An unmanned aerial vehicle power set aging test system and method

Abstract

This application relates to an aging test system for a drone power sleeve, comprising: a drone fuselage with a mounting position for installing the power sleeve; a damping rod including a cylinder and a piston rod; the piston rod being connected to the drone fuselage; a universal ball joint assembly including a universal ball joint rod and a universal ball socket, the universal ball joint rod and the universal ball socket being movably connected to form a spherical pair; the universal ball joint rod being connected to the cylinder; a round steel plate connected to the universal ball socket; a spring shock absorber connected to the round steel plate; and a fixed base connected to the spring shock absorber. This invention can reproduce outdoor flight conditions as closely as possible, improving the accuracy of aging test results. It can also achieve uninterrupted cyclic testing indoors, improving testing efficiency, reducing labor and time costs, and avoiding various risks associated with outdoor flight operations, such as drone crashes, airspace violations, and weather conditions.

Description

Technical Field

[0001] This application relates to the field of drone aging test technology, and in particular to a drone power sleeve aging test system and method. Background Technology

[0002] The drone power kit (including motor, ESC, and propeller) is a core actuator of the drone, responsible for providing the lift, thrust, and torque output required for flight. Its reliability directly determines the safety of drone flight operations and the success rate of mission execution. Therefore, during the research and development and mass production stages of drones, rigorous aging tests must be conducted on the power kit to verify its operational stability and reliability throughout its entire life cycle.

[0003] In existing technologies, aging tests are primarily conducted through outdoor flight testing. However, outdoor flight testing is affected by environmental conditions and weather factors, making 24-hour continuous testing impossible. Aging tests for power systems require numerous tests and long periods of continuous operation to obtain sufficient statistically significant reliability data. Relying entirely on outdoor flight testing would result in lengthy testing cycles, extremely high manpower and time costs, and potential risks of flight safety accidents. Furthermore, existing technologies include test benches, such as the UAV power system test platform disclosed in CN205670022U. These test benches cannot effectively simulate real-flight conditions, limiting the reference value of aging test results.

[0004] Therefore, there is a need for a test system and method for aging of UAV power kits that can reproduce actual flight conditions as closely as possible and can be repeatedly simulated indoors. Summary of the Invention

[0005] Therefore, it is necessary to provide an aging test system and method for the power sleeve of a UAV, the specific technical solution of which is as follows.

[0006] An aging test system for a drone power kit includes: The drone fuselage has mounting positions for installing the power sleeve; The damping rod includes a cylinder and a piston rod; the piston rod is connected to the fuselage of the drone. The universal ball assembly includes a universal ball joint rod and a universal ball socket, wherein the universal ball joint rod and the universal ball socket are movably connected to form a spherical pair; the universal ball joint rod is connected to the cylinder body; Round steel plate, connected to universal ball joint; Spring shock absorber, connected to round steel plate; The fixed base is connected to the spring shock absorber.

[0007] Furthermore, it also includes an XY-axis limiting mechanism; the XY-axis limiting mechanism includes an annular steel pipe assembly and a limiting member, the annular steel pipe assembly being mounted on a circular steel plate; the damping rod passing through the annular steel pipe assembly; the limiting member being located at the end of the annular steel pipe assembly away from the circular steel plate, used to limit the maximum swing angle of the damping rod.

[0008] Furthermore, the inner ring of the limiting member is provided with a bevel.

[0009] Furthermore, the testing system also includes a Z-axis limiting component, which includes a steel wire rope; one end of the steel wire rope is connected to the drone body, and the other end is connected to a circular steel plate, used to limit the maximum rotation angle of the drone body around the Z-axis.

[0010] Furthermore, a plurality of spring shock absorbers arranged in a ring array are provided between the round steel plate and the fixed base. One end of the spring shock absorber is connected to the round steel plate, and the other end is connected to the fixed base.

[0011] Furthermore, the steel wire rope is connected to the carbon tube on the fuselage of the UAV, and steel wire ropes are provided on both sides of one carbon tube.

[0012] Furthermore, a limiting clamp is fixedly installed on the carbon tube, and the limiting clamp restricts the movement of the wire rope.

