Onboard generator system User Manual V1.4
Contents
1. Vin V Figure 5Efficiency at 12 Volt output vs input voltage 35 30 25 20 15 Generated voltage V 10 0 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 Engine speed rpm No load 23 5 A load Figure 6 Generated voltage against engine speed measured at the generator output terminals UAV Factory USA LLC 50 South Buckhout Street Irvington NY 10533 USA Phone 1 914 591 3070 Fax 1 914 591 3715 Email josephm Ouavfactory com UAV Factory LTD EUROPE 24A 52 Ganibu Dambis LV1005 Latvia Phone 371 29119398 Fax 371 63048747 Email sales uavfactory com 110 100 390 Short term operation a E 40 Continuous Ll Ll Continuous power W 30 20 10 0 1000 2000 3000 4000 5000 6000 7000 8000 Engine speed rpm Figure 7 Recommended continuous system load power 5 Onboard generator system operation At approximately 4000 rpm the voltage generated is less than 13 V which means that the onboard battery will be used for powering the unmanned aircraft system This is not a problem since aircraft do not generally fly at low idle settings for extended periods of time and the power requirements can be met by the adequate sized onboard battery The onboard battery capacity needs to be calculated depending on the actual mission profile of the UAV taking into account possible aircraft descend time as2. Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com 13 FACTORY 11 Serial communication Firmware V1 1 Serial communication allows monitoring system variables such as generator and battery voltage battery and load currents total system power and RPM value Serial protocol uses 84 bytes packet and send it two times per second Figure 14 shows the output string format Variables are separated with 3 spaces The output string example is Rpm 3400 Vgen 27 3 Vbatt 11 82 Ibatt 1 3 l6v 1 2 112v 0 8 Pout 16 8 r n Rpm rpm value Vgen generated voltage Vbatt battery voltage Ibatt battery current negative value for charging l6v load current at 6 V line 112v load current at 12 V line Pout total output power Serial communication settings Baud rate 9600 Bits 8 No parity Important GPU serial connection uses 5V TTL communication fla ll did hd hd dl o baad ll ddl dd A O lll A td ha al ll ll cd ad al cl ll lll 000 ll 0 EEE UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com 14 FACTORY i Le ld ad lll a ll dad nd ed bal a ll ol bb Le i ddd dad dll al lad ld
3. Ignition system 6 V out RPM sensoron 12 V out 0 Battery External power Figure 13 Onboard generator system wiring diagram UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com 12 FACTORY Table 1 Wiring description red GEN red red a red Brushed generator lead red red ma red red red 10 LED Indication Four indication LEDs are located on the front side of the GPU see Figure 10 for reference The main purpose of LEDs is to facilitate set up procedure simplify pre flight checks as well as to provide clear identification of the battery status before the flight The following LED operation is implemented in the GPU 6 V green LED indicates 6 V voltage presence 12 V green LED indicates 12 V voltage presence BAT green LED indicates that battery is supplying the system When LED is off the generator or external power is supplying the system CHRG red LED indicates battery charging When LED is flashing the battery voltage is low and needs recharging please connect external power supply for recharging the battery UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia
4. ARR a a a GG Figure 14 Output string format UAV Factory USA LLC 50 South Buckhout Street Irvington NY 10533 USA Phone 1 914 591 3070 Fax 1 914 591 3715 Email josephm uavfactory com 15 UAV Factory LTD EUROPE 24A 52 Ganibu Dambis LV1005 Latvia Phone 371 29119398 Fax 371 63048747 Email sales uavfactory com FACTORY GS80U Penguin B generator upgrade kit battery is not included 12 Order Information IO S Cable set with plug for J2 50 cm SJ205 Cable set with plug for J1 100 cm J110 Cable set with plug for J2 100 cm SJ210 History Manual Version Description Date Editedby User Manual V1 0 created po AG ks Table 1 and Figure 14 revision 7 11 2011 Company information updated Images updated 13 12 2011 K Popiks 1 1 Serial Communication updated to Firmware 1 1 all 29 07 2011 A Guks generator systems with S N GPU0008 and up have Firmware 1 1 UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com 16
5. onboard generator system installed in Penguin B UAV UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com Key Features Light weight small and efficient FACTORY Up to 80 W continuous load power 6 V and 12 V output Peak load current up to 10 A Short circuit protection Battery backup connection 3 cell Li Poly integrated charger External power connection Integrated current sensors Serial connection IP 64 housing IP 68 on request 3 Specifications Electrical Specifications Generator voltage range External power supply voltage range Battery Type Battery Voltage Maximum battery charging current Maximum continuous generator current Maximum continuous battery current Maximum continuous external power current Output voltage Output voltage accuracy Maximum output voltage ripple Continuous load current 6 Volt output Continuous load current 12 Volt output Maximum GPU efficiency Maximum complete system efficiency Maximum peak load current No load GPU current Tachometer range Tachometer accuracy Current sensor range Current sensor accuracy Voltage sensor accuracy Serial Communication Mechanical Specifications Engine speed GPU Dimensions GPU Weight Complete Onboard
6. Email sales uavfactory com FACTORY The GPU performance graphs are presented below Efficiency for the 6 V output against the input voltage is shown in 4 Performance Figure 4 efficiency for 12 V output is shown in Figure 5 Generator performance graphs are presented in Figure 6 and Figure 7 Please refer to Figure 7 for generator operation regime in case of generator voltage drop below 13 Volts GPU uses the backup battery for the power source The continuous generator system operation regime is shown as the blue area the battery operation regime is shown with the green area The short term operation area can only be used for a short duration power peaks The maximum continuous power of the system is dependent on the engine speed ambient temperature and the ability to dissipate heat generated by the GPU At no circumstances operating GPU enclosure temperature should reach 70 C 95 00 Load current 5 A no cents o eee OID INIA ps DI it tt a LL fo 00 FOO 65 00 15 ZU pis 30 a1 Vin V Figure 4 Efficiency at 6 Volt output versus input voltage UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com Eff 95 00 94 00 93 00 92 00 91 00 90 00 59 00 55 00 ef 00 66 00 69 00
