Large-size flight unit performance test system and method

Abstract

The invention belongs to the technical field of flight vehicle design, and particularly relates to a large-size flight unit performance test system and method, and the system comprises a test bench, a drive motor, a sensor module, a rotor module, a data collection card, a motor controller, a heat dissipation system, a power supply distribution device, and an upper computer. The positions of the rotor modules and the driving motors are adjusted through the adjustable platform, heat dissipation and power supply of the driving motors are achieved through the heat dissipation system and the power supply distribution device, and linear testing, square wave step testing, frequency sweeping testing and heat balance testing are conducted through the upper computer. And further obtaining performance parameters and safe use boundaries of the large-size flight unit under different positions, voltages and heat dissipation conditions. The requirements of high voltage, high heat dissipation and the like of the large-size flight unit are considered, auxiliary systems such as a heat dissipation system and a bidirectional power supply distribution device are designed, the actual application scene of the large-size flight unit is better met, the test error is small, and the applicability is high.

Description

Technical Field

[0001] The present invention belongs to the technical field of flying vehicle design, and in particular relates to a large-scale flying unit performance test system and method. Background Art

[0002] With the rapid development of technology, flying cars have profound social, economic, environmental, and strategic implications. First, by building a three-dimensional "ground-air" transportation network, they can effectively alleviate urban traffic congestion, enable point-to-point direct transportation, and significantly improve travel efficiency. For example, traditional ground transportation averages less than 20 kilometers per hour during peak hours, while flying cars can reach 150-200 kilometers per hour, reducing commuting times by 80% and revolutionizing urban transportation. Second, the flying car industry chain spans multiple sectors, including aviation manufacturing, new energy, and artificial intelligence. The market is expected to reach $1.5 trillion by 2040, creating millions of high-skilled jobs and driving the development of emerging industries such as air taxi services and drone delivery for logistics.

[0003] Environmentally friendly, flying cars often utilize electric or hybrid powertrains, reducing carbon emissions per kilometer by 50%-70% compared to traditional vehicles, contributing to green and sustainable development. They also possess significant value in emergency rescue and public services, enabling rapid response to disaster relief, emergency medical care, and other tasks, significantly enhancing public service capabilities. Furthermore, flying car research promotes multidisciplinary technological integration, fostering breakthroughs in key technologies such as high-energy-density batteries, autonomous flight control, and lightweight materials, driving industrial upgrading and enhancing national competitiveness.

[0004] From a social perspective, flying cars will reshape future lifestyles, provide personalized travel experiences, optimize urban space utilization, and free up more land for greening and public infrastructure development. Strategically, flying car technology can be transformed into a military vertical takeoff and landing platform for rapid deployment, reconnaissance, and surveillance missions. It will also promote the development of low-altitude airspace resources and create new growth points for the low-altitude economy.

[0005] The flight unit is the core of a flying car, determining its performance and safety. Its vertical takeoff and landing (VTOL) capability enables flexible takeoff and landing in urban areas without a runway. The highly efficient flight unit ensures a smooth transition between VTOL and horizontal cruising, balancing hovering stability with high-speed flight efficiency. Multi-redundant designs (such as distributed flight units) and intelligent control technologies (such as autonomous obstacle avoidance) enhance safety and reliability. Flight units require extensive bench testing to verify their performance and ensure safe operation. With evolving technology and operational requirements, large-scale electric flight units are becoming a key technology in the design of large-tonnage flying cars. Large-scale electric flight units typically consist of a drive motor and a rotor or ducted fan. Due to their large size, high power requirements, significant aerodynamic interference, and numerous auxiliary system components, performance testing of large-scale electric flight units is demanding, challenging, and complex. Conventional small-scale flight unit test platforms lack safety, suffer from large test errors, and struggle to meet the requirements for auxiliary system testing, making them unable to meet the rapid development needs of future large-tonnage flying cars.

[0006] Therefore, there is an urgent need for a large-scale flight unit performance test system and method. Summary of the Invention

[0007] (1) Technical issues to be resolved

[0008] The technical problem to be solved by the present invention is: in view of the needs of the existing technology, how to provide a large-scale flight unit performance test system and method to solve the problems of poor safety, large test errors, and difficulty in taking into account the auxiliary system testing requirements in the existing technology. It can improve the efficiency of large-scale flight unit performance testing, and the method also has very broad application prospects in the design and development process of large-tonnage flying cars.

