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Test Stand for Propellers and Rotors in VTOL Drone Systems

Transactions on Aerospace Research
Volume 2023 (2023): Issue 1 (March 2023)
By:
Open Access
|Mar 2023

Figures & Tables

LY-70KGF Thrust Stand and Dynamometer Wing Flayng
LY-70KGF Thrust Stand and Dynamometer Wing Flayng
WF-CO-30KGF Coaxial Thrust Stand Wing Flayng
WF-CO-30KGF Coaxial Thrust Stand Wing Flayng
Series 1780 Test Stand TYTO Robotics
Series 1780 Test Stand TYTO Robotics
Modular Stand for testing aircraft electric propulsion systems NASA
Modular Stand for testing aircraft electric propulsion systems NASA
Rotor/propeller test stand in Hover Institute of Aviation
Rotor/propeller test stand in Hover Institute of Aviation

Figure 1.

Propeller thrust test stand – visualisation [own elaboration].
Propeller thrust test stand – visualisation [own elaboration].

Figure 2.

The principle of measuring the propeller thrust on the presented stand [own elaboration].
The principle of measuring the propeller thrust on the presented stand [own elaboration].

Figure 3.

Map of reduced stress according to the Huber-Von-Mises hypothesis with a point measurement in the vicinity of the calculated transverse opening [own elaboration].
Map of reduced stress according to the Huber-Von-Mises hypothesis with a point measurement in the vicinity of the calculated transverse opening [own elaboration].

Figure 4.

Structural calculation: (top) mounting plate model; (bottom) map of the mounting plate effort according to the Huber-Von-Mises hypothesis [own elaboration].
Structural calculation: (top) mounting plate model; (bottom) map of the mounting plate effort according to the Huber-Von-Mises hypothesis [own elaboration].

Figure 5.

Propeller thrust test stand – electrical diagram [own elaboration].
Propeller thrust test stand – electrical diagram [own elaboration].

Figure 6.

Dynamic model – block diagram [own elaboration].
Dynamic model – block diagram [own elaboration].

Figure 7.

Construction of regulators in the MATLAB Simulink program [own elaboration].
Construction of regulators in the MATLAB Simulink program [own elaboration].

Figure 8.

Propeller model with moments of inertia [own elaboration].
Propeller model with moments of inertia [own elaboration].

Figure 9.

Model of the entire system built in MATLAB Simulink [own elaboration].
Model of the entire system built in MATLAB Simulink [own elaboration].

Figure 10.

Tests’ propellers: commercial wooden Aerobat (left), and carbon composite from the Łukasiewicz – Institute of Aviation (right).
Tests’ propellers: commercial wooden Aerobat (left), and carbon composite from the Łukasiewicz – Institute of Aviation (right).

Figure 11.

Course of step excitations for: 1st cycle (left) and 2nd cycle (right) [own elaboration].
Course of step excitations for: 1st cycle (left) and 2nd cycle (right) [own elaboration].

Figure 12.

Summary of Aerobat propeller rotational speed and torque in the 1st cycle [own elaboration].
Summary of Aerobat propeller rotational speed and torque in the 1st cycle [own elaboration].

Figure 13.

Summary of Aerobat propeller rotational speed and torque in the 2nd cycle [own elaboration].
Summary of Aerobat propeller rotational speed and torque in the 2nd cycle [own elaboration].

Figure 14.

Comparison of actual results with the simulation results for Aerobat propeller [own elaboration].
Comparison of actual results with the simulation results for Aerobat propeller [own elaboration].

Figure 15.

Course of step excitations for 1st cycle (left) and 2nd cycle (right) [own elaboration].
Course of step excitations for 1st cycle (left) and 2nd cycle (right) [own elaboration].

Figure 16.

Summary of Łukasiewicz – Institute of Aviation propeller rotational speed and torque in the 1st cycle [own elaboration].
Summary of Łukasiewicz – Institute of Aviation propeller rotational speed and torque in the 1st cycle [own elaboration].

Figure 17.

Summary of Łukasiewicz – Institute of Aviation propeller rotational speed and torque in the 2nd cycle [own elaboration].
Summary of Łukasiewicz – Institute of Aviation propeller rotational speed and torque in the 2nd cycle [own elaboration].

Figure 18.

Comparison of actual results with the simulation results for the carbon composite Łukasiewicz – Institute of Aviation propeller [own elaboration].
Comparison of actual results with the simulation results for the carbon composite Łukasiewicz – Institute of Aviation propeller [own elaboration].

