Research & Development for Unmanned Aerial Systems
With an ongoing investment in our sophisticated on-site testing facility, experienced R&D staff and alliances with reliable vendors and suppliers — NWUAV is the unmanned aerial systems R&D partner you've been searching for. From propulsion systems to propellers, research and development to development and integration, check out the projects we're working on below or tell us about the UAS research you're interested in doing today.
“Engine development is critical. And spending months or even years, working on a propulsion solution for your unmanned system can get very expensive if you don't select reliable vendors and suppliers from the start.
We have tested our fair share of vendors and suppliers over the years, and we've settled on a select few that are responsive, resourceful and challenge driven. When you combined our alliance's strengths with our in-house resources, manufacturing and testing capabilities — the result will be an engine solution that meets or even beats your expectations within a time frame that works.”
Chris Harris, President, Founder & Engineer - Northwest UAV
At Northwest UAV, Our Research & Development Facilities and Equipment Include:
- Engine dynamometers for small engine characterization
- Sound booth for noise characterization of engines and propellers
- Altitude chamber
- Environmental chamber
- Five gas exhaust analyzers
- Fuel flow transmitters
- Sixty-nine engine run-in stations for fully automated engine break-in procedures
Heavy-Fuel Engine Conversions
If you're looking to use a commercial off-the-shelf (COTS) engine with heavy-fuels like JET A-1, C10, JP5 or JP8 for your unmanned aerial systems, NWUAV has the conversion expertise you're looking for. Our team of propulsion engineers and technicians is highly skilled in converting COTS engines for operation using heavy-fuels, with experience working with OEM Engine manufacturers such as Honda, Zenoah, Rotron, Desert Aircraft and 3W-Modellmotoren GmbH. Utilizing a three-phased approach with a go-no-go decision point built into the conclusion of each phase, we greatly limit risk and save you time and money.
- 1. Baseline testing of the proposed engine core (JET A-1, C10, JP5 or JP8) for development of a heavy fuel propulsion unit.
- 2. Development and manufacturing of the base heavy-fuel engine and associated components for engine testing completed at NWUAV.
- 3. Build prototype units for customer testing and integration
- Engine and Cylinder Head Temperature (CHT) systems
- Low noise muffler systems
- Vibration isolation systems, including PMU mounting interface to airframe
- Connectors to interface PMU to airframe
- Engine board/Engine Control Unit (ECU)
- Intake systems for fuel and air
- Sensor interface for cylinder head temperature, inlet air temperature, manifold air pressure (MAP), or others as indicated by the PMU
- Propeller, propeller mounting hardware and interface
- Electric fuel injection or electronic altitude compensating carburetion systems
- Ignition systems
- Generator systems and generator control boards
- EMI enclosures
- Wiring harnesses and connectors
- Secure IP address to allow all testing in Oregon to be observed and manipulated remotely
NWUAV Fuel Injection Systems
NWUAV continues to explore what's possible with our own fuel injection system, always pushing the design to integrate with different applications and still reliably delivering clean high-pressure fuel. Within a small footprint, NWUAV's fuel injection system provides a conformal header tank with acrobatic pickup, fuel filtration, a fuel pump, pressure regulation and bingo level and pressure sensing functions. And all components are compatible with either gasoline or heavy-fuels. Though it's purpose-built for unmanned applications, the lightweight and compact design is easily customized to fit a variety of vehicles, allowing us to continue to work on development and integration for different applications as needed.
- Weighs 433 grams dry
- Footprint of 148.8mm (L) x 101.9mm (W) x 67.09mm (H)
- Fuel particle filtration to 17 micron with a serviceable filter
- Self-priming with acrobatic fuel pickup
- Easily customized flow rate, pressure, footprint/layout and more for your application
NWUAV Hybrid Propulsion Systems
For quieter, more efficient operation. Current UAV Internal Combustion Engine (ICE) systems are sized to provide sufficient power and speed for takeoff. However, with the slight variations each unmanned vehicle has, ICE systems based solely on size may cause less efficient operation during regular flight hours. Not to mention, ICE systems are typically noisy due to exhaust emissions. Though electric motor (EM) based systems resolve noise issues, they have a limited range of operation if they can't be charged during operation. That's why NWUAV continues to research and develop a hybrid system, taking advantage of the efficient operation of ICE systems and the quiet nature of EM systems.
