In this study, a cost-effective high-fidelity six-degree of freedom module augmented with an onboard controller is developed. The unmanned aerial vehicle (UAV) under consideration is a wing-alone configuration with a cropped delta planform and reflex airfoil cross-section designed to perform manoeuvres at high angles of attack. The six-degree of freedom dynamics for the aforementioned configuration is developed based on Newtonian mechanics incorporating linear and nonlinear aerodynamic models to expand flight simulations in corresponding regimes. Aerodynamic stability and control parameters for the simulations are obtained from full-scale wind tunnel measurements and flight tests. It is observed that the linear aerodynamic model is valid in angle of attack (α) domain −5°≤α≤10°, followed by nonlinearity up to α≈21°, post which lift coefficient remains almost constant with angle of attack till 45°. The simulation model is validated with the corresponding flight data obtained from flight tests. A user-friendly graphical interface with real-time animation of UAV has been developed for the aforementioned configuration by integrating MATLAB and Flightgear environment with real-time control input from the hardware to enable the pilot for visual and tactile feedback, respectively. A controller based on total energy control is designed for velocity and altitude hold modes, while an attitude hold controller is designed for pitch and roll angle tracking to enable controller-in-the-loop remote piloting simulations. In order to enhance practical applicability, the designed module has been tested under various simulated wind conditions. It is noticed from the results that the steady-state error in attitude remains below 2% with a maximum overshoot of 5° from reference. The total energy controller achieves a zero steady-state error with a maximum overshoot of 2 m/s for velocity and 6 m for altitude, respectively. The developed module enhances remote piloting training, flight response assessment, and control algorithm testing for cropped delta planform UAVs.
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