Modular Motor Drive with Programming and Configuration Tools for the Development of Small Aircraft Electric Power and Propulsion Systems

ABSTRACT:Unmanned Air Vehicle (UAV) developers have limited marketplace options for motor speed controllers. The largest commercial controllers are generally limited to below 12 kW and battery voltages of less than 50 V, Although these are well suited to 800 Class helicopters and Giant scale fixed-wing aircraft, they are not powerful enough for larger UAV development. A few high-power options exist up to 25 kW, though they are substantially heavier with less modularity and selection. To scale up to higher powers, UAV designers are often forced to utilize industrial controllers, which are not packaged for minimal weight and flight capability. To address this need for expanded controller options, this proposal outlines a modular, open architecture motor controller system comprising a main control module, recommended I/O module, and interchangeable power stage modules. In the Phase I effort, PCKA will develop and demonstrate initial modules in a complete motor control solution through a combination of modeling, simulation, analysis, and hardware prototyping. The proposed solution will have open access to the motor control software and logic with a software infrastructure that enables users without embedded systems experience to utilize the system while also allowing advanced users the capability to fully customize the controls. BENEFIT:The proposed modular, open architecture motor controller system offers several benefits to UAV developers, the first commercialization opportunity that this SBIR will target, including: (1) reduced development time and cost due to the availability of a common control platform with complete and open control software examples, (2) better opportunities to optimize the platform performance and capabilities due to the expanded range of current / voltage options as well as the ability to tailor the needed peripheral communications options to the platform, and (3) the ability to rapidly implement custom control algorithms to meet particular platform or mission needs. In addition to the direct benefits to UAV developers in both the military and commercial markets, there is potential for application with minor adaptation in a wide range of other applications that require motor controllers in the target voltage and current ranges including: (1) terrestrial and marine vehicles, (2) industrial automation, (3) autonomous robotics, and (4) mobile power generation units.