firmware updates, telemetry diagnostics, and emergency power input, enhancing operational flexibility and user interaction.

In some of the embodiments, the processing unit of the flight controller system is configured to provide dual control of the UAVs with the ground station device, and a remote-control device, and an automatic control (autopilot) wherein the processing unit is configured to receive prior instructions and operate the UAV, safely land the UAVs in scenario of communication breakdown, and control the operation of UAVs with a ground station device in scenario of communication breakdown from the remote-control device and overwrite the instructions of safe landing of the UAVs.

In some of the embodiments, the processing unit is configured to receive the information/data from the connected peripheral(s)/unit(s)/device(s), process the information/data, and operate the connected peripheral(s)/unit(s)/device(s). For example, the peripheral(s)/unit(s)/device(s), include a propeller, a camera, the remote-control device (for instance a joystick), sensors, and the ground station device (for instance a computer).

In some embodiments, the flight controller system comprises a graphical user interface for receiving instructions from the user and displaying messages, including status of operations of various peripheral(s)/unit(s)/device(s).

An example of the working of adaptive control module is described. Consider a scenario wherein the weather becomes windy during operation of UAV. The system on receiving information of windy weather, and UAV not being in a stable state due to wind. The system processes the data relating to the wind received from sensors, and operation of propellers. To stabilize the UAV, the system increases the speed of operation of one of the propellers. Therefore, the adaptive control module is configured to process the data from multiple sources and provide stable operation of the UAV.

An example of operation of the UAVs in the scenario of communication breakdown from the remote-control device is described. The system is configured to communicate with the remote-control device and in an event of breakdown of the communication from the remote-control device, the system is configured to automatically activate the failsafe mode which enables safe landing of the UAVs. Additionally, in an event of communication failure/breakdown with the remote-control device, the system is configured to receive the instructions from the ground station device thereby overwriting the failsafe mode once the ground station device instructs the UAVs for a particular operation.

An example of working with a dual microcontroller is described. The flight controller system comprises two (2) microcontrollers, wherein the first microcontroller is configured to perform a specific set of process/instructions and the second microcontroller is configured to perform another set of process/instructions. Additionally, the microcontrollers are configured to perform the essential process of another microcontroller in a scenario of failure of one of the microcontrollers. Therefore, the present invention comprises an enhanced built-in redundancy control mechanism which provides an additional layer of reliability crucial for mining operations.

INDUSTRIAL APPLICABILITY
The present invention has industrial applicability and provides following features:
1. Mining Operations Optimization: The flight controller system performs under harsh mining conditions, such as high dust concentrations, vibrations, extreme temperatures, and rough terrain. The robust design of the system ensures that all critical electronic components are shielded from environmental factors, maintaining stable performance during continuous UAV operations in mining areas. This includes enhanced vibration isolation and thermal management to mitigate damage from mining-related factors such as machinery, explosions, and environmental hazards.

2. Payload Flexibility: The flight controller system provides scalability, offers support for larger payloads without degrading the performance of the UAV. The integration of optimized power management and a high-torque motor interface allows for efficient handling of additional sensors or mining equipment, such as thermal imaging cameras or gas detectors. This capability is crucial for accommodating the diverse payloads required for mining inspections, geospatial mapping, and environmental monitoring.

3. Compatibility and Flexibility: The flight controller system provides firmware having adaptability to various autopilot software stacks, allowing for seamless integration into existing mining UAV systems. This flexibility extends to the controller's ability to support proprietary algorithms, sensor configurations, and communication protocols tailored for specific mining operations. The advanced I2C, SPI, and UART interfaces ensure compatibility with a wide range of third-party sensors and modules, enabling customization based on the operational requirements of different mining environments.