[0009] (2) Technical solution

[0010] To solve the above technical problems, the present invention provides a large-scale flight unit performance test system, which includes: a test bench, a drive motor, a sensor module, a rotor module, a data acquisition card, a motor controller, a heat dissipation system, a power distribution device and a host computer;

[0011] The top of the test bench is fixedly connected to the drive motor by bolts, the top of the drive motor is connected to the sensor module by a flange, and the sensor module is connected to the rotor module by a flange; the drive motor is connected to the motor controller through a communication cable and a power supply cable, the drive motor is connected to the cooling system through a water pipe, the sensor module is connected to the data acquisition card through a communication cable, and the motor controller, data acquisition card, and cooling system are all communicated with the host computer through communication cables; the power distribution device is connected to the cooling system and the motor controller through a power supply cable.

[0012] The host computer includes: a drive motor control module, a heat dissipation system control module, a data recording and display module, and a safety protection module;

[0013] The safety protection module is used to preset protection values ​​for the parameters of tension, voltage, current, infrared temperature, commutation speed, photoelectric speed, total power, and amplitude displacement;

[0014] When a certain type of real-time test value reaches a preset protection value, the safety protection module executes an alarm function and performs a throttle lock operation.

[0015] The sensor module includes: a tension sensor, a speed sensor, a vibration sensor, and a noise sensor.

[0016] The heat dissipation system includes: a water tank, an oil tank, a cooling fan, and a temperature sensor, which are used to meet the temperature control requirements of the cooling water of the drive motor.

[0017] The power distribution device includes: a current control module, a voltage control module, and a bidirectional transmission module, which are used to meet the power demand of the motor controller; the adjustment range of the voltage control module is 10V-1100V.

[0018] The test bench includes: a main frame, an oblique support, a side support, an adjustable platform, a flight unit fixing platform, a flight unit fixing flange, a counterweight, and fixing locking bolts;

[0019] An adjustable platform is provided above the main frame of the test stand via fixed locking bolts, a flight unit fixing platform is provided above the adjustable platform, and a flight unit fixing flange is provided above the flight unit fixing platform via bolts;

[0020] The platform oblique support and the platform side support are used to jointly provide lateral support to the front and rear sides of the platform main frame;

[0021] Counterweight blocks are fixedly installed on the left and right sides of the platform main frame and the bottom of the platform side supports.

[0022] Wherein, the main frame of the platform includes a base frame and a longitudinal frame;

[0023] The base frame includes a base frame crossbeam, a base frame longitudinal beam, a base frame diagonal beam, and fixed feet;

[0024] The three base frame cross beams are vertically crossed and fixedly connected with the five base frame longitudinal beams to form a square frame body in the form of a rack frame. The two sides of the base frame cross beams are fixedly connected with the two base frame oblique beams respectively;

[0025] A fixed foot is installed at the bottom of the base frame, and a counterweight is installed above the fixed foot;

[0026] The longitudinal frame includes: a longitudinal frame cross beam, a longitudinal frame longitudinal beam, a longitudinal frame support beam, a longitudinal frame oblique beam, and a longitudinal frame middle connecting beam;

[0027] The two longitudinal frame cross beams are fixedly connected to the two longitudinal frame longitudinal beams to form a rectangular frame, the two diagonals of the rectangular frame are each provided with a longitudinal frame support beam, and longitudinal frame diagonal beams are provided on both sides of the longitudinal frame where the longitudinal frame longitudinal beams are located;

[0028] The middle connecting beam of the longitudinal frame is horizontally arranged at the connection point of the two longitudinal frame support beams, and its two ends are respectively connected to the longitudinal frame oblique beams on both sides;

[0029] The longitudinal frame longitudinal beam is provided with a through hole connected to the adjustable platform

[0030] The platform oblique supports are arranged in pairs, the number of which matches the longitudinal beams of the base frame, and there are five pairs;

[0031] On a square frame body in the form of a rack frame formed by three base frame cross beams and five base frame longitudinal beams, for each base frame longitudinal beam, of the three connection points formed by its connection with the three base frame cross beams, the two connection points on both sides are each connected to the lower end of a platform diagonal support, and the upper ends of the two platform diagonal supports converge and are connected to the middle connection beam of the longitudinal frame;

[0032] Due to a pair of platform oblique supports and a corresponding longitudinal beam of the base frame, three sides of an equilateral triangle support structure are formed, the vertex of the equilateral triangle support structure is located on the middle connecting beam of the longitudinal frame, and the two bottom points are located on the cross beam of the base frame;

[0033] By analogy, five pairs of platform diagonal supports and five base frame longitudinal beams form five groups of equilateral triangle support structures, which are evenly spaced and distributed on the middle connecting beam of the longitudinal frame and the cross beam of the base frame.

