Kailash Propeller Test

Propeller Characterization
Practical Training Report Submitted by

Kailash Kotwani
Under guidance of
Professor S K Sane and Dr. Hemendra Arya
Center for Aerospace System and Design Engineering

Department of Aerospace Engineering
Indian Institute of Technology, Bombay
August, 2003
1
Abstract
Selecting correct combination of engine and propeller is very crucial step in

design of any airworthy vehicle. Whether the output power produced by selected engine
propeller combination will be sufficient enough to provide esteemed mission
requirements, is the chief question in front of any design engineer. Power vs Velocity
and Thrust vs Velocity characteristics are very important for the design purpose. The
information regarding these characteristics is not available in open literature for small
propellers and engine s used for MAVs. The objective of present study is to establish a
measurement system and obtain performance maps for mini propellers and small engines.
To reduce the efforts involved and widen the range of analysis, the characteristics are
studied using non-dimensional parameters (C P , CT , J etc). Another important aspect is
optimizing performance by selecting propeller of best efficiency in the required velocity
ranges.
These characteristics are determined experimentally using the wind tunnel system
built for the MAV development purpose. Different engine-propeller combinations are
tested in wind tunnel at different flow velocities. Required plots are generated using data
obtained from experiments.
Nomenclature
A = Area (m2 )
c = Chord Length (m)
CP = Coefficient of Power
CT = Coefficient of Thrust
CQ = Coefficient of Torque
d = Diameter (inch/m)
D = Drag (N)/Diameter (inch/m)
Eb = Back EMF (V)
I = Current Supplied (A)
J = Advance Ratio
K = DC motor constant
L = Lift (N)
N = RPM (1/min)
n = RPS or Rotational frequency (1/s)
P = Power (W)
p = pitch (inch)
PI = Input Power (W)
Po = Output Power (W)
PA = Net or Useful power for thrust production (W)
Q = Torque (N.m)
r = radius (inch/m)
Ra = Armature Resistance ()
T = Thrust (N)
TA = Thrust Available (N)
2
V = Voltage Across motor (V)/Flow Velocity (m/s)
VR = Resultant flow Velocity (m/s)
V = Translational Velocity Component (Upstream flow velocity) (m/s)
Vr = Rotational Velocity Component (m/s)
x = Efficiency of x
= DC motor flux
= Pitch angle or angle of airfoil with plane of rotation (radian/degree)
= Rotational Velocity (rad/s)
= Angle to direction of motion to which VR acts (radian/degree)
= Angle of attack of airfoil (radian/degree)
Contents
Abstract
Nomenclature
Contents
1. Introduction
2. Theory and background
3. Operation Limitations
3.1 Motor Operating Limiations
3.2 Propeller Operating Limitations
4. Experiment to determine NO LOAD characteristics of Motor

4.1 Apparatus
4.2 Theory
4.3 Set Up Description and Measurements4.4 Observation:
4.5 Calculations and Analysis
4.6 Conclusions
5. Experiment to predict the shaft power of DC motor

5.1 Apparatus
5.2 Theory
5.3 Experimental Set-up and description
5.4 Observations
5.5 Calculation and Analysis
6. Discussion and Further work

References
Appendix
A) Motor Specifications
B) Observation and Calculation tables
C) Matlab Codes
Acknowledgement
3
1. Introduction
Because of Simplicity, efficiency and cost effectiveness, propeller based IC

engines are the best choice as means for thrust production at the first stage of developing
a MAV (Mini aerial Vehicle). Thrust and Power generated by a propeller is function of
propeller geometry (This include pitch, diameter, airfoil sections at different crossections,
weight, no. of blades etc.), flow velocity, RPM and torque applied by the shaft of engine.
The MAV being developed will encounter flow velocities in the range of 20 m/s. A wind
tunnel system (test section of crossection 1mX1m) has been developed which can
generate flow velocities up to 10 m/s (Image 1). In future it will be upgraded to generate
velocities in the range of 20 to 25 m/s. So with present system experiments have been
conducted upto the velocity of 10 m/s only.
Image 1: Wind Tunnel for experimentation on MAV

As running an IC engine inside the tunnel involves many complexities e.g.
starting trouble, oil in exhaust, variable RPM at constant fuel supply etc. So it was
decided to use an electric DC motor for experimentation purpose which is very easy to
handle though an IC engine will be used for onboard flights. Here an Astro 15 Cobalt
Geared Motor (Model no. p/n 615G) was used for experimentation. Motor is shown in
Image 2 and its specifications are given in appendix (A).
4
Image 2: Cobalt Geared DC Motor
There are two methods by which power at the shaft of motor can be estimated
1) Determining No load characteristics then assuming that Back EMF vs RPM
characteristics and Mechanical Losses at No Load and Loaded conditions are
same.
2) Directly measuring torque at the shaft using torque sensor
The task of power measurement using first method has been completed till now (With
an 11X7 Masterscrew glass filled nylon propeller) and is discussed in this section. In this
method first armature resistance of motor is measured by short-circuiting it at the supply
of very low current and voltage (Armature Resistance is measured at beginning and at the
end of experiment because it is sensitive to temperature of motor which varies during the
operation). Motor is run under No Load condition (No propeller at the shaft) and input
power consumption at different RPM is measured. Hence back EMF and mechanical
losses are calculated using theoretical relationship. Again motor is run at loaded
condition and Input power consumption is measured at different RPM. Using no load
characteristics of back EMF and mechanical losses, shaft power is calculated. This way
we obtain Shaft Power vs RPM characteristics. Experiment under Loaded condition is
repeated for different flow velocities in wind tunnel and corresponding CP vs J plot is
obtained. Shaft Power vs RPM plot at different flow velocities is cross-plotted to obtain
Shaft power vs flow velocity plot at different RPM. All these characteristics are analyzed
carefully and compared with ones available in literature for larger propeller.
5
2. Theory and Background
Similar to wings propellers are made up of airfoil sections designed to generate an

