UAV Propulsion Analysis System with Reconfigurable Controller Feature

In this paper, a custom measuring system for propulsion units of multi-rotor UAV is presented. Designed solution provides measurements of thrust, rotational speed and power consumption of popular electric propulsion systems consisting of BLDC motor, electronic speed controller (ESC) and various propellers. The method is applicable to both single and twin (coaxial) configurations of rotors. Thanks to the use of a precision 6-axis force/torque sensor and sensorless method of speed measurement it is possible to record performance of propulsion with convenient PC software. The system is equipped with complete galvanic isolation between power and sensory circuits. A unique feature of presented solution is the possibility of remote reconfiguration of various controllers, governing speed or thrust of the propeller. Possible applications of the presented test rig are: estimating the performance of UAV design (flight time, power consumption, payload capabilities), mathematical modelling of electric propulsion and analysis of faulty states of rotor operation