[0034] There are two side supports for the platform, the upper ends of which are connected to the middle part of the connecting beam in the middle of the longitudinal frame, and the lower ends extend obliquely to the horizontal ground and are fixed by bolts.

[0035] In addition, the present invention also provides a large-scale flight unit performance test method, which is implemented based on the above system and includes the following steps:

[0036] Step 1. Secure the adjustable platform to the test bench using the locking bolts according to the test requirements. For flight unit tests without considering ground effect, the vertical distance between the adjustable platform and the base frame should be greater than 1 times the diameter of the rotor module.

[0037] Step 2: Connect the test bench, drive motor, sensor module, rotor module, data acquisition card, motor controller, cooling system, power distribution device, and host computer with power supply cables, communication cables, and water pipes.

[0038] Step 3: Design the output steady-state voltage U through the power distribution device, start the power distribution device, and supply power to the cooling system and motor controller;

[0039] Step 4: Design the coolant outlet temperature T of the cooling system through the host computer to ensure the cooling requirements of the drive motor;

[0040] Step 5: Design the motor controller parameters through the host computer. First, start the linear test. The speed of the drive motor increases linearly from 0% to 100%. According to a certain fixed slope α, the torque-speed curve, thrust-speed curve, power-speed curve and data are measured by the host computer.

[0041] Step 6: Perform a square wave step test through the drive motor control module of the host computer; the speed input of the drive motor is increased from 0% to 100% in steps, with a step gradient of φ, and then decreased after reaching 100%. The dynamic characteristics of acceleration and deceleration at different speed positions are tested to obtain the corresponding output thrust curve and data; after data analysis, the parameters of the boost time, initial stabilization time, and super stabilization time are obtained;

[0042] Step 7: Perform a frequency sweep test through the drive motor control module of the host computer; the speed input of the drive motor is sinusoidally varied from 50% to 75% according to the change frequency f, and the speed-torque curve and speed-tension curve are measured; after data analysis, the system response time, power overshoot value, and safety control frequency parameters are obtained;

[0043] Step 8. Perform a thermal balance test through the drive motor control module of the host computer; increase the speed input of the drive motor linearly from 10% to 100%, and pause for t minutes every 5% of the speed to observe whether the motor temperature rises at this speed; record the speed, over-temperature operation time, and inlet and outlet coolant temperatures at the final thermal balance;

[0044] Step 9: Change the output steady-state voltage U or the coolant outlet temperature T, and repeat the test contents of steps 5 to 8 to obtain the performance parameters and safe use limits of the flight unit under different voltage and heat dissipation conditions.

[0045] (3) Beneficial effects

[0046] Compared with the prior art, the present invention has the following beneficial effects:

[0047] (1) The present invention provides a test bench with an adjustable platform, which can be used to install flight units of different sizes. In particular, for large-sized flight units, the height can be adjusted as required to carry out performance tests with and without considering the impact of ground effect. The device is flexible and highly applicable.

[0048] (2) The present invention adopts a frame-type test bench and installs and fixes safety supports and counterweights in multiple directions to ensure the safety of large-scale flight unit testing; at the same time, the vertical bench is adopted. Compared with the conventional horizontal small test bench, its test error is smaller and the test environment is more in line with the actual application scenario.

[0049] (3) The test system of the present invention takes into account the high voltage and high heat dissipation requirements of large-sized flight units, designs auxiliary systems such as a heat dissipation system and a bidirectional power distribution device, and fully considers the actual application conditions of large-sized flight units on flying cars; at the same time, by setting different auxiliary system boundaries, more comprehensive flight unit performance data and safe use boundaries are obtained, providing important data support for the flight test of flying cars.

[0050] (4) The test method proposed in the present invention includes linear testing, square wave step testing and frequency sweep testing, which can obtain the static characteristics and dynamic response characteristics of the flight unit, providing important data for the design of the flight controller control strategy of the flying car, thereby ensuring the subsequent flight stability and safety of the flying car.

