Tags:hybrid-electric propulsion, real-time operating system, resistive load bank and test bench
Abstract:
Present work describes the design process, building and testing of an electronically-controlled resistive load bank. This device is part of an aircraft hybrid-electric propulsion test bench for stationary analysis. One of the targets is for the bank to be low-cost and easy to handle in safety. It was sized and its operation scaled to simulate the variable mechanical load that an aircraft propeller applies to the drivetrain axis, at different rotation speeds on steady state. The load bank support frame that houses the resistive elements and cooling fans was designed and assembled. Two sensor boards were developed to measure voltages and currents. The bank’s controller is assembled in an Arduino board, with embedded programming on a real-time operating system (RTOS), and communicates with supervisory hosted on a computer through a Controller Area Network (CAN) bus. The program’s user interface was created as a Windows Forms App to allow ease of use and real-time monitoring of the bank’s operation. Tests were performed to validate sensor performance, and thermal response curves were acquired. Results indicate the system operates predictably and reliably, encouraging further developments.
Design, Specification and Instalation of a Resistive Load Bank for a Hybrid-Electric Propulsion Test Bench