Test stand overview [8–10]_

Test StandThrustTorquePropeller diameterElectric parametersRPM

LY-70KGF Thrust Stand and Dynamometer Wing Flayng

±70 daN±50 NmMax ~ 1.52 mCurrent: 0–300 AVoltage: 5-110 V60,000 – 150,000 RPM

WF-CO-30KGF Coaxial Thrust Stand Wing Flayng

±30 daN±20 NmMax ~1.00 mCurrent: 0–150 AVoltage: 5–65 V60,000 – 150,000 RPM

Series 1780 Test Stand TYTO Robotics

±75 daN±48 NmMax ~1.77 mCurrent: 0–500 AVoltage:0–100 V100,000 RPM

Modular Stand for testing aircraft electric propulsion systems NASA

±225 daN±200 NmMax ~1.77 mN/A20,000 RPM

Rotor/propeller test stand in Hover Institute of Aviation

±3,000 daN±4,800 NmMax ~10 mElectric power: 315 kWMin. 126 RPM, max. 1,500 RPM

Initial parameters, step function of the torque and the corresponding currents - 1st cycle_

No.Starting point - torque (Nm)RMS current corresponding to torque (A)Ending point - torque (Nm)RMS current corresponding to torque (A)
1 8.514.2
26.010.010.016.7
3 14.023.3
4 25.542.5
523.038.327.045.0
6 31.051.7
7 35.559.2
833.055.037.061.7
9 41.068.3
10 47.579.2
1145.075.049.081.7
12 53.088.3
13 60.5100.8
1458.096.762.0103.3
15 66.0110.0
16 70.5117.5
1768.0113.372.0120.0
18 76.0126.7

Initial parameters, step function of the torque and the corresponding currents — 2nd cycle_

No.Starting point - torque (Nm)RMS current corresponding to torque (A)Ending point - torque (Nm)RMS current corresponding to torque (A)
16.010.076.0126.7
223.038.3
333.055.0
445.075.0
558.096.7
668.0113.3

Comparison of actual results with the simulation results for the same RMS currents, Aerobat propeller_

Experimental researchNumerical model research
Current (A)Torque (Nm)Rotational speed (RPM)Torque (Nm)Rotational speed (RPM)
3.862.4640.02.3720.0
8.765.31,065.05.31,087.0
17.4510.71,550.010.51,534.0
29.0818.02,030.017.51,980.0
36.8022.72,280.022.12,226.0
44.7027.82,520.026.82,456.0
53.633.12,755.032.22,688.0
66.540.53,020.039.92,995.0

Adjustment time for Łukasiewicz — Institute of Aviation propeller — 2nd cycle_

Lp.Starting point - torque (Nm)Ending point - torque (Nm)Adjustment time (s)
16.076.03.4
223.076.03.1
333.076.03.0
445.076.02.9
558.076.02.8
668.076.02.2

Comparison between the actual results and the simulation results for the same RMS currents, for the carbon composite Łukasiewicz — Institute of Aviation propeller_

Experimental researchNumerical model research
Present current (A)Torque (Nm)Rotational speed (RPM)Torque (Nm)Rotational speed (RPM)
11.097.62565.06.65540.0
23.9915.35825.014.39794.0
38.9624.401,045.023.381,011.0
54.3233.371,215.032.691,195.0
63.9938.731,305.038.391,296.0
75.3745.151,405.045.221,406.0
89.2952.301,515.053.571,531.0
103.8159.351,615.062.291,651.0
121.9966.911,715.073.191,789.0
137.1672.611,770.082.301,897.0

Moments of inertia of elements included in the model_

I (kg mm2)
The knot from the engine to the propeller attachment13,503
Propeller mounting hub4,350
Propeller246,083

Adjustment time for Aerobat propeller — 1st cycle_

No.Starting point - torque (Nm)Ending point - torque (Nm)Adjustment time (s)
16.08.53.9
210.03.9
314.03.9
423.025.52.5
527.02.5
631.02.5
733.035.52.1
837.02.1
941.02.1
1045.047.52.0
1149.02.0
1253.02.0

Adjustment time for Łukasiewicz — Institute of Aviation propeller — 1st cycle_

No.Starting point - torque (Nm)Ending point - torque (Nm)Adjustment time (s)
1 8.56.0
2610.06.0
3 14.06.0
4 25.54.7
52327.04.5
6 31.04.5
7 35.53.7
83337.03.7
9 41.03.7
10 47.53.0
114549.03.0
12 53.03.0
13 60.52.8
145862.02.7
15 66.02.7
16 70.52.2
176872.02.2
18 76.02.2

Adjustment time for Aerobat propeller — 2nd cycle_

No.Starting point - torque (Nm)Ending point - torque (Nm)Adjustment time (s)
16.053.02.5
216.053.02.4
323.053.02.3
432.053.02.3
540.053.02.2
647.053.02.0
DOI: https://doi.org/10.2478/tar-2023-0006 | Journal eISSN: 2545-2835
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Language: English
Page range: 67 - 85
Submitted on: Nov 30, 2022
Accepted on: Feb 9, 2023
Published on: Mar 17, 2023
Published by: Sciendo
In partnership with: Paradigm Publishing Services
Publication frequency: 4 times per year
Keywords:
synchronous motors,
numerical model,
VTOL,
propeller,
test stand
Related subjects:
Engineering,
Introductions and overviews,
Engineering, other,
Geosciences,
Geosciences, other,
Materials sciences,
Materials sciences, other,
Physics,
Physics, other

© 2023 Małgorzata Wojtas, Przemysław Wyszkowski, Mirosław Mądro, Maciej Osiewicz, Paweł Kmita, published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

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