[0051] (5) The above-mentioned system and speed measurement method can be applied to the research and development of flying cars, vertical take-off and landing vehicles, drones, and other fields. The device is reliable and flexible, and the test method is comprehensive and reliable, which can effectively improve the efficiency of research and development. In addition, the flight unit information obtained can also provide strong support for applications such as health monitoring and structural fault diagnosis of flying cars, and has broad application prospects and benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 This is a schematic diagram of a large-scale flight unit performance test system of the present invention;

[0053] Figure 2 This is an axial view of the test bench in the present invention;

[0054] Figure 3 is a side view of the test bench of the present invention;

[0055] Figure 4 is a top view of the test bench in the present invention;

[0056] Figure 5 This is a front view of the test bench in the present invention;

[0057] Figure 6 This is a main frame axis view of the test bench of the present invention;

[0058] Figure 7 It is an axial view of the base frame of the test bench main frame of the present invention;

[0059] Figure 8 It is a longitudinal frame axis view of the main frame of the test bench of the present invention;

[0060] Figure 9 Schematic diagram of the rotor module in the embodiment of the present invention.

[0061] Figure 10 This is a schematic diagram of the linear test of the host computer flight unit in an example of the present invention.

[0062] Figure 11 This is a schematic diagram of a square wave step test of a flight unit of a host computer in an example of the present invention.

[0063] Figure 12 This is a schematic diagram of a frequency sweep test of a host flight unit in an example of the present invention.

[0064] Among them, 1-test bench, 2-drive motor, 3-sensor module, 4-rotor module, 5-data acquisition card, 6-motor controller, 7-cooling system, 8-power distribution device, 9-host computer;

[0065] 1-1- Main frame of the test bench, 1-2- Oblique support of the test bench, 1-3- Side support of the test bench, 1-4- Adjustable platform, 1-5- Flight unit fixing platform, 1-6- Flight unit fixing flange, 1-7- Counterweight, 1-8- Fixing locking bolt;

[0066] 1-1-1-base frame, 1-1-2-longitudinal frame;

[0067] 1-1-1-1-base frame crossbeam, 1-1-1-2-base frame longitudinal beam, 1-1-1-3-base frame diagonal beam, 1-1-1-4-fixed foot;

[0068] 1-1-2-1-Longitudinal frame crossbeam, 1-1-2-2-Longitudinal frame longitudinal beam, 1-1-2-3-Longitudinal frame supporting beam, 1-1-2-4-Longitudinal frame diagonal beam. DETAILED DESCRIPTION

[0069] In order to make the purpose, content, and advantages of the present invention more clear, the specific implementation methods of the present invention are further described in detail below with reference to the accompanying drawings and examples.

[0070] In order to solve the above technical problems, the present invention provides a large-scale flight unit performance test system, such as Figures 1-8 As shown, the system includes: a test bench, a drive motor, a sensor module, a rotor module, a data acquisition card, a motor controller, a heat dissipation system, a power distribution device and a host computer;

[0071] The top of the test bench is fixedly connected to the drive motor by bolts, the top of the drive motor is connected to the sensor module by a flange, and the sensor module is connected to the rotor module by a flange; the drive motor is connected to the motor controller through a communication cable and a power supply cable, the drive motor is connected to the cooling system through a water pipe, the sensor module is connected to the data acquisition card through a communication cable, and the motor controller, data acquisition card, and cooling system are all communicated with the host computer through communication cables; the power distribution device is connected to the cooling system and the motor controller through a power supply cable.

[0072] The host computer includes: a drive motor control module, a heat dissipation system control module, a data recording and display module, and a safety protection module;

[0073] The safety protection module is used to preset protection values ​​for the parameters of tension, voltage, current, infrared temperature, commutation speed, photoelectric speed, total power, and amplitude displacement;

[0074] When a certain type of real-time test value reaches the preset protection value, the safety protection module executes the alarm function (the real-time data display position appears to flash red and the device emits an alarm sound) and performs the throttle lock operation.

[0075] The sensor module includes: a tension sensor, a speed sensor, a vibration sensor, and a noise sensor.

[0076] The heat dissipation system includes: a water tank, an oil tank, a cooling fan, and a temperature sensor, which are used to meet the temperature control requirements of the cooling water of the drive motor.