4. Autonomous Navigation: The flight controller system provides a precise navigation algorithm optimized for GPS-denied environments, which are common in underground and remote mining sites. The integration of sensor fusion, particularly the use of an Extended Kalman Filter (EKF), allows for the precise estimation of UAV position and velocity, even in environments with limited or no GPS signal. The system uses data from the MPU-6050 IMU, HMC5883L magnetometer, and BME280 barometric sensor to continuously correct navigation, enabling safe and efficient operation in complex mining environments.

5. Advanced Failsafe Mode: The failsafe mechanism is implemented through real-time sensor fusion and dynamic weighting adjustments via EKF algorithms. This allows the flight controller to maintain stable flight even when external navigation sources, such as GPS or magnetic data, become unreliable. The integration of these advanced failsafe protocols ensures that in case of sensor failure or navigation discrepancies, the flight controller will adjust its sensor data priorities, shifting to IMU and magnetometer inputs to ensure continued stability and reliable operation in harsh, dynamic mining conditions.

6. Intrinsically Safe Power Supply: The system's power architecture is engineered to meet the stringent requirements of mining environments, especially in areas where explosive gases or combustible dust are present. By utilizing intrinsically safe design principles, the flight controller ensures that all electrical systems operate below the ignition threshold, preventing the risk of sparking or causing explosions. The use of high-efficiency voltage regulators, including the LM2596ADJ buck converter and RT9080-33GJ5 LDO, ensures that the power supply to all critical components remains stable, while minimizing the risk of failure due to power surges or malfunctions.

7. Fly-By-Wire Technology: The Fly-By-Wire module within the flight controller system offers manual control via joystick input, ensuring that operators can take over in adverse conditions. The system's real-time communication interfaces, including i-BUS, SBUS, and PPM, provide low-latency, secure communication links, allowing for precise control over the UAV’s flight path even when the autonomous system may face operational challenges. This capability is particularly important for mine operators who may need to adjust flight trajectories manually in response to sudden obstacles or unexpected environmental changes.

8. Redundancy and Reliability: The flight controller system provides triple autopilot core redundancy, providing an advanced layer of fault tolerance. In the event of a core failure, the system will automatically reroute control to a healthy core, ensuring uninterrupted operation. The failure detection and recovery mechanisms are integrated into the firmware, which is built to maintain operational integrity by monitoring the health of the system in real-time. This level of redundancy is essential for reducing the risk of mission interruption, minimizing the likelihood of costly downtime, and improving the overall reliability of UAV operations in critical mining tasks.

ECONOMIC SIGNIFICANCE
The present invention provides following economic advantage:
1. Optimized Power Management: The dual-stage voltage regulation, using the LM2596ADJ buck converter and RT9080-33GJ5 LDO, reduces power consumption, ensuring efficient operation over extended periods. This efficiency decreases the frequency of battery recharging and extends the overall lifespan of UAV components, leading to lower operational costs. In comparison to traditional flight controllers with less optimized power systems, the flight controller’s design provides better energy utilization, lowering long-term maintenance costs.

2. Sensor Fusion Efficiency: By utilizing sensor fusion techniques such as EKF-based state estimation, the system minimizes the dependency on expensive external sensors while still providing high precision. The IMU (MPU-6050), magnetometer (HMC5883L), and barometric sensor (BME280) work in tandem to provide highly accurate flight data, reducing the need for costly, specialized sensors. This sensor redundancy ensures reliability without requiring additional external hardware, making it a more economical choice for operations like mining, where cost-effective and robust solutions are essential.

3. Redundancy and Fault Tolerance: The inclusion of triple autopilot cores and the automatic shifting of control in case of failure reduces the likelihood of costly downtime, a critical factor in high-stakes environments such as mining. This feature significantly enhances operational uptime, leading to greater productivity and reduced costs associated with repairs or system malfunctions.

4. Customizability and Compatibility: The flight controller system’s ability to integrate with existing software and adapt to specific mining requirements through proprietary firmware reduces the need for purchasing entirely new systems for different tasks. Users can modify the system according to their operational needs, lowering upfront investment costs and enhancing system longevity through software updates and adaptability.

