Dynamometer Development (R&D)

Development of the thrust and efficiency data for our KDE Direct UAS Brushless MotorElectronic Speed Controller (ESC), and Propeller Blade series is a critical design aspect of our Research and Development.  Performance Charts are posted for each motor edition on the KDE Direct website under the "Technical Media" tab for each respective edition and are continuously updated as Engineering researches methods to replicate and more accurately simulate real-world flight conditions.  In addition, the data is directly loaded into the KDE Direct Build Your System application - an excellent resource for clients to select the optimal equipment for complete systems, based on a range of detailed specifications.

KDE Direct UAS Multi-Rotor Series

KDE Direct Build Your System Application

As an Engineering-focused company based in the United States, we felt it's best to show you our latest custom-dynamometer and the critical features installed for accuracy.  We recently completed the new Dynamometer V3 installation, with laboratory-grade equipment and custom-CNC machined components, so that Engineering and Quality Analysis can provide the most accurate data possible to match real-life flight conditions.  The entire system was qualified and calibrated at a local laboratory, and then put into use at our new HQ facility (based in Bend, Oregon).  Real-life flight conditions vary greatly, depending on setup and environmental affects (humidity, altitude, temperature, etc.), so the data provided is the conditions as collected and described further below.

The Dynamometer is not a standard static bench-test system (albeit, it can operate in this manner as needed).  The system is designed to replicate real-world flight-logs, collected from various airframe systems of multiple sizes and propulsion capabilities (ArduPilot, DJI, and Micropilot based flight-controllers).  Using an Arduino 32-bit based controller, the real-world flight logs are able to be replayed through the system to produce the full performance curves more accurately representing real-world results.  Due to the fluctuation of voltage and regenerated energy (from the Synchronous Rectification physics during acceleration/deceleration motor control stages), the voltage will range from nominal to maximum during the test - allowing for these optimizations to be measured during operation that are unseen or inconsistent with static bench-tests.  In this regard, differences will be found to static bench-tests; many of which the static systems are generally inaccurate and misrepresentations of real-world, in-flight results.



All the data is collected on the Dynamometer, custom built to our needs.  The components are:

 

Brushless Motor: KDE Direct UAS Brushless Motor Series
Electronic Speed Controller: KDE Direct UAS Electronic Speed Controller Series
Propeller Blade: KDE Direct UAS Multi-Rotor Propeller Blade Series
Power Supply: TDK Lambda AC/DC Power Supply GEN 100-150 (15000W/100V/150A output capability)
Force Gauge: MARK-10 Advanced Digital Force Gauge Series 4 (25kg maximum, 10g incremental accuracy)
Linear Roller Slide: Del-Tron RS2-2
Transmitter and Receiver: Futaba 18MZ-WC, R6202SBW
PWM (PPM) Signal Generator: Hitec HFP-30 Digital Servo Programmer
PWM (PPM) Computer Based Signal Generator: Arduino Zero 32-Bit and LabJack U3-LV
Thermal Camera (Spot): FLIR TG167
Thermocouple Data Logger: OMEGA OM-CP-QUADTEMP2000
Sound Lever Meter and Data Logger: OMEGA HHSL402SD
Oscilloscopes: Tektronix TBS1102B and TBS1052B
Resistance Meter (mΩ): Hioki RM3544

Environment Conditions: 72°F (22°C), 35% Relative Humidity, 3730 ft (1137 m) Elevation Altitude, 30.3 inHg (1025 hPa) Atmospheric Pressure

 

The system was designed and built at our KDE Direct CNC facility in Washington, USA and then installed into our HQ location for R&D development.  The system is capable of testing all motors, from the KDE1806XF series on 7.4V up to the KDE10218XF-105 at 100V, so full capability and high-accuracy for UAS development now and into the future.  Not only are all KDE Direct passed through performance testing, but also alternate aftermarket brands; making sure the KDE Direct Propulsion Equipment is always leading the market in the latest technology, safety, and performance capabilities.  Our goal is to provide the best data possible and there's always ways to argue results or the methods for collection - any deviations from this will provide variable results, depending on the accuracy of your own system and environmental effects.

 

KDE Direct Dynamometer Development V3 (.pdf): Download Link