[0077] The power distribution device includes: a current control module, a voltage control module, and a bidirectional transmission module, which are used to meet the power demand of the motor controller; the adjustment range of the voltage control module is 10V-1100V.

[0078] The test bench includes: a main frame, an oblique support, a side support, an adjustable platform, a flight unit fixing platform, a flight unit fixing flange, a counterweight, and fixing locking bolts;

[0079] An adjustable platform is provided above the main frame of the test stand via fixed locking bolts, a flight unit fixing platform is provided above the adjustable platform, and a flight unit fixing flange is provided above the flight unit fixing platform via bolts;

[0080] The platform oblique support and the platform side support are used to jointly provide lateral support to the front and rear sides of the platform main frame;

[0081] Counterweight blocks are fixedly installed on the left and right sides of the platform main frame and the bottom of the platform side supports.

[0082] Wherein, the main frame of the platform includes a base frame and a longitudinal frame;

[0083] The base frame includes a base frame crossbeam, a base frame longitudinal beam, a base frame diagonal beam, and fixed feet;

[0084] The three base frame cross beams are vertically crossed and fixedly connected with the five base frame longitudinal beams to form a square frame body in the form of a rack frame. The two sides of the base frame cross beams are fixedly connected with the two base frame oblique beams respectively;

[0085] A fixed foot is installed at the bottom of the base frame, and a counterweight is installed above the fixed foot;

[0086] The longitudinal frame includes: a longitudinal frame cross beam, a longitudinal frame longitudinal beam, a longitudinal frame support beam, a longitudinal frame oblique beam, and a longitudinal frame middle connecting beam;

[0087] The two longitudinal frame cross beams are fixedly connected to the two longitudinal frame longitudinal beams to form a rectangular frame, the two diagonals of the rectangular frame are each provided with a longitudinal frame support beam, and longitudinal frame diagonal beams are provided on both sides of the longitudinal frame where the longitudinal frame longitudinal beams are located;

[0088] The middle connecting beam of the longitudinal frame is horizontally arranged at the connection point of the two longitudinal frame support beams, and its two ends are respectively connected to the longitudinal frame oblique beams on both sides;

[0089] The longitudinal frame longitudinal beam is provided with a through hole connected to the adjustable platform

[0090] The platform oblique supports are arranged in pairs, the number of which matches the longitudinal beams of the base frame, and there are five pairs;

[0091] On a square frame body in the form of a rack frame formed by three base frame cross beams and five base frame longitudinal beams, for each base frame longitudinal beam, of the three connection points formed by its connection with the three base frame cross beams, the two connection points on both sides are each connected to the lower end of a platform diagonal support, and the upper ends of the two platform diagonal supports converge and are connected to the middle connection beam of the longitudinal frame;

[0092] Due to a pair of platform oblique supports and a corresponding longitudinal beam of the base frame, three sides of an equilateral triangle support structure are formed, the vertex of the equilateral triangle support structure is located on the middle connecting beam of the longitudinal frame, and the two bottom points are located on the cross beam of the base frame;

[0093] By analogy, five pairs of platform diagonal supports and five base frame longitudinal beams form five groups of equilateral triangle support structures, which are evenly spaced and distributed on the middle connecting beam of the longitudinal frame and the cross beam of the base frame.

[0094] The number of the bench oblique supports can also be adjusted according to the test site.

[0095] There are two side supports for the platform, the upper ends of which are connected to the middle part of the connecting beam in the middle of the longitudinal frame, and the lower ends extend obliquely to the horizontal ground and are fixed by bolts.

[0096] In addition, the present invention also provides a large-scale flight unit performance test method, which is implemented based on the above system and includes the following steps:

[0097] Step 1. Secure the adjustable platform to the test bench using the locking bolts according to the test requirements. For flight unit tests without considering ground effect, the vertical distance between the adjustable platform and the base frame should be greater than 1 times the diameter of the rotor module.

[0098] Step 2: Connect the test bench, drive motor, sensor module, rotor module, data acquisition card, motor controller, cooling system, power distribution device, and host computer with power supply cables, communication cables, and water pipes.

[0099] Step 3: Design the output steady-state voltage U through the power distribution device, start the power distribution device, and supply power to the cooling system and motor controller;

[0100] Step 4: Design the coolant outlet temperature T of the cooling system through the host computer to ensure the cooling requirements of the drive motor;

[0101] Step 5: Design the motor controller parameters through the host computer. First, start the linear test. The speed of the drive motor increases linearly from 0% to 100%. According to a certain fixed slope α, the torque-speed curve, thrust-speed curve, power-speed curve and data are measured by the host computer.

