An unmanned aerial vehicle power system integrated test system

Abstract

The utility model discloses a kind of unmanned aerial vehicle power system integrated test system, it is related to unmanned aerial vehicle test technical field.The system includes host computer, data acquisition and control unit and integrated test platform.The integrated test platform is provided with motor test module, drive board test module and the switching connecting seat between the two.The motor test module includes motor fixed clamp, the load device and mechanical parameter sensor coaxially connected with the motor to be measured;Drive board test module includes drive board fixed clamp and electrical parameter detection component.The switching connecting seat is provided with conductive channel, and the interface of its two ends is respectively configured as with the motor to be measured drive board and motor to be measured detachable connection.The utility model is through integrated architecture and specific connecting structure, realizes the efficient integrated test and data linkage analysis of motor and electronic governor.

Description

Technical Field

[0001] This utility model relates to the field of unmanned aerial vehicle (UAV) testing technology, and in particular to an integrated testing system for UAV power systems. Background Technology

[0002] The drone's power system mainly consists of a brushless motor and an electronic speed controller, whose performance directly determines the drone's payload, range, and response speed. Precise measurements of various parameters of the motor and electronic speed controller are required during the research, development, production, and quality inspection stages.

[0003] Currently, testing of drone motors and electronic speed controllers typically employs a separate testing approach. Motor testing utilizes a separate motor test bench, including torque sensors, encoders, and load devices, which can only test the motor's mechanical characteristics. Electronic speed controller testing uses an oscilloscope, current probe, and electronic load to build a temporary platform, manually measuring input and output parameters. This separate testing approach suffers from problems such as dispersed equipment, high cost, and large footprint. Furthermore, the testing process relies on manual operation, resulting in low automation, inconsistent data formats, and difficulties in alignment and correlation analysis on the same timeline, making it impossible to obtain the true performance characteristics after system matching. In addition, existing technologies lack the ability to simulate dynamic operating conditions and perform high-frequency synchronous data acquisition, making it difficult to accurately assess the dynamic response characteristics of drones in complex flight environments.

[0004] Therefore, how to achieve efficient integrated testing and data linkage analysis of motors and electronic speed controllers has become a technical problem that urgently needs to be solved in this field. Utility Model Content

[0005] The main purpose of this utility model is to provide an integrated testing system for the power system of unmanned aerial vehicles (UAVs), which aims to achieve efficient integrated testing and data linkage analysis of motors and electronic speed controllers.

[0006] To achieve the above objectives, this utility model proposes an integrated testing system for a UAV power system, including a main control computer, a data acquisition and control unit, and an integrated testing platform. The main control computer is communicatively connected to the data acquisition and control unit. The integrated testing platform is equipped with a motor testing module and a drive board testing module. The motor testing module includes a motor fixing fixture, a load device, and a mechanical parameter sensor. The input shaft of the load device is configured to be coaxially connected to the motor under test mounted on the motor fixing fixture. The drive board testing module includes a drive board fixing fixture and an electrical parameter detection component. The integrated testing platform is also equipped with an adapter connector located between the motor fixing fixture and the drive board fixing fixture. The adapter connector has a first interface end and a second interface end. The first interface end is configured to be detachably connected to the drive board under test on the drive board fixing fixture, and the second interface end is configured to be detachably connected to the motor under test on the motor fixing fixture. The adapter connector has a conductive channel connecting the first interface end and the second interface end. The load device, the mechanical parameter sensor, and the electrical parameter detection component are electrically connected to the data acquisition and control unit.

[0007] Preferably, the adapter connector includes a current transmission terminal for transmitting three-phase drive power and a signal transmission connector for transmitting control signals.

[0008] Preferably, the load device includes a magnetic powder brake, which is electrically connected to the main control computer, and the main control computer is configured to control the load torque of the magnetic powder brake by adjusting the excitation current.

[0009] Preferably, the mechanical parameter sensor includes a torque sensor and a photoelectric encoder connected to the output shaft of the motor under test.

[0010] Preferably, the motor test module further includes a first signal conditioning circuit, the input terminal of which is connected to the torque sensor and the photoelectric encoder respectively, and the output terminal of which is connected to the data acquisition and control unit.

[0011] Preferably, the motor fixing fixture includes a base and an adjustable or replaceable clamping assembly disposed on the base, the clamping assembly being configured to clamp the motor under test of different sizes.

[0012] Preferably, the driver board fixing fixture is provided with a universal slot and a position-adjustable conductive probe, the conductive probe being configured to make electrical contact with the pins of the driver board under test.

[0013] Preferably, the electrical parameter detection component includes a high-voltage differential voltage probe for acquiring voltage waveforms and a high-bandwidth current probe for acquiring current waveforms.