[0013] A method using the testing system described in any one of the above claims includes the following steps: Step 1: Import the flight data into the DataLink data box to complete the pre-configuration of the test conditions; Step 2: Install the power kit onto the drone body, connect the ESC throttle signal interface to the DataLink data box, connect the power kit power supply interface to the controllable power supply, and connect the DataLink data box level signal interface to the control terminal of the power supply. Step 3: Configure the number of test cycles and the single-cycle process timing in the DataLink data box. The single-cycle process includes: power-on standby → takeoff throttle output → air attitude action throttle output → landing throttle output → power-off shutdown. Step 4: Start the DataLink data box and control the power kit to execute the preset loop process until the preset number of loops is reached; Step 5: After the test is completed, retrieve the voltage and current operating data of the power supply, as well as the ESC operating log. Disassemble the power kit to check the condition of the motor bearings, stator, and ESC components, and complete the aging reliability verification of the power kit.

[0014] Beneficial Effects: The UAV power sleeve aging test system provided by this invention achieves three-axis rotational freedom through a universal ball joint assembly, perfectly simulating the UAV's pitch, roll, and yaw movements. The damping rod enables vertical displacement of the UAV, accurately simulating dynamic conditions such as takeoff and landing. The flexible connection formed by the spring damper and damping rod reproduces the vibration environment of actual flight, allowing the test system to replicate outdoor flight conditions as closely as possible and improving the accuracy of aging test results. It enables continuous cyclic testing indoors, improving testing efficiency, reducing labor and time costs, and avoiding various risks associated with outdoor flight, such as crashes, airspace violations, and weather conditions. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the overall testing system; Figure 2 Side view of the test system Figure 3 for Figure 2 A schematic diagram of the section cut along AA; Figure 4 This is an exploded view of the test system; Figure 5 This is a partial schematic diagram of the test system under explosion conditions; Figure 6 This is a schematic diagram of a swivel ball assembly; Figure 7 This is a side view of the omnidirectional ball assembly; Figure 8 for Figure 7 A cross-sectional view along BB.

[0017] Explanation of reference numerals in the attached diagram: 1. UAV fuselage; 2. Damping rod; 3. Universal ball assembly; 4. Fixed base; 5. Annular steel pipe assembly; 6. Round steel plate; 7. Steel wire rope; 8. Spring shock absorber; 9. Power sleeve; 11. Carbon fiber tube; 12. Tie rod; 13. First screw; 21. Piston rod; 22. Cylinder block; 31. Universal ball joint tie rod; 32. Universal ball socket; 33. Universal ball joint flange lock; 34. First bolt; 35. Third screw; 41. Flange mounting plate; 51. Limiting component; 52. Second screw; 61. Lifting eye; 62. Second bolt; 71. Limiting clamp; 81. Third bolt; 82. Fourth bolt. Detailed Implementation

[0018] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0019] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0020] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0021] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0022] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0023] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0024] Example 1 Reference Figure 1-8 As shown, this embodiment provides an aging test system for a drone power kit 9, including a drone fuselage 1, a damping rod 2, a ball joint assembly 3, a round steel plate 6, a spring shock absorber 8, and a fixed base 4. The power kit 9 ​​referred to in this embodiment includes a motor, an electronic speed controller (ESC), and a propeller. The drone fuselage 1 has mounting positions for installing the power kit 9. Specifically, the drone fuselage 1 is configured to correspond to the model of the power kit 9 ​​to be tested. The power kit 9 ​​is mounted on a carbon fiber tube 11, and then the carbon fiber tube 11 is mounted on the drone fuselage 1. This allows the power kit 9 ​​to be tested as part of the drone, rather than testing individual components of the power kit 9, improving the accuracy of the aging test results. When different models of power kit 9 ​​need to be tested, the corresponding model of the drone fuselage 1 can be replaced. Therefore, the test system provided in this embodiment can adapt to the aging tests of different models of power kit 9.