- After being awarded a contract by the Air Force Research lab to develop a hybrid propulsion system, NWUAV got to work tackling the objective to use the combined strengths of electrical-based and ICE-based power/propulsion systems through advanced hybrid configurations to anticipate and meet the current and future needs of small and medium-sized UAVs. This hybridized propulsion system will meet a variety of operational conditions — full power takeoff and dash modes for 10% of mission duration and part-power cruise, hold conditions for 80% of mission time, cruise with segments of quiet operation for 10-30% of the total mission duration, and have segments of flight with increased electric payload power draw. Thus far, the hybrid propulsion system includes:
- Hybrid drive propulsion system for quiet operation and performance upgrades
- Power generation system for UAS and ground robotic applications for lower cost
- Variable pitch propeller system for increased flight duration
- Quiet propeller blade design for noise reduction and increased efficiency
- NWUAV muffler system for lower noise and increased engine power
Electric Propulsion System
Custom all-electric propulsion systems for unmanned systems in the air, on land and at sea. Utilizing our expertise from designing and manufacturing unmanned aerial power generation systems, NWUAV is able to develop complete electric propulsion systems from design through development and high-volume manufacturing. From choosing the right COTS electric motor to customize, to the best battery or super-cap for your application, to the Controller/EMU and control panel pair that provide you with the control and data you need — NWUAV has the tools and expertise to develop the electric propulsion system for your unmanned application.
- An engine unit chosen based on:
- 1. Industry research into what is currently considered state-of-the-art technology
- 2. A vetting process based on industry research findings and pragmatic analysis
- 3. Lab testing (if necessary) to determine efficiency
- 4. Durability metrics
- An AC-DC Rectifier designed by NWUAV to rectify the AC output of the alternator, making the output of the AC-DC module unregulated DC voltage. The DC voltage can increase or decrease as a function of the alternator RPM.
- A DC-DC Converter that regulates the output of the AC-DC rectifier to produce a stable DC voltage that can then be used to drive a DC-AC inverter to produce AC voltage at 60Hz, as well as charge a battery or super-capacitor (see below for details) for a generator application.
- A DC-AC Inverter that regulates the output of the DC-DC Converter produces a clean sine-wave AC voltage with minimal harmonic distortion. Our team will investigate if there are suitable COTS inverters. If none are found to meet the power, voltage and MIL-STD environmental specification requirements we will design one for your application.
- A battery or super-capacitor (super-cap) for sufficient short-term capacity to meet sudden increases in electrical load. Though batteries traditionally are the industry standard, advancements in super-cap technology have made them a viable option for certain applications. Our team understands the pros and cons of both batteries and super-caps, giving them the expertise to decide which will work best in your application.
- A controller/EMU that is microprocessor-based senses the electrical load so that it can vary the engine RPM to meet the load requirements. Utilizing circuitry and software designed by NWUAV, the Controller/EMU monitors engine and alternator temperature and engine oil level to keep your vehicle within safe limits.
- A control panel designed with switches and indicators that the operator uses to control the generator and receive operational status. The interface controls and all cable wiring harnesses are designed and built by NWUAV.
Custom Power Generation
Utilizing our in-house design expertise combined with sophisticated electrical development and a testing lab, NWUAV designs and develops custom power generation systems that enable efficient operation, while reducing electrical noise signature. NWUAV has developed a variety of systems including UAV power generation for small to medium UAS, ground robotics power generation for range extension utilizing JP8 heavy fuel engines, portable power generation, APUs for vehicle application, hybrid generators for multi-rotors and VTOL UAVs, and RCV generator systems. Tell us about your project and the power you need. Thanks to our alliances with generator manufacturers, we're able to custom design and build specifically for your application.
- Frameless, Brushless Generators
- Heavy-Fuel Generator Sets
- Custom UAV Power Generation
- Generator and generator board development and manufacturing for several SUAS
- Electrical design and assembly lab
- Electrical testing facilities
- Circuit card design
- Silicon mold design
- Castings and engine housing design
- EMI shielding and enclosures
- Generator system integration — COTS and custom wound
- Wire harness design and electrical assembly
- Environmental controlled engine endurance chamber
Propellers — Variable Pitch and Low Noise
From variable pitch propellers to low noise propellers to entire propeller systems — NWUAV continues to design, develop and integrate our propellers and propeller systems for a variety of small to mid-sized UAVs. Our variable pitch propeller system can be customized to your UAV, allowing us to optimize the length and twist of the blade to increase your engine performance, lower your engine speeds, add launch thrust and decrease your acoustic signature. Extremely reliable, the lightest weight unit in its category and virtually maintenance free, NWUAV variable pitch propellers are designed to meet and exceed applicable FAA and ASTM construction and safety standards. Manufactured in various blade configurations fand materials.
- Unique solution to an elliptical lift distribution along the blade span makes for efficient use of the entire span
- Unique blade design tapers thrust off to virtually none at the tip, greatly decreasing energy losses and increasing the conversion of input energy to thrust overall
- Unique shape lowers the acoustic signature
- Final shape used for your UAV is determined by both aerodynamic performance and efficient manufacturability