[0014] Preferably, the driver board test module further includes a simulated load, which includes a high-power resistor group configured to be electrically connected to the driver board fixing fixture.

[0015] Preferably, the data acquisition and control unit includes a programmable DC power supply and a data acquisition card; the programmable DC power supply is electrically connected to the drive board fixing fixture to provide drive power; the data acquisition card is connected to the mechanical parameter sensor and the electrical parameter detection component respectively.

[0016] The above technical solution has the following advantages: This utility model provides an integrated testing system for UAV power systems. By integrating a motor testing module and a drive board testing module onto an integrated testing platform and utilizing an adapter connector to achieve rapid electrical connection between the two, it solves the problems of scattered testing and cumbersome connections in existing technologies. This system, in conjunction with a main control computer and a data acquisition and control unit, can simultaneously collect mechanical and electrical parameters, enabling linked data analysis and effectively improving testing efficiency and data accuracy. This provides a reliable basis for the overall performance evaluation of UAV power systems. Attached Figure Description

[0017] The present invention will now be described in detail with reference to specific embodiments and accompanying drawings, wherein: Figure 1 A schematic diagram of the overall architecture of the UAV power system integration test system provided in this embodiment of the utility model. Detailed Implementation

[0018] The embodiments of this application will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0019] A core objective of this application is to address the problems of fragmented testing, cumbersome connections, and difficulties in integrated data analysis of UAV power systems in existing technologies. To this end, this application designs an integrated hardware architecture that, through specific physical connection structures and electrical layouts, enables rapid joint testing of the motor and driver.

[0020] Example 1 This embodiment provides an integrated testing system for a UAV power system. Its overall architecture mainly includes a main control computer 1, a data acquisition and control unit 2, and an integrated testing platform 5. The main control computer 1 serves as the system's control center, responsible for sending commands and processing data, and establishes a communication connection with the data acquisition and control unit 2. The data acquisition and control unit 2 is responsible for specific voltage output control and signal acquisition.

[0021] The core of this embodiment lies in the integrated test platform 5. Unlike existing technologies that place the motor and driver on separate desktops for testing, this embodiment integrates both the motor test module 3 and the driver board test module 4 on the integrated test platform 5. This integrated design ensures the stability of the mechanical structure and the consistency of spatial position during the testing process.

[0022] Specifically, the motor test module 3 is equipped with a motor mounting fixture 31 for mounting the motor under test. To accommodate different specifications of UAV motors, the motor mounting fixture 31 includes a base and adjustable or replaceable clamping components mounted on the base. These clamping components can be adjusted or replaced according to the outer diameter of the motor under test, thus ensuring compatibility with multiple models.

[0023] The driver board test module 4 is equipped with a driver board mounting fixture 41 for mounting the driver board under test (i.e., the electronic speed controller, ESC). Considering that driver boards typically lack standard mounting holes, the driver board mounting fixture 41 is designed with universal slots and position-adjustable conductive probes. These conductive probes are configured to make direct electrical contact with the pads or pins of the driver board under test, thereby avoiding a cumbersome soldering process and achieving rapid clamping.

[0024] To address the issue of messy and non-standard wiring between the motor and the drive board, this embodiment includes a dedicated adapter connector 51 on the integrated testing platform 5. This adapter connector 51 is located between the motor mounting fixture 31 and the drive board mounting fixture 41. The adapter connector 51 is not simply a wire, but a physical intermediary component. It has a first interface end 511 and a second interface end 512. The first interface end 511 faces the drive board and is configured for detachable connection to the output end of the drive board under test on the drive board mounting fixture 41; the second interface end 512 faces the motor and is configured for detachable connection to the input end of the motor under test on the motor mounting fixture 31.

[0025] More importantly, the adapter connector 51 has a conductive channel inside that connects the first interface terminal 511 and the second interface terminal 512. This means that once the tester installs the drive board and motor into place and connects them to the adapter connector 51, electrical continuity is immediately established between them, eliminating the need for manually constructing long wires. This structure not only significantly shortens the connection path and reduces the impact of line impedance on test accuracy, but also ensures the consistency of the connection status during each test.

[0026] Furthermore, the adapter connector 51 integrates current transmission terminals for transmitting three-phase drive power and signal transmission connectors for transmitting control signals. The high-current terminals are responsible for carrying the main power current of the drive motor, while the standard signal connectors are used to transmit control commands such as servo signals, thus achieving standardized transmission of power flow and signal flow.

[0027] Example 2 Based on the mechanical structure of Embodiment 1, this embodiment further elaborates on the electrical load and sensing architecture of the system, aiming to solve the problem that existing technologies are unable to capture dynamic operating condition data.

