Tilt Rotor Power Assembly Test Bench for Flight Load Simulation
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Solution Overview
Problem
Existing testing technologies for electrically-driven composite blade tilt rotor power assemblies in hovercars are inadequate, leading to risks due to unstable systems, imperfect design, and lengthy test processes, which increase development costs and pose safety hazards.
Innovation Solution
A testing device comprising a tilt rotor flight power assembly, flange platform, rotatable cantilever shaft, six-component balance, tilt motor, and substrate, with a data acquisition system, designed to simulate various flight conditions and accurately record performance data, ensuring safety and stability through high-strength substrates and precise motor control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sets of tooling are used to match different test systems, then the test verification of rotor system can be completed, but the device complexity and test period are increased
Solution Approach 1:
The patent implements a universal hinge type tilt mechanism that can accommodate multiple test systems and configurations through a single integrated platform. The mechanism includes adjustable linkages and universal joints that allow the same base structure to perform different test verifications, eliminating the need for multiple specialized tooling sets and reducing overall device complexity.
Solution Approach 2:
The test device is divided into modular components including separate tilt mechanisms, balance systems, and measurement instruments that can be independently configured. This segmentation allows flexible reconfiguration for different test requirements without requiring complete replacement of tooling, thereby maintaining versatility while controlling complexity.
2Adaptability or versatility
If the test bench includes supporting cover body and platform body with multiple adjustments, then the rotor system test can be performed, but the operation complexity and test period are increased
Solution Approach 1:
The test bench is pre-configured with preset adjustment positions and pre-calibrated measurement systems. The tilt mechanism includes pre-set angular positions and the balance system comes pre-calibrated, allowing operators to perform test verifications without complex manual adjustments, thereby reducing operation complexity while maintaining full test capability.
3Reliability
If the substrate height is increased to 2-6m, then the ground interference is avoided and safety is improved, but the device complexity and manufacturing difficulty are increased
Solution Approach 1:
The substrate is designed with adjustable height mechanisms and telescopic support structures that allow the platform to be dynamically positioned at different heights (2-6m) depending on test requirements. This dynamic adjustability provides safety benefits when needed while avoiding the permanent complexity of fixed high-altitude structures, making the system easier to manufacture and assemble.
Data Source
AI summary
A testing device and a testing method of a composite blade tilt rotor power assembly are related. The testing method includes the following steps: installing a tilt rotor flight power assembly on a flange platform of a testing device through a connector; confirming normal operation of an external power supply, the tilt rotor flight power assembly and a data acquisition computer; starting the tilt rotor flight power assembly, and controlling a tilt motor to rotate a cantilever shaft according to a tilt angle instruction; and recording the energy consumption and the tensile forces and torques in x, y and z directions of the tilt rotor flight power assembly by the data acquisition computer in real time. The testing method has the beneficial effects that the processes of starting, starting and stopping, hovering and descending can be simulated for the composite blade tilt rotor power assembly which is a core driving component of a vertical take-off and landing type electric driving hovercar, and the flight performance of the hovercar can be tested. The testing method can also be used for cold rotation test, take-off strategy verification test, hover strategy verification test, durability test and acceleration performance test of the composite blade tilt rotor power assembly.