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UAV and eVTOL Propulsion Testing Solution

With the rapid development of modern aviation, especially unmanned aerial vehicles (UAVs) and electric vertical takeoff and landing vehicles (eVTOLs), dynamic testing has become a key step to ensure their performance optimization and safe operation.

Tyto Robotics offers a full range of professional test solutions, from all-electric propulsion systems to fuel power systems to distributed electric propulsion (DEP) and hybrid power systems. The following are detailed UAV/eVTOL power test solutions, including eVTOL-Flight Stand 500 (DAQ) high precision external extended integration test solutions, as well as specific test solutions for DEP (Distributed Electric Propulsion Power System) and hydraulic systems.

Ⅰ. EVTOL Power System and Its Scalability Test Solution

Product Overview

The Flight Stand 500 is a powered test stand designed for large motors and propellers to accurately measure and evaluate the performance of motors and propellers. It is equipped with a high-precision force measurement system that provides highly accurate readings of tension and torque without friction.

Main technical highlights:
■  All-solid-state deformation measurement technology, extremely exquisite appearance design, dedicated to aerodynamic testing.
■  1,000 Hz real-time dynamic test, deep correlation analysis of tension, torque, vibration, harmonic, current, etc.
■  Complies with ASTM standards for the highest level of professional accuracy.
■  Python API control: support PID, MATLAB simulation, CAN bus test.


Scalability and versatility

The DAQ acquisition system of the Flight Stand 500 is highly scalable and integrated, supporting simultaneous correlation testing of up to eight power systems, suitable for various types of thrusters and motors.

with the following main functions:
■  It supports high-resolution and high-accuracy data acquisition, including 8 analog ports, 6 digital interfaces and 2 synchronous interfaces, to maximize the external expansion needs of different types and functions.
■  Supports maximum current of 100mA (analog port) and 30mA (digital port).
■  ADC with 24-bit resolution, 0.2% of full scale error.
■  Modular configuration: Easily extend test capabilities by synchronizing multiple DAQ units for complex systems with multiple motors and propellers.
■  Support 6-Dof force measurement unit and synchronous test acquisition of multiple sensors, including thermocouple, Hall effect and voltage sensor, optical fiber RPM sensor, airspeed pressure sensor, analog sound level meter, fuel flow sensor, etc.
■  Built-in custom conversion function can directly apply formulas in the software to calculate indicators to adapt to specific project parameters.
■  Underwater test applications: Ability to connect DAQ to underwater sensors and load cells to evaluate cavitation and marine propulsion performance.


Ⅱ. Test Scheme of Distributed Electric Propulsion (DEP)

DEP technology has great potential in the field of aviation, which can significantly improve aircraft efficiency, reduce fuel consumption and improve safety. The comprehensive DEP professional test platform provided by Tyto Robotics supports testing up to 8 power systems at the same time, evaluates the performance of DEP systems more accurately and efficiently, helps to develop more efficient and safe DEP systems, and lays a solid foundation for future aviation innovation.

  

Core technical performance of DEP test system:
■  Exquisite design: reduce air flow interference, closer to the actual flight test conditions.
■  Real coaxial twin-propeller power test: support multiple configurations, simulate and restore multiple aircraft power designs.
■  CAN ESC compatibility: CAN ESC control via In/Out API.
■  Python API Control: Allows users to program tests in an external text editor, providing rich examples and test templates to help get started.
■  Flight playback function: allows the user to upload flight control data and reconstruct throttle point data in the test system.
■  Full-scene test scheme: support frequency sweep and step test, PID tuning of complete power system, MATLAB simulation test, efficiency and power characteristic test, durability and reliability test, etc.

Ⅲ. Fuel Engine Power Test Scheme

Fuel engine power test is a necessary means to ensure engine performance, optimize performance parameters, ensure safety and reliability, and support diversified applications. Through accurate measurement and comprehensive testing, users can continuously improve the performance of fuel power system to meet various complex work needs.

Tyto Robotics' Flight Stand 60 ICE test bench supports the measurement of pull, torque, speed, fuel flow, temperature, power and propeller efficiency of internal combustion engines and propellers, helping users to accurately describe and evaluate their performance parameters in order to continuously optimize and improve the performance of fuel power systems.

■  Highly accurate measurement
Flight Stand 60 ICE can accurately measure pull up to 60 KGF, torque up to 30 Nm, speed up to 16,800 RPM, fuel flow up to 800 mL/min and temperature up to 800 ℃.

■  Vibration quarantine
Flight Stand 60 has an anti-vibration design that includes shock absorbers customized for a variety of engine sizes. The 1,000 Hz sampling rate enables dynamic testing and detailed analysis of harmonics, vibration, and torque.

■  ASTM Compliant
This test bench uses an ASTM calibrated measurement system that meets professional-level testing standards. Its rigorous and accurate calibration method further improves the accuracy and reliability of the test results, and further ensures the fairness and objectivity of the test data.


  

Flight Stand 60 ICE not only has excellent technical performance, but also covers a wide range of application scenarios, making Flight Stand 60 ICE an indispensable tool in the field of fuel engine testing:
■  Carburetor calibration and engine running-in
■  Engine Propeller Performance Test
■  Fuel durability simulation test
■  Cylinder synchronization analysis
■  3D engine performance map
■  Wind Tunnel Test of Variable Pitch Propeller and Optimization of Crankshaft Angle

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