It should be noted that the description merely illustrates the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter. Furthermore, all embodiments recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the foregoing description.

The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the disclosure.
,CLAIMS:We claim:
1. A flight controller system for unmanned aerial vehicles (UAVs), the system comprises:
1.1. an enclosure;
1.2. a multi-layer printed circuit board (PCB), placed within the enclosure, with dedicated ground planes, and differential signal routing to provide integrated electromagnetic interference (EMI) shielding, electromagnetic conductance (EMC) shielding, and electromagnetic susceptibility (EMS) shielding for stable operation in high-noise environments; wherein the PCB comprises:
1.2.1. a sensor unit;
1.2.2. a power unit;
1.2.3. distributed surface-mount device (SMD) capacitors; and
1.2.4. a 25 MHz industrial-grade crystal oscillator;
1.3. a processing unit mounted on the PCB, the processing unit comprises:
1.3.1. at least one microcontroller centrally positioned on the PCB to minimize trace lengths to associated components, wherein the microcontroller is thermally isolated from high-power components to prevent performance degradation, wherein the microcontroller comprises:
1.3.1.1. an Extended Kalman Filter (EKF)-based navigation module configured to provide real-time state estimation by utilizing data received from the sensor unit for normal operation as well as operations in failsafe condition by allowing immediate corrective actions during system failures or communication loss in GPS-denied environments;
1.3.1.2. a failsafe module operatively connected to the Extended Kalman Filter (EKF)-based navigation module wherein the failsafe module being configured to detect failsafe triggering events and operational anomalies to autonomously initiate safety measures to prevent operational failure; and
1.3.1.3. an adaptive control module coupled to the microcontroller and the sensor unit, wherein the adaptive control module is configured to dynamically adjust flight parameters in response to environmental changes to maintain stable flight and enhance operational reliability;
1.3.2. a communication module for communication to and from microcontroller; and
1.3.3. a microcontroller memory unit connected to the microcontroller; and
1.4. a peripheral unit, connected to the PCB, and operatively coupled to the processing unit, wherein the peripheral unit comprises:
1.4.1. a port for battery connection;
1.4.2. an input-output (I/O) port;
1.4.3. a peripheral memory unit; and
1.4.4. a plurality of connection ports for connecting peripherals as required by the user.

2. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, wherein the PCB comprises:
2.1. a sensor unit comprises:
2.1.1. an inertial measurement unit (IMU) configured to provide real-time orientation and acceleration data;
2.1.2. a magnetometer for providing heading information;
2.1.3. a barometric sensor for altitude measurement; and
2.1.4. a GPS unit to provide position and navigation related data.
2.2. a power unit, to control impedance for optimized power management, comprises:
2.2.1. a switching voltage regulator;
2.2.2. a low-dropout regulator;
2.2.3. an inductor; and
2.2.4. a schottky rectifier for reverse current protection, wherein low forward voltage drop minimizes power losses and prevents damage to critical subsystems during transient power fluctuations;
2.3. distributed surface-mount device (SMD) capacitors mounted to sensor unit and the power unit, wherein the surface-mount device (SMD) capacitors is mounted on the sensor unit for noise filtering (decoupling), and precise signal conditioning, and wherein the surface-mount device (SMD) capacitors is mounted on the power unit for power stabilization, and noise filtration; and
2.4. a 25 MHz industrial-grade crystal oscillator, wherein precise clock stability ensures accurate execution of real-time control loops, high-fidelity sensor sampling, and error-free digital communication.

3. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 2, wherein the inertial measurement unit (IMU) is a MPU-6050 which comprises of a gyroscope and accelerometer along with Digital Motion Processor, wherein the magnetometer is HMC5883L, and wherein barometric sensor is BME280.

4. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 2, wherein the power unit is configured to optimize power management and utilises techniques, including EMI suppression, ferrite bead filtering, and PCB trace optimization, wherein the power unit provides minimal power loss, mitigates EMI, and maintains compliance with industrial EMC standards.

5. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 2, wherein the low-dropout regulator and switching voltage regulator are high-current power components which are physically segregated from low-noise analog and digital signal paths using copper pours and ground separation zones, wherein this structural design prevents cross-talk, enhances sensor stability, and maintains reliable communication in EMI-prone environments.

6. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 2, wherein the switching voltage regulator is LM2596, wherein the low-dropout regulator is RT9080-33GJ5, wherein the inductor is a 68µH, and wherein the schottky rectifier is SS34.

7. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, wherein the PCB has dedicated ground loops and differential signal routing to prevent EMI, EMC, EMS, mitigate cross-talk, and ensure compliance with industrial EMC regulations for stable operation in hazardous environments.

8. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, wherein the power unit comprises an intrinsically safe power architecture with galvanically isolated circuits and transient voltage suppressors.

9. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, wherein the microcontroller is configured to communicate with the inertial measurement unit (IMU), the magnetometer, the barometric sensor, and the GPS unit of the sensor unit for sending and/or receiving the data.

10. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, wherein the microcontroller is STM32F4 series, preferably, STM32F411.
11. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, wherein the communication module is configured with optimized pull-up resistor values and clock stretching mechanisms to enable low-latency data transmission based on protocol, including, an Inter-Integrated Circuit (I2C), and a Serial Peripheral Interface (SPI) protocols.

12. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, wherein the processing unit comprises:
12.1. an integrated Fly-By-Wire (FBW) module comprises a sensor validation submodule that cross-validates redundant sensor data to isolate faults and ensure accurate state estimation; an autonomous mode transition submodule for stable switching between manual and autonomous control upon detecting sensor discrepancies; a failsafe mechanism submodule that overrides manual inputs to maintain stability during critical failures; a priority-based command processor submodule for superseding critical commands over non-essential inputs; a low-latency communication interface submodule for rapid signal transmission; and an integrated stability control submodule that counteracts environmental disturbances for precise flight control;
12.2. a real-time manual UAV control module having capability of priority override logic; and
12.3. a low-latency communication module having protocols, including i-BUS, SBUS, PPM, and ExpressLRS for communication through input-output (I/O) port to communicate with unmanned aerial vehicles (UAVs).

13. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, the processing unit comprises:
13.1. a monitoring and feedback module for continuously tracking critical subsystems including power management, communication interfaces, and sensor health, wherein the monitoring and feedback module enhances UAVs operational reliability by enabling predictive maintenance and mitigating potential failures before they impact mission performance.
13.2. a telemetry module capable of real-time diagnostics and fault prediction;
13.3. an adaptive thresholding module for proactive anomaly detection; and
13.4. a remote-control override module for overriding the control of remote control in event of remote-control failure.
14. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 13, wherein the remote-control override module, comprises:
14.1. a signal capture submodule that utilizes hardware interrupts and timers to receive and measure pulse-width modulation (PWM), SBUS (Serial Bus), or iBUS signals with microsecond precision;
14.2. a control arbitration submodule configured to switch between autopilot and manual control based on RC signal validity;
14.3. a direct memory access (DMA) submodule to enable low-latency processing of RC signals without CPU polling;
14.4. an input smoothing mechanism submodule having an extended Kalman filter (EKF) to ensure stable actuator transitions during control mode switches;
14.5. an error detection submodule having cyclic redundancy checks (CRC) to validate and discard corrupted RC signals; and
14.6. a failover submodule having a watchdog timer to detect signal loss and trigger failsafe actions including return-to-home (RTH) or controlled landing.
15. The flight controller system for unmanned aerial vehicles (UAVs) as claimed in claim 1, wherein the peripheral memory unit comprises a high-speed NOR Flash memory with error correction code (ECC) support for telemetry buffering and secure firmware storage.