[0102] Step 6: Perform a square wave step test through the drive motor control module of the host computer; the speed input of the drive motor is increased from 0% to 100% in steps, with a step gradient of φ, and then decreased after reaching 100%. The dynamic characteristics of acceleration and deceleration at different speed positions are tested to obtain the corresponding output thrust curve and data; after data analysis, the parameters of the boost time, initial stabilization time, and super stabilization time are obtained;

[0103] Step 7: Perform a frequency sweep test through the drive motor control module of the host computer; the speed input of the drive motor is sinusoidally varied from 50% to 75% according to the change frequency f, and the speed-torque curve and speed-tension curve are measured; after data analysis, the system response time, power overshoot value, and safety control frequency parameters are obtained;

[0104] Step 8. Perform a thermal balance test through the drive motor control module of the host computer; increase the speed input of the drive motor linearly from 10% to 100%, and pause for t minutes every 5% of the speed to observe whether the motor temperature rises at this speed; record the speed, over-temperature operation time, and inlet and outlet coolant temperatures at the final thermal balance;

[0105] Step 9: Change the output steady-state voltage U or the coolant outlet temperature T, and repeat the test contents of steps 5 to 8 to obtain the performance parameters and safe use limits of the flight unit under different voltage and heat dissipation conditions.

[0106] Example 1

[0107] This embodiment provides a large-scale flight unit performance test system and method. The specific test process is as follows:

[0108] like Figure 9 As shown, the diameter of the rotor module is 2 meters, and the test device of the present invention is used to test the static characteristics and dynamic response characteristics of the rotor without considering the influence of ground effect. After the rotor module, sensor module and drive motor are installed on the test bench, the adjustable platform is adjusted to a vertical distance of 2.5 meters from the base frame, and then fixedly connected to the test bench by fixing the locking bolts. The test bench is fixed in a preset site, and the four counterweights are set to a weight of 20 kilograms according to the results of the rotor numerical simulation. Then the drive motor is connected to the motor controller through a communication cable and a power supply cable, the drive motor is connected to the heat dissipation system through a water pipe, the sensor module is connected to the data acquisition card through a communication cable, and the motor controller, data acquisition card, and heat dissipation system are all connected to the host computer through communication cables. The power distribution device is connected to the heat dissipation system and the motor controller through a power supply cable.

[0109] After checking that the entire test system is connected and communicating normally, the power distribution device is used to output a steady-state voltage U of 900V. The power distribution device is started to supply power to the cooling system and motor controller. The coolant outlet temperature T of the cooling system is set to 65°C via the host computer. The motor controller parameters are designed via the host computer, and the static linear test is started first. The speed of the drive motor is linearly increased from 0% to 100%, with a fixed slope α of 50. The thrust-speed curve and power-speed curve are measured via the host computer, as shown in the following figure. Figure 10shown.

[0110] Then, the drive motor control module of the host computer performs a square wave step test. The speed input of the drive motor increases from 0% to 100% in steps, with a step gradient of φ of 10%. After reaching 100%, it decreases in steps. The dynamic characteristics of acceleration and deceleration at different speed positions are tested to obtain the corresponding output thrust curve and other data, such as Figure 11 As shown in the figure, data analysis shows that the time from signal reception to performance stabilization is approximately 300ms. A frequency sweep test was performed using the drive motor control module on the host computer. The drive motor speed input was sinusoidally varied from 50% to 75% at a frequency f of 50 Hz, increasing in increments. Real-time speed and tension response curves were measured. Data analysis revealed a system response time of approximately 500ms.

[0111] Finally, a thermal balance test is performed on the drive motor control module of the host computer. The drive motor speed input is linearly increased from 10% to 100%, and the speed is stopped at 5% for 20 minutes. The motor temperature is observed to see if it rises at this speed. The speed, over-temperature operation time, inlet and outlet coolant temperatures, and other information at the final thermal balance are recorded.

[0112] After one round of testing, the output steady-state voltage U or coolant outlet temperature T is changed, and the static linear test, square wave step test, frequency sweep test and thermal balance test are repeated to obtain the flight unit performance parameters and safe use boundaries under different voltage and heat dissipation conditions.