7. FACTORY 80 W ONBOARD GENERATOR SYSTEM USER MANUAL 1 4 UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com FACTORY 1 Description Onboard Generator system consists of a Generator Power Unit GPU belt driven industrial grade coreless generator mounts and wiring necessary for installation on 3W 28i pusher engine System was specifically developed to be used with UAV Factory s Penguin B UAV but can also be used in other applications GPU is designed to provide onboard dual voltage regulated power supply of 6 and 12 Volts Despite small size GPU offers outstanding efficiency as well as unique features such as the ability to monitor load battery current engine rom generator and battery voltage through serial communication All power distribution parameters can be transmitted to the UAV ground control station and monitored during the flight Integrated Lithium Polymer charger is used for the backup battery which is switched on during the pre flight checks low engine speed or in the event of the engine failure GPU is packed in a sealed aluminum enclosure and fitted with the high end industrial push pull connectors Please refer to Figure 1 for a view of installed onboard generator system Figure 1 80W
8. Generator System weight Maximum GPU enclosure temperature Environmental protection Operating temperature Electrical connectors 1 Generator continuous current must not exceed 3 5 A FACTORY 2 Enclosure temperature must not exceed 70 C additional cooling may be required UAV Factory USA LLC 50 South Buckhout Street Irvington NY 10533 USA Phone 1 914 591 3070 Fax 1 914 591 3715 Email josephm uavfactory com 13 35 V 13 50 V 3 cells Lithium Polymer 12 6 V 2A 3 5A 8A 8A 6V and 12 V 0 2 V 50 mV 6V 50 mV 12V 5A 5A 90 75 10 A for 10 seconds 110 mA 1000 9000 rpm 200 rpm Oto 10A 0 2 A 0 1 V 5V TTL 1500 8500 RPM 59 4 x 115 8 x 32 4 mm 190 grams 500 grams 70 C IP 64 standard IP 68 on request 40 C to 50 C Fischer 104 Series push pull connector UAV Factory LTD EUROPE 24A 52 Ganibu Dambis LV1005 Latvia Phone 371 29119398 Fax 371 63048747 Email sales uavfactory com FACTORY NO a LO q l i 115 8 4 56 J 106 9 4 21 i 1 Tt Y C Os N pr Y st o o LO wT Figure 2 GPU dimensions in millimeters g 106 i 7 225 E Figure 3 General view of generator assembly UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm Ouavfactory com
9. USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com FACTORY Integrators should use the following formula to calculate approximate battery capacity for their UAV configuration Battery capacity Ah operation time h X average load power W battery voltage V 0 8 Where operation time is desired operation time battery voltage typically is 11 1 V and 0 8 is regulator typical efficiency Do not use other type of battery except Lithium Polymer 3 cell batteries Maximum battery current should not exceed 8A When battery voltage is less than 12 6 V the charger charges the battery with current of lt 2 A It is recommended to connect battery to the system through a switch with current rating not less than 10 A When the battery source is used GPU is not producing exactly 12 volt power output please see Figure 9 for details The battery voltage and output voltage difference is approximately 0 4V Please note that GPU cannot provide 12 V voltage if battery voltage is less than 12 4 V 14 ee 8 a 6 Volt output Output voltage V 10 105 11 11 5 12 12 5 13 Battery voltage V Figure 9 Output voltage in battery source mode 8 External Power Supply External power supply can be used as a power source when the e
10. ngine is no operating This is especially useful for laboratory environment testing during set ups during pre flight checks on field as well as for charging the onboard battery The input voltage should be in the range of 13 50 Volts UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com 10 FACTORY 9 Connector Description GPU enclosure has two electrical connectors J1 and J2 as seen on Figure 10 Pinout of J1 connector is shown in Figure 11 and pinout for J2 is shown in Figure 12 The layout of the onboard generator system is shown in Figure 13 please use Table 1 for wiring description during integration procedure Figure 10 Input Output connectors and status LEDs Red mark Serial GND pf 12V out Figure 11 Connector J1 description UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com 11 FACTORY Red mark Generator Generator GND RPM sensor Battery External power GND Figure 12 Connector J2 description Ignition power 6 V
11. well as desired pre flight operation time please see Section 7 for more details on battery capacity estimation Please use adequate safety factor for your battery capacity estimation results UAV Factory USA LLC UAV Factory LTD EUROPE 50 South Buckhout Street 24A 52 Ganibu Dambis Irvington NY 10533 USA LV1005 Latvia Phone 1 914 591 3070 Phone 371 29119398 Fax 1 914 591 3715 Fax 371 63048747 Email josephm uavfactory com Email sales uavfactory com FACTORY The GPU has integrated short circuit protection for avoiding the regulator damage in case of a short circuit 6 Short circuit protection In case multiple loads are used on the same voltage line it is highly recommended to use fuses this will allow the GPU to operate in the event of load short circuit Please see Figure 8for a diagram of fuse installation As an example fuses can be installed before the payload rf transmitters as well as before the individual servos Figure 8 Fuse installation 7 Battery backup External battery provides power supply to the onboard system in case the input voltage drops below the battery voltage This may occur because of several reasons a During engine idle when generator provides insufficient voltage at the given load b During pre flight preparation when the engine is not operating and the external power supply is not connected c During mechanical generator failure d During engine failure UAV Factory
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