[0025] Reference Figure 5 As shown, the damping rod 2 includes a cylinder 22 and a piston rod 21, which is connected to the drone fuselage 1. Specifically, a pull rod 12 is provided below the drone fuselage 1, and the pull rod 12 is connected to the drone fuselage 1 by a first screw 13, allowing direct connection between the piston rod 21 and the pull rod 12. In this embodiment, the damping rod 2 is a damping hydraulic rod. (Refer to...) Figure 6-8As shown, the universal ball assembly 3 includes a universal ball joint rod 31 and a universal ball socket 32, which are movably connected to form a spherical pair; the universal ball joint rod 31 is connected to the cylinder body 22. The round steel plate 6 is connected to the universal ball socket 32, and the universal ball socket 32 ​​can be connected to the round steel plate 6 by a first bolt 34. The round steel plate 6 is connected to the spring shock absorber 8 by a third bolt 81. The spring shock absorber 8 is connected to the fixed base 4 by a fourth bolt 82 and a nut. The fixed base 4 is directly fixed to the workbench or the ground.

[0026] Specifically, refer to Figure 6-8 As shown, the universal ball assembly 3 also includes a universal ball head flange lock 33, which is connected to the universal ball socket 32 ​​by a third screw 35 and surrounds the ball head on the universal ball head tie rod 31, thus forming a complete unit.

[0027] During testing, the omnidirectional ball assembly 3 allows the drone to rotate along three axes (X, Y, and Z), perfectly simulating the drone's pitch, roll, and yaw maneuvers. The damping rod 2 enables vertical movement, simulating the dynamic conditions of takeoff and landing. A flexible connection is formed between the spring damper 8 and the damping rod 2, replicating the vibration environment of actual flight.

[0028] It should be noted that when a drone is hovering, lift and gravity are in balance. When the lift changes, it will directly manifest as a change in acceleration, i.e., F. 升 -mg=ma, where m is the mass of the drone, g is the gravitational acceleration, and a is the acceleration of the drone. In this embodiment, by setting up a damping rod 2, a damping force is applied to the drone, so that the force balance of the drone becomes F. 升 -mg-F 阻 =ma, by adjusting the damping coefficient, the acceleration response and velocity change of the UAV can be made to maintain a similar proportional relationship to free flight, except that overshoot is suppressed, oscillation is attenuated, and a dissipation term is added, making the dynamic process in the test smoother and easier to observe and analyze. In this embodiment, by adjusting the damping coefficient of damping rod 2, the aerodynamic damping characteristics generated by the coupling of propellers and other components with the air under the vertical motion state of the UAV can be simulated, further restoring the force situation under the real flight state and further improving the accuracy of aging test results.

[0029] This embodiment provides an aging test system for a UAV power kit 9. The system achieves three-axis rotational freedom through a omnidirectional ball joint 3, perfectly simulating the UAV's pitch, roll, and yaw movements. A damping rod 2 enables vertical displacement of the UAV, accurately simulating dynamic conditions such as takeoff and landing. A flexible connection is formed between the spring damper 8 and the damping rod 2, replicating the vibration environment of actual flight. This allows the test system to reproduce outdoor flight conditions as closely as possible, improving the accuracy of aging test results. It enables continuous cyclic testing indoors, improving testing efficiency, reducing labor and time costs, and avoiding various risks associated with outdoor flight, such as crashes, airspace violations, and weather conditions.

[0030] In one embodiment, the testing system further includes an XY-axis limiting mechanism. (See reference...) Figure 3-5 As shown, the XY-axis limiting mechanism includes an annular steel pipe assembly 5 and a limiting member 51. The annular steel pipe assembly 5 is mounted on a circular steel plate 6. The damping rod 2 passes through the annular steel pipe assembly 5. The limiting member 51 is located at the end of the annular steel pipe assembly 5 away from the circular steel plate 6, and is used to limit the maximum swing angle of the damping rod 2. When the damping rod 2 swings with the UAV, it is restrained by the limiting member 51 and cannot continue to swing outward. Specifically, the maximum pitch and roll angles of the X / Y axes can be limited to ±30°. The limiting member 51 can be fixed inside the annular steel pipe assembly 5 by a second screw 52, ​​and the size of the limiting member 51 can be selected according to the maximum swing angle.

[0031] In one embodiment, the inner ring of the limiting member 51 is provided with a slope. This slope is used to abut against the pull rod 12. When the pull rod 12 abuts against the slope, it is in surface contact, which can reduce contact stress, avoid damage to the damping rod 2, and also reduce vibration caused by collision, thereby improving the accuracy of aging test results.

