1 kHz Multi-channel Propulsion Test Stand

NI DAQ-based dynamometer capturing thrust, torque, RPM, phase current, and winding temperature at fidelity exceeding commercial dynamometers at the required scale

Built a high-fidelity propulsion test stand from scratch at VTOL Aviation India to support physics-based model development for eVTOL systems.

Hardware

  • NI DAQ hardware with 1 kHz multi-channel data acquisition
  • Simultaneous measurement of: thrust, torque, RPM, phase current, winding temperature
  • Measurement fidelity exceeds commercial dynamometers available at the required scale

Software

  • Python and C++ post-processing pipelines to systematically calibrate MATLAB propulsion models against test stand data
  • Reduced model prediction error to within 3% across the full operating envelope

Impact

The calibrated models replaced empirical estimates as the design authority for eVTOL control law development, enabling physics-based gain scheduling and accurate simulation-to-flight correlation.

Large propulsion test stand

Large propulsion test setup

Small high-fidelity test stand

Small high-fidelity propulsion test setup

Engine test bench

Engine test bench setup

Coaxial propulsion setup

Coaxial propulsion setup

Dynamic load test bench

Dynamic load test bench

Drop test bench

Drop test bench