[0028] In the motor test module 3, in addition to the fixed structure, a load device 32 and mechanical parameter sensors are also included. The input shaft of the load device 32 is configured to be coaxially connected to the motor under test mounted on the motor fixture 31. In this embodiment, a magnetic powder brake is specifically selected as the load device 32. Compared with uncontrollable loads such as wind turbine blades, the magnetic powder brake is electrically connected to the main control computer 1, and the main control computer 1 can precisely control the load torque applied to the motor shaft by adjusting the excitation current. This programmable load characteristic allows the system to simulate various drag changes during the flight of the UAV.

[0029] To obtain accurate mechanical performance data, the mechanical parameter sensors include a torque sensor 33 and a photoelectric encoder 34 connected to the output shaft of the motor under test. The torque sensor 33 is used to monitor the torque output of the motor in real time; for example, a high-precision sensor with a range of ±5 Nm is selected. Specifically, the torque sensor 33 can be an HBM T series sensor with a nonlinearity of less than 0.1% FS and an output signal of 0-10V analog. The photoelectric encoder 34 is used to accurately capture the speed and position information of the motor. An embodiment of this encoder can be an Omron E6B2-CWZ6C, which has a resolution of 2000 pulses / revolution, a response frequency of up to 100kHz, and adopts an ABZ three-phase differential signal output. To ensure the purity of signal transmission, the motor test module 3 is also equipped with a first signal conditioning circuit. The raw signals collected by the torque sensor 33 and the photoelectric encoder 34 first enter the first signal conditioning circuit for amplification, filtering, and isolation processing. The processed high-quality signal is then transmitted to the data acquisition and control unit 2.

[0030] On one side of the driver board test module 4, an electrical parameter detection component is equipped to comprehensively evaluate the electrical performance of the driver board. This component specifically includes a high-voltage differential voltage probe 42 and a high-bandwidth current probe 43. The high-voltage differential voltage probe 42 is used to acquire the PWM voltage waveform output by the driver board. It can be a Tektronix THDP0200 with a bandwidth of 200MHz and a common-mode rejection ratio greater than 60dB at 1MHz. The high-bandwidth current probe 43 is used to acquire transient current waveforms. It can be a Pearson 411 with a bandwidth covering DC-4MHz, a sensitivity of 0.1V / A, an input impedance greater than 1MΩ, and a common-mode rejection ratio greater than 80dB. These probes are connected to the data acquisition and control unit 2, enabling the capture of nanosecond-level waveform changes, thereby analyzing key indicators such as switching losses and dead time of the driver board. To further optimize signal quality, the driver board test module 4 also includes a second signal conditioning circuit, used to condition the signals acquired by the voltage and current probes before sending them to the acquisition unit.

[0031] Furthermore, considering that in some debugging scenarios it is necessary to test the driver board separately without connecting it to the motor, the driver board test module 4 also includes a simulated load 45. The simulated load 45 includes a set of high-power resistors configured to be electrically connected to the driver board mounting fixture 41. By switching, the output of the driver board can be directed to this set of high-power resistors, thereby verifying the basic power output function of the driver board without rotating the motor.

[0032] Example 3 This embodiment focuses on explaining the system's integrated control architecture and data flow, demonstrating how the system achieves synchronized data linkage through hardware integration.

[0033] The data acquisition and control unit 2 includes a programmable DC power supply and a data acquisition card. The programmable DC power supply is electrically connected to the driver board mounting fixture 41, providing precise DC drive power to the driver board under test to simulate battery discharge characteristics. This programmable DC power supply can be a Keysight N6700 series, with an output range of 0-60V / 0-20A, a programming accuracy of ±0.05%+2mV, and a dynamic response time of less than 100μs. The data acquisition card acts as a data aggregation center, connecting to both the mechanical parameter sensor (via a first signal conditioning circuit) and the electrical parameter detection component (via a second signal conditioning circuit). Specifically, the data acquisition card can be an NI USB-6366, which features multi-channel synchronous sampling, a sampling rate of up to 2MS / s, a 16-bit analog input resolution, a range supporting ±10V, and 24-line programmable digital I / O.

[0034] During operation, the main control computer 1 manages the entire process through its built-in test control and data analysis software. This software integrates multiple functional modules, including: a system self-test module to check the communication status between the main components and the main control computer 1, and whether the equipment itself is functioning correctly; a user management module for operators with administrator privileges to manage user information; and a parameter configuration module for configuring DC power supply parameters, sensor parameters, and overcurrent and overvoltage protection parameters. Users can select test modes in the software interface, such as individual motor testing, individual drive board testing, or combined testing. The system, according to instructions, controls the output voltage of the programmable DC power supply and sends throttle control signals, such as PWM waves, to the drive board under test via a data acquisition card. The drive board drives the motor to rotate through the adapter connector 51, while the main control computer 1 controls the magnetic powder brake 32 to apply a set load.