[0113] Based on the flight unit performance information predicted in the above steps, further analysis can be performed to determine whether the flight unit meets technical requirements, guiding the design of optimized flying vehicle performance. Furthermore, this information can provide strong support for applications such as health monitoring and structural fault diagnosis, demonstrating broad application prospects and benefits.

[0114] In summary, the present invention belongs to the technical field of flying vehicle design, and specifically relates to a performance test system and method for a large-scale flight unit. The system includes a test bench, a drive motor, a sensor module, a rotor module, a data acquisition card, a motor controller, a heat dissipation system, a power distribution device, and a host computer. The position of the rotor module and drive motor is adjusted via an adjustable platform, heat dissipation and power supply to the drive motor are achieved via the heat dissipation system and the power distribution device, and linear tests, square wave step tests, frequency sweep tests, and thermal balance tests are performed via the host computer to obtain the performance parameters and safe operating limits of the large-scale flight unit under different positions, voltages, and heat dissipation conditions. The present invention takes into account the high voltage and high heat dissipation requirements of large-scale flight units and designs auxiliary systems such as a heat dissipation system and a bidirectional power distribution device. These systems are more suitable for the actual application scenarios of large-scale flight units, have low test errors, and are highly applicable. They can provide important data support for the research, development, design, and testing of flying vehicles.

[0115] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A large-scale flight unit performance test system, characterized in that: The system includes: a test bench, a drive motor, a sensor module, a rotor module, a data acquisition card, a motor controller, a heat dissipation system, a power distribution device and a host computer; The top of the test bench is fixedly connected to the drive motor by bolts, the top of the drive motor is connected to the sensor module by a flange, and the sensor module is connected to the rotor module by a flange; the drive motor is connected to the motor controller through a communication cable and a power supply cable, the drive motor is connected to the cooling system through a water pipe, the sensor module is connected to the data acquisition card through a communication cable, and the motor controller, data acquisition card, and cooling system are all communicated with the host computer through communication cables; the power distribution device is connected to the cooling system and the motor controller through a power supply cable.

2. The large-scale flight unit performance test system according to claim 1, characterized in that: The host computer includes: a drive motor control module, a heat dissipation system control module, a data recording and display module, and a safety protection module; The safety protection module is used to preset protection values ​​for the parameters of tension, voltage, current, infrared temperature, commutation speed, photoelectric speed, total power, and amplitude displacement; When a certain type of real-time test value reaches a preset protection value, the safety protection module executes an alarm function and performs a throttle lock operation.

3. The large-scale flight unit performance test system according to claim 1, characterized in that: The sensor module includes: a tension sensor, a speed sensor, a vibration sensor, and a noise sensor.

4. The large-scale flight unit performance test system according to claim 1, characterized in that: The heat dissipation system includes: a water tank, an oil tank, a cooling fan, and a temperature sensor, which are used to meet the temperature control requirements of the cooling water of the drive motor.

5. The large-scale flight unit performance test system according to claim 1, characterized in that: The power distribution device includes: a current control module, a voltage control module, and a bidirectional transmission module, which are used to meet the power demand of the motor controller; the adjustment range of the voltage control module is 10V-1100V.

6. The large-scale flight unit performance test system according to claim 1, characterized in that: The test bench includes: a test bench main frame, a test bench oblique support, a test bench side support, an adjustable platform, a flight unit fixing platform, a flight unit fixing flange, a counterweight, and fixing locking bolts; An adjustable platform is provided above the main frame of the test stand via fixed locking bolts, a flight unit fixing platform is provided above the adjustable platform, and a flight unit fixing flange is provided above the flight unit fixing platform via bolts; The platform oblique support and the platform side support are used to jointly provide lateral support to the front and rear sides of the platform main frame; Counterweight blocks are fixedly installed on the left and right sides of the platform main frame and the bottom of the platform side supports.