[0032] In one embodiment, the end of the annular steel pipe assembly 5 near the fixed base 4 is connected to the circular steel plate 6 via a second bolt 62. The testing system also includes a Z-axis limiting assembly, which includes a steel wire rope 7. One end of the steel wire rope 7 is connected to the UAV fuselage 1, and the other end is connected to the circular steel plate 6, used to limit the maximum rotation angle of the UAV fuselage 1 around the Z-axis. By limiting the maximum rotation angle of the UAV fuselage 1 around the Z-axis, yaw exceeding the limit is avoided. Specifically, the steel wire rope 7 is connected to the carbon tube 11 of the UAV fuselage 1, and steel wire ropes 7 are respectively provided on both sides of one carbon tube 11. In this embodiment, the UAV fuselage 1 includes four carbon tubes 11, and steel wire ropes 7 are provided on both sides of each carbon tube 11, for a total of eight steel wire ropes 7. Limiting clamps 71 are installed on the carbon tubes 11, and the limiting clamps 71 press the steel wire ropes 7 against the UAV fuselage 1, limiting the movement of the steel wire ropes 7, preventing the steel wire ropes 7 from coming off, and ensuring precise limiting. A lifting ring 61 is also connected to the round steel plate 6. One end of the steel wire rope 7 is connected to the carbon tube 11, and the other end is connected to the lifting ring 61.

[0033] In one embodiment, a plurality of spring dampers 8 arranged in a ring array are provided between the circular steel plate 6 and the fixed base 4. One end of each spring damper 8 is connected to the circular steel plate 6 by a third bolt 81, and the other end is connected to the fixed base 4 by a fourth bolt 82. By setting the damping rod 2 in combination with the spring dampers 8, a flexible structure can be formed between the UAV fuselage 1 and the fixed base 4, replicating the vibration environment in actual flight, thereby further approximating the dynamic characteristics of real flight and improving the accuracy of aging test results.

[0034] Specifically, in this embodiment, four spring dampers 8 are provided, and the four spring dampers 8 are evenly distributed.

[0035] In one embodiment, the bottom of the fixed base 4 is equipped with a flange mounting plate 41, which is fixed to the ground by expansion bolts to ensure the overall stability of the test system and provide rigid support for the entire test system.

[0036] Example 2 This embodiment provides a method for performing aging tests using the test system described in Embodiment 1, including the following steps: Step 1: Import the flight data into the DataLink data box to complete the pre-configuration of the test conditions.

[0037] The actual flight data is collected through the UAV flight control system, providing complete data on actual flight operations. This data includes at least throttle curve data covering the entire process, including takeoff, flight path, turns, and landing, as well as flight attitude and maneuver data. The corresponding throttle signal data is then extracted and imported into the DataLink data box.

[0038] Step 2: Install the power kit 9 ​​onto the drone body 1, connect the ESC throttle signal interface to the DataLink data box, connect the power supply interface of the power kit 9 ​​to the controllable power supply, and connect the level signal interface of the DataLink data box to the control terminal of the power supply.

[0039] After installing the power sleeve 9, adjust the maximum limiting angle of the Z-axis limit assembly to limit the maximum Z-axis yaw angle to ±60°. Then, select the corresponding limit component 51 to adjust the maximum limiting angle of the X / Y axes to limit the maximum pitch and roll angles of the X / Y axes to ±30°. Step 3: Configure the number of test cycles and the single-cycle sequence in the DataLink data box. The single-cycle sequence includes: power-on standby → takeoff throttle output → air attitude action throttle output → landing throttle output → power-off shutdown.

[0040] The system can be configured to automatically power on when a high-level signal is received and automatically power off when a low-level signal is received. Specifically, the cycle count can be set to 1000 times. The specific timing of a single cycle is as follows: power-on standby 30s → takeoff throttle output 30s → in-flight attitude control throttle output 13min → landing throttle output 30s → power-off shutdown 30s.

[0041] Step 4: Start the DataLink data box and control the power kit 9 ​​to execute the preset loop process until the preset number of loops is reached.