[0035] At this point, due to the integrated architecture of the system, the data acquisition card can utilize the same clock source to synchronously trigger the acquisition of voltage, current, torque, and speed. This means that mechanical and electrical data are strictly aligned on the time axis. Based on this hardware synchronization, the system software, using a built-in data synchronization algorithm, can calculate the overall system efficiency at each moment, i.e., mechanical output power divided by electrical input power, thereby generating a MAP diagram of the overall system efficiency that includes the common characteristics of the motor and drive board. Furthermore, when performing throttle step tests, the system can simultaneously record the moment of throttle signal change, the moment of current response, and the moment of torque build-up, thus accurately analyzing the dynamic response delay of the power system. After the test is completed, the software can automatically store and process the acquired data and generate a standardized test report.

[0036] Example 4 This embodiment introduces alternative solutions to the above hardware architecture to demonstrate the scalability and flexibility of the technical solution of this application.

[0037] In the above embodiment, the load device 32 employs a magnetic powder brake. In other alternative embodiments, the load device 32 can also adopt a "coupling motor + load controller" scheme. That is, another motor is used as a generator, coaxially connected to the motor under test, and the load is applied by consuming the electrical energy generated by the generator through the load controller.

[0038] For the data acquisition and control unit 2, in addition to using a separate data acquisition card, another implementation can use a high-precision oscilloscope or power analyzer with more integrated functions as the main acquisition device. These devices can communicate with the main control computer 1 via GPIB or LAN cable to upload data and issue commands.

[0039] Regarding the adapter connector 51, in addition to using physical pluggable terminals, magnetic connectors or wireless slot structures can also be considered, provided that high current transmission reliability is met, to further simplify the connection steps and improve testing efficiency. These alternative solutions do not deviate from the core concept of this application, namely, to achieve integrated testing of the motor and drive board.

[0040] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An integrated testing system for a drone power system, characterized in that, The system includes a main control computer, a data acquisition and control unit, and an integrated testing platform. The main control computer is communicatively connected to the data acquisition and control unit. The integrated testing platform is equipped with a motor testing module and a drive board testing module. The motor testing module includes a motor mounting fixture, a load device, and mechanical parameter sensors. The input shaft of the load device is configured to be coaxially connected to the motor under test mounted on the motor mounting fixture. The drive board testing module includes a drive board mounting fixture and an electrical parameter detection component. The integrated testing platform is also equipped with an adapter connector located between the motor mounting fixture and the drive board mounting fixture. The adapter connector has a first interface end and a second interface end. The first interface end is configured to be detachably connected to the drive board under test on the drive board mounting fixture, and the second interface end is configured to be detachably connected to the motor under test on the motor mounting fixture. The adapter connector has a conductive channel connecting the first interface end and the second interface end. The load device, the mechanical parameter sensor, and the electrical parameter detection component are all electrically connected to the data acquisition and control unit.

2. The UAV power system integration test system according to claim 1, characterized in that, The adapter connector includes a current transmission terminal for transmitting three-phase drive power and a signal transmission connector for transmitting control signals.

3. The UAV power system integration test system according to claim 1, characterized in that, The load device includes a magnetic powder brake, which is electrically connected to the main control computer. The main control computer is configured to control the load torque of the magnetic powder brake by adjusting the excitation current.

4. The UAV power system integration test system according to claim 1, characterized in that, The mechanical parameter sensor includes a torque sensor and a photoelectric encoder connected to the output shaft of the motor under test.

5. The UAV power system integration test system according to claim 4, characterized in that, The motor test module further includes a first signal conditioning circuit, the input of which is connected to the torque sensor and the photoelectric encoder respectively, and the output of which is connected to the data acquisition and control unit.

6. The UAV power system integration test system according to claim 1, characterized in that, The motor fixing fixture includes a base and an adjustable or replaceable clamping assembly disposed on the base, the clamping assembly being configured to clamp the motor under test of different sizes.

7. The UAV power system integration test system according to claim 1, characterized in that, The driver board fixing fixture is provided with a universal slot and a position-adjustable conductive probe, which is configured to make electrical contact with the pins of the driver board under test.

8. The UAV power system integration test system according to claim 1, characterized in that, The electrical parameter detection component includes a high-voltage differential voltage probe for acquiring voltage waveforms and a high-bandwidth current probe for acquiring current waveforms.

9. The UAV power system integration test system according to claim 1, characterized in that, The driver board test module also includes a simulated load, which includes a high-power resistor group configured to be electrically connected to the driver board fixing fixture.

10. The UAV power system integration test system according to claim 1, characterized in that, The data acquisition and control unit includes a programmable DC power supply and a data acquisition card; the programmable DC power supply is electrically connected to the drive board fixing fixture to provide drive power; the data acquisition card is connected to the mechanical parameter sensor and the electrical parameter detection component respectively.

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