7. The large-scale flight unit performance test system according to claim 6, characterized in that: The main frame of the platform includes a base frame and a longitudinal frame; The base frame includes a base frame crossbeam, a base frame longitudinal beam, a base frame diagonal beam, and fixed feet; The three base frame cross beams are vertically crossed and fixedly connected with the five base frame longitudinal beams to form a square frame body in the form of a rack frame. The two sides of the base frame cross beams are fixedly connected with the two base frame oblique beams respectively; A fixed foot is installed at the bottom of the base frame, and a counterweight is installed above the fixed foot; The longitudinal frame includes: a longitudinal frame cross beam, a longitudinal frame longitudinal beam, a longitudinal frame support beam, a longitudinal frame oblique beam, and a longitudinal frame middle connecting beam; The two longitudinal frame cross beams are fixedly connected to the two longitudinal frame longitudinal beams to form a rectangular frame, the two diagonals of the rectangular frame are each provided with a longitudinal frame support beam, and longitudinal frame diagonal beams are provided on both sides of the longitudinal frame where the longitudinal frame longitudinal beams are located; The middle connecting beam of the longitudinal frame is horizontally arranged at the connection point of the two longitudinal frame support beams, and its two ends are respectively connected to the longitudinal frame oblique beams on both sides; The longitudinal frame longitudinal beam is provided with a through hole connected to the adjustable platform.

8. The large-scale flight unit performance test system according to claim 7, characterized in that: The platform oblique supports are arranged in pairs, the number of which matches the longitudinal beams of the base frame, and there are five pairs; On a square frame body in the form of a rack frame formed by three base frame cross beams and five base frame longitudinal beams, for each base frame longitudinal beam, of the three connection points formed by its connection with the three base frame cross beams, the two connection points on both sides are each connected to the lower end of a platform diagonal support, and the upper ends of the two platform diagonal supports converge and are connected to the middle connection beam of the longitudinal frame; Due to a pair of platform oblique supports and a corresponding longitudinal beam of the base frame, three sides of an equilateral triangle support structure are formed, the vertex of the equilateral triangle support structure is located on the middle connecting beam of the longitudinal frame, and the two bottom points are located on the cross beam of the base frame; By analogy, five pairs of platform diagonal supports and five base frame longitudinal beams form five groups of equilateral triangle support structures, which are evenly spaced and distributed on the middle connecting beam of the longitudinal frame and the cross beam of the base frame.

9. The large-scale flight unit performance test system according to claim 8, characterized in that: The platform side supports are provided with two, the upper ends of which are connected to the middle part of the connecting beam in the middle of the longitudinal frame, and the lower ends are obliquely extended to the horizontal ground and fixed by bolts.

10. A large-scale flight unit performance test system, which is implemented based on the system according to claim 9, characterized in that: The method comprises the following steps: Step 1. Secure the adjustable platform to the test bench using the locking bolts according to the test requirements. For flight unit tests without considering ground effect, the vertical distance between the adjustable platform and the base frame should be greater than 1 times the diameter of the rotor module. Step 2: Connect the test bench, drive motor, sensor module, rotor module, data acquisition card, motor controller, cooling system, power distribution device, and host computer with power supply cables, communication cables, and water pipes. Step 3: Design the output steady-state voltage U through the power distribution device, start the power distribution device, and supply power to the cooling system and motor controller; Step 4: Design the coolant outlet temperature T of the cooling system through the host computer to ensure the cooling requirements of the drive motor; Step 5: Design the motor controller parameters through the host computer. First, start the linear test. The speed of the drive motor increases linearly from 0% to 100%. According to a certain fixed slope α, the torque-speed curve, thrust-speed curve, power-speed curve and data are measured by the host computer. Step 6: Perform a square wave step test through the drive motor control module of the host computer; the speed input of the drive motor increases from 0% to 100% in steps, and the step gradient is After reaching 100%, the speed is gradually reduced to test the dynamic characteristics of acceleration and deceleration at different speeds and positions, and the corresponding output thrust curve and data are obtained; after data analysis, the parameters of boost time, initial stabilization time, and super stabilization time are obtained; Step 7: Perform a frequency sweep test through the drive motor control module of the host computer; the speed input of the drive motor is sinusoidally varied from 50% to 75% according to the change frequency f, and the speed-torque curve and speed-tension curve are measured; After data analysis, the system response time, power overshoot value and safety control frequency parameters are obtained; Step 8. Perform a thermal balance test through the drive motor control module of the host computer; increase the speed input of the drive motor linearly from 10% to 100%, and pause for t minutes every 5% of the speed to observe whether the motor temperature rises at this speed; record the speed, over-temperature operation time, and inlet and outlet coolant temperatures at the final thermal balance; Step 9: Change the output steady-state voltage U or the coolant outlet temperature T, and repeat the test contents of steps 5 to 8 to obtain the performance parameters and safe use limits of the flight unit under different voltage and heat dissipation conditions.

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