[0042] The DataLink data box outputs a high-level signal to automatically power on the power supply, energizing the power kit 9. Following a pre-stored actual flight throttle curve, it automatically sends throttle signals to the electronic speed controller (ESC). The power kit 9 ​​operates under real flight conditions. During the test, attitude changes are simulated via the omnidirectional ball joint 3, vertical takeoff and landing via the damping rod 2, and flight vibrations via the spring damper 8, fully replicating the entire real flight process. After a single cycle is completed, the DataLink data box outputs a low-level signal to automatically power off the power supply, completing one test cycle. This cycle is repeated until 1000 cycles are completed, after which the machine automatically shuts down, requiring no manual intervention throughout the entire process.

[0043] Step 5: After the test is completed, retrieve the voltage and current operating data of the power supply, as well as the ESC operating log. Disassemble the power kit 9 ​​to check the condition of the motor bearings, stator, and ESC components, and complete the aging reliability verification of the power kit 9.

[0044] The aging test method provided in this embodiment, which uses the test system described in Embodiment 1, achieves automatic reproduction of throttle signals and automatic power-on / off control through the DataLink data box. It can completely reproduce the entire process of real flight, realize 24 / 7 unattended continuous cyclic testing, eliminate the need for frequent manual operation, and the number of test cycles that can be completed in a single month far exceeds that of outdoor actual flight, greatly reducing labor costs. At the same time, the test process is standardized and the test consistency is extremely strong.

[0045] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0046] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. An aging test system for a drone power sleeve, characterized in that, include: The drone fuselage has mounting positions for installing the power sleeve; The damping rod includes a cylinder and a piston rod; the piston rod is connected to the fuselage of the drone. The universal ball assembly includes a universal ball joint rod and a universal ball socket, wherein the universal ball joint rod and the universal ball socket are movably connected to form a spherical pair; the universal ball joint rod is connected to the cylinder body; Round steel plate, connected to universal ball joint Spring shock absorber, connected to round steel plate. The fixed base is connected to the spring shock absorber.

2. The aging test system for a UAV power sleeve according to claim 1, characterized in that, It also includes an XY axis limiting mechanism; the XY axis limiting mechanism includes an annular steel pipe assembly and a limiting member, the annular steel pipe assembly is mounted on a circular steel plate; the damping rod passes through the annular steel pipe assembly; the limiting member is located at the end of the annular steel pipe assembly away from the circular steel plate, and is used to limit the maximum swing angle of the damping rod.

3. The aging test system for a UAV power sleeve according to claim 2, characterized in that, The inner ring of the limiting component has a bevel.

4. The aging test system for a UAV power sleeve according to claim 2, characterized in that, The testing system also includes a Z-axis limiting component, which includes a steel wire rope. One end of the steel wire rope is connected to the drone body, and the other end is connected to a round steel plate, which is used to limit the maximum rotation angle of the drone body around the Z-axis.

5. The aging test system for a UAV power sleeve according to claim 4, characterized in that, Multiple spring dampers arranged in a ring array are provided between the round steel plate and the fixed base. One end of each spring damper is connected to the round steel plate, and the other end is connected to the fixed base.

6. The aging test system for a UAV power sleeve according to claim 4, characterized in that, The steel wire rope is connected to the carbon tube on the fuselage of the UAV, and steel wire ropes are provided on both sides of one carbon tube.

7. The aging test system for a UAV power sleeve according to claim 6, characterized in that, A limit clamp is fixedly installed on the carbon tube, and the limit clamp restricts the movement of the wire rope.

8. A method using the testing system according to any one of claims 1 to 7, characterized in that, Includes the following steps: Step 1: Import the flight data into the DataLink data box to complete the pre-configuration of the test conditions; Step 2: Install the power kit onto the drone body, connect the ESC throttle signal interface to the DataLink data box, connect the power kit power supply interface to the controllable power supply, and connect the DataLink data box level signal interface to the control terminal of the power supply. Step 3: Configure the number of test cycles and the single-cycle process timing in the DataLink data box. The single-cycle process includes: power-on standby → takeoff throttle output → air attitude action throttle output → landing throttle output → power-off shutdown. Step 4: Start the DataLink data box and control the power kit to execute the preset loop process until the preset number of loops is reached; Step 5: After the test is completed, retrieve the voltage and current operating data of the power supply, as well as the ESC operating log. Disassemble the power kit to check the condition of the motor bearings, stator, and ESC components, and complete the aging reliability verification of the power kit.

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