Performance Testing of UAV Power System Pipelines
Project name: Performance Testing of UAV Power System Pipelines
In 2011 and 2012, a leading aviation industry group procured:
A 64-channel DE-944 dynamic signal testing and analysis system
A 48-channel SE-944 dynamic strain testing and analysis system
These systems were deployed for comprehensive performance testing of the pipeline system in a new-generation unmanned combat aircraft prototype, specifically for real-time strain and stress monitoring during power system operation.
Test Objectives & Critical Requirements
(1) Pipeline Integrity Under Dynamic Conditions
Monitor vibration-induced stress from engines/pumps
Measure thermal strain during extreme temperature cycles (-40°C to +120°C)
Detect fluid hammer effects during sudden valve actuation
(2) Safety Validation
Ensure no leakage/fatigue cracks under 6,000+ hours of accelerated life testing
Verify compliance with MIL-STD-810G for vibration and DO-160 for fluid systems
2. Testing System Capabilities
(1) DE-944 System (64 Channels)
10kHz high-speed sampling for capturing transient pressure waves
Simultaneous measurement of:
Dynamic pressure (via piezoelectric sensors)
Vibration spectra (3-axis accelerometers)
Temperature (RTDs integrated with strain gauges)
(2) SE-944 System (48 Channels)
1με resolution for micro-strain detection in thin-wall titanium pipelines
Wireless telemetry for rotating component monitoring
Automatic temperature compensation for accurate data in thermal gradients
3. Test Methodology
Mission Profile Simulation:
Replicate 20+ flight modes (hover, dash, high-G turns)
Induce controlled fluid transients (e.g., emergency shutdowns)
Multi-Physics Correlation:
Cross-reference strain data with:
CFD fluid dynamics models
FEM structural simulations
4. Key Findings & Improvements
Identified resonance risk at 387Hz (redesigned pipe supports eliminated issue)
Reduced weight by 15% through optimized wall thickness verification
Achieved zero failure in 8,000+ test cycles
Next Steps: Integration with digital twin platform for predictive maintenance alerts during operational deployment.
Conclusion
The UAV power system pipeline testing successfully verified the structural integrity, thermal resilience, and vibration tolerance of the aircraft’s fluid and power distribution networks. By identifying resonance risks and optimizing wall thickness, the program ensured zero failures across thousands of test cycles. The data collected supports compliance with MIL-STD-810G and DO-160 standards while enabling predictive maintenance integration through digital twin platforms, ultimately enhancing the reliability, safety, and operational readiness of next-generation unmanned combat aircraft.
