Testbed for Hybrid-Electric Aircraft with Distributed Propulsion

Overview

In the current age of global warming, carbon footprint and emissions are ever important in designing aircraft to meet regulations. Upcoming concepts often feature hybrid powertrains, where both an engine and an electrical power source supply power to the propulsion system.

Objectives

PAC Lab has requested us to develop a testbed that is representative of a distributed electric powertrain, wherein electric motors are coupled to make up a dynamometer, where one acts as a load on the system and replicates realistic flight drag conditions.

Approach

• We used feedback from our sponsors and analytic hierarchy process (AHP) matrix to find that safety and controls are most important customer needs.
• We performed background research to find similar testbed setups from other institutions like NASA.
• We generated concepts for narrowing down the scope of the project based on budget and timeline.
• Multiple CAD models were created, they include the motor mounts, 80/20 cage structure, and a holder for the safety switch.
• Finite Element Analysis simulations were performed to analyse structural stability of motor mounts.
• We made a modular mobile testbed prototype that was delivered to our sponsor and incorporated the necessary safety features for testing.
• Testbed testing was performed using a built-in VESC tool that allows for direct motor control and parameter input.
• A Simscape simulation was developed as proof of concept of test runs that would be intended on physical hardware.

Outcomes

• A physical testbed prototype with a single dynamometer setup was completed and equipped with safety features.
• BLDC motors were able to be spun and controlled across a wide RPM range using an integrated VESC tool and Hall sensors.
• A Simscape model paralleled to physical hardware design specifications and provide insight into system performance modelling across potential operating points.