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Test Stand for Propellers and Rotors in VTOL Drone Systems

Wojtas Małgorzata, Wyszkowski Przemysław, Mądro Mirosław, Osiewicz Maciej, Kmita Paweł

Transactions on Aerospace Research

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2023

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Nr 1 (270)

67--85

EN

The paper proposes a stand that can be used for the testing of propellers and rotors with diameters up to 2.4 m, whose areas of application encompass, inter alia, vertical takeoff and landing (VTOL) type multi-rotor drone systems. The presented solution allows for testing propellers in systems with electric motors. To a certain extent, it is possible to achieve an increase in the measuring range by changing electric motors, power supply systems and measuring sensors. The paper presents several solutions for test stands that can be applied in the testing of propeller parameters, and commercially available propellers have also been deployed in the testing routines. The paper briefly presents the concept of the stand and its design, as well as the principle of operation and structural calculations underlying its functioning, after which the numerical model of the test stand is explained. The article then demonstrates the particular results of the test stand model’s functioning using the EMRAX 188 electric motor and two propellers, namely a commercial Aerobat propeller and a composite propeller designed and manufactured at the Łukasiewicz - Institute of Aviation. Thus, the paper presents both the theoretical results that follow from the model and the results of experimental research.

2

Ground test stands for testing rotors in insulated conditions

Wojtas Małgorzata, Czajkowski Łukasz, Szumański Kazimierz

Transactions on Aerospace Research

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2021

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Nr 1 (262)

15--23

EN

The paper generally discusses Whirl Tower research stands. Whirl Tower stands are used to test, among others, rotorcrafts main rotors in hovering. The work presents an overview of similar solutions of test stand presented in the available literature and online data. Beyond these solutions the paper also contains test stands used so far at the Institute of Aviation, these solutions were prepared for testing onetype of rotor (for example: only for gyroplane rotors). The article provides information about new (Whirl Tower) test stand fully designed and manufactured in Łukasiewicz Research Network ‒ Institute of Aviation (Ł-ILOT). One of the basic assumptions is that it will be a universal test stand, giving the possibility to test different types of rotors. Moreover, the article discusses the types of tests and research that can be carried out on this type of test stand, tests that are performed to ensure the safety of the rotor design.

PL

W artykule omówiono ogólnie stanowiska badawcze typu Whirl Tower. Stanowiska Whirl Tower służą do badania m.in. wirników głównych wiropłatów w zawisie. W pracy przedstawiono przegląd podobnych rozwiązań stanowisk badawczych prezentowanych w dostępnej literaturze i danych internetowych. Poza tymi rozwiązaniami w pracy przedstawiono również stanowiska dotychczas stosowane w Instytucie Lotnictwa, które były przygotowane do badania jednego typu wirnika (np. tylko dla wirników żyrokopterów). W artykule podano informacje o nowym stanowisku (Whirl Tower) w całości zaprojektowanym i wykonanym w Sieci Badawczej Łukasiewicz – Instytucie Lotnictwa. Jednym z podstawowych założeń jest to, że będzie to stanowisko uniwersalne, dające możliwość badania różnych typów wirników. Ponadto w artykule omówiono rodzaje testów i badań, które mogą być prowadzone na tego typu stanowisku, testów, które wykonuje się w celu zapewnienia bezpieczeństwa konstrukcji wirnika.

3

Prototype test stand for testing insolated rotor systems

Wojtas Małgorzata, Czajkowski Łukasz

Journal of KONES

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2019

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Vol. 26, No. 3

257--264

EN

The article discusses assumptions for a prototype test stand designed for testing rotors in the conditions of work at their nominal speed, in particular gyrocopter and helicopter rotors. In the work presents an overview of similar solutions of test stand presented in the available literature and solutions proposed by companies, such as Swangate International or Luftfahrttechnik GmbH. Beyond these solutions the article also contains test stand used so far at the Institute of Aviation, these solutions were prepared for testing one type of rotor (for example: only for gyroplane rotors). The article provides the steps of designing a new test stand, which one of the basic assumptions is that it will be a universal test stand, giving the possibility to test different types of rotors. The article discusses two concepts of the stand with electric engine as a drive, gives the advantages and disadvantages of each concept, and indicates the selected solution. In addition to design and applied drive solution of the stand, the measuring part and data acquisition were also discussed. Moreover, the article focus on the advantages of rotor testing using the presented solution, as well as problems encountered during tests, in particular related to construction free vibrations and resonance. Vibration and resonance of the test stand are very important aspect of the entire design process, because it affects the quality and safety of the tests.

4

2019Gyroplane rotor hubs strength tests

Wojtas Małgorzata, Sobieszek Agnieszka

Journal of KONES

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2019

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Vol. 26, No. 3

265--270

EN

In this article a review of rotor,hub constructions were presented. Discussed rotor’s hub ismade of composite or aluminum alloys materials. Two types of rotor hub were presented (four-blades and two-blades teetering rotor hub), each of them are dedicated to gyroplanes. Typical gyroplane main rotors are characterized by simple design, especially in case of rotors forlight gyroplanes. In the following part of the article thetype of strength tests required by certification process were shown. The test programs based on legal aspects of admission to the flight tests taking into account legislation such as CS 27 (Subpart C – Strength Requirements), CAP 643 British Civil Airworthiness requirements Section T Light gyroplanes, ASTM F2972. Furthermore, this articlediscusses strength tests of gyroplane rotor hub such as measured parameters, methodology of measurement, types of sensors, course of test, test stands, and limit loads. The loads during “pull-up from level flight” manoeuvreare limit loads during tests. Required additional processes, like averification the same parameters by two types of method were shown i.e.deformation of structure were tested by strain gauges and reverse engineering.Strength tests had to be made before flight test, based on results of them aircrafts are flight authorized. In conclusion,the results of tests were presented and fulfilment of legal assumptions and requirements were shown.