Motor and ESC test
On our test bench, we can accurately measure torque, rpm, throttle, voltage, current and temperature of a specific motor with ESC combination. Static tests are performed at different mechanical loads, input voltages and throttle settings, resulting in a 3D lookup-table which verifies the efficiency and allows to select the best suited propeller. Dynamic tests reveal how crisp the motor with ESC combination responds to quickly changing throttle signals. The measurements are presented in a report, table data or any requested file format to plug it directly into your own simulation or design process.
Our propulsion test benches allow measuring the static thrust and torque of the propeller, as well as the noise, balance and inertia. We can test propellers ranging from 4 to 30 inch in diameter. For in-flight propeller performance we have 3 sizes of quadcopters with known and calibrated aerodynamics that allow measuring the propeller behavior throughout all flight phases. Also here the measurements can be presented in a report, as table data or in a requested file format to plug it directly into your own simulation or design process.
Batteries are a crucial part in the performance of electrical vehicles. Li-Po batteries are typically used for drones but with an increasing number of used cycles, changing temperatures and case specific power profiles, the available capacity can deviate greatly from the advertised cell capacity. An automated test setup in a temperature controlled environment allows to test the exact conditions and available capacity for your mission.
With our test procedure and data-analysis, we can measure and identify the steady state performance of the drone in terms of aerodynamics, efficiency, speed, power, distance, payload as well as the dynamic behavior in terms of control bandwidth, frame inertia, maximum accelerations and rotation speeds etc. This allows to benchmark a new design or check the influence of a design change to the overall vehicle performance.
Drone design or improvement and prototyping
If there is no drone on the market that meets your mission requirements, a new design can be made by varying all design parameters until an optimal solution to the requirements is found. From this parameter set, the components such as battery, ESCs, motors, propellers and the frame dimensions can be determined. In a next step, our over-sided 3D printers can be used to build a flying prototype of the design with the same geometry and propulsion system in order to validate simulated performance. An existing drone can also be analyzed and small changes in the design can be proposed to improve the performance. For example "which propeller would make our drone fly faster without overloading the current motors?".
Mission simulation & Predictive maintenance
Unlike other simulators which are used to train pilots and simulate the flight behavior, we can accurately calculate the required power throughout all flight phases and predict how much energy will be left in the battery at the end of a mission. This is critical for situations in which a drone is used for long-distance missions such as off-shore inspections in which you want to make sure the drone is able to make it back to the shore before the battery runs out. Comparing each flown mission to our simulation allows us to identify changes in the flight behavior of the drone and perform predictive maintenance on for example aging batteries, demagnetized motors, worn-out bearings, failing capacitors, damaged propellers or unwanted shifts in center of gravity.