aerodynamic force. The wing force provides lift to sustain the airplane in the air; the
propeller force provides thrust to push the airplane through the air. A sketch of a simple
three-blade propeller is given in Fig 1, illustrating that a cross section is indeed an airfoil
shape. However, unlike a wing, where the chord lines of the airfoil sections are
essentially all in the same direction, a propeller is twisted such that the chord line changes
angle from root at prop- hub to tip. This is illustrated in Fig 2, which shows a side view of
the propeller, as well as two sectional views, one at the tip and the other at the root. The
angle between the chord line and the propellers plane of rotation is defined as the pitch
angle . The distance from root to given section is r. Note that = (r).1
Fig 1: Crossection of a three bladed propeller1
Fig. 2: Varying pitch angle along the span of propeller1
6
VR = V2 + Vr2 (1)
Where V is the translational velocity component and Vr is the rotational
component. This resultant VR acts at a certain angle to the plane of rotation, and this
angle is defined as
V V V
tan = = = (2)
Vr r 2rn
The airflow seen by a given propeller is combination of the airplanes forward
motion and the rotation of the propeller itself. This is sketched in Fig. 3a, where the
airplanes relative wind is V and the speed of the blade section due to rotation of the
propeller is r. Here, denotes the angular velocity of the propeller in radians per
second. Hence, the relative wind seen by the propeller section is the vector sum of V and
r, as shown in Fig 3b.
Fig 3: Resultant local velocity seen by a section of propeller1

If the chord line of the airfoil section is at an angle of attack with respect to the
local relative wind VR, then lift and drag (Perpendicular and parallel to VR, respectively)
are generated. In tur n, as shown in Fig. 4, the components of L and D in the direction of
V produce a net thrust T:
Fig 4: Lift and drag force on an airfoil of a propeller1
T = L cos - D sin (3)
Where = - (4)
This thrust, when summed over the entire length of the propeller blades, yields the
net thrust available. (TA) which drives the airplane forward.
7
There is one more important parameter, propeller efficiency () which is defined
as
PA TA V C
?P = = = J T (5)
P P CP
Where P is power at the shaft of engine, J is advance ratio, CT is thrust coefficient
and CP is power coefficient. The advance ratio J, which is a measure of how far the
propeller moves forward through the medium per rotation of the propeller, is defined as
V
J = (6)
nD
For a propeller the non dimensional thrust coefficient is defined as
T
CT = (7)
n 2 D 4
Similarly, Power coefficient is defined as
P
CP = (8)
n 3 D 5
A propeller is nomenclatured in terms of two parameters, pitch and diameter.
Pitch is defined as the horizontal distance moved by propeller in one complete rotation at
100 % efficiency and zero slipping. So airfoil at particular section of propeller performs
motion in helical direction as shown in Fig. 5. If the helix is unwrapped onto a two
dimensional plane, the length p is defined geometrically as
p = 2r. tan (9)
Fig. 5: Measuring Pitch of a propeller4

It should be noted that industry standards are that pitch is measured at 75% of
radius that is value of r and in eqn (9) is what at 75% of radius.
8
3 Operation Limitations
3.1 DC Motor Operating Limitation
1) Voltage, Current and Power Limitations

Normal voltage range specified = 8 to 12 Volt (Appendix A)
Though 12 volt is not ma ximum upper limit because the same motor has been used with
12 Nicads battery (Expected performance mapping Appendix A)
Maximum Applied voltage = 1.2*12=14.4 Volt.
For performance mapping manufacturer has crossed 12 Volt, is confirmed from the fact
that with 12 Nicads batteries power consumption was 325 Watt at 24 A current supply
Applied voltage at that time = 325/24=13.54 Volt
Another way to obtain maximum voltage across the motor is through maximum
continuous current and power specified by manufacturer
Maximum Continuous current = 25 A
Maximum Continuous power= 400 W
Maximum applied voltage = 400/25 = 16 V
This analysis shows that it is not unsafe to run motor between 12 to 16 Volt range. One
thing should be kept in mind that in high voltage ranges mo tor should not be run for
longer time as motor becomes too hot. Secondly armature resistance is sensible to
temperature of motor.
Analysis of manufacturers specification from three different perspectives is giving three
different values of Maximum voltage. This confirms that specification provided by
manufacturer is not suitable for engineering analysis and one should develop ones own
safeguards and measuring systems for engineering and research analysis.
2) RPM and Torque Limitations

This cobalt motor uses a gear for reducing the final RPM at the shaft.
Gear Ratio = 2.38 to 1 (Appendix A)
Motor Speed/volt = 1488 rpm/volt
Geared motor speed/volt = 652 rpm/volt
Lets say maximum applied voltage across the motor = 15 V
Geared motor speed = 652*15= 9780 rpm
Ungeared motor speed = 22320 rpm
This large ungeared speed can be utilized by taking out gear and using motor directly.
Even with gear motor provides decent rpm which is in the range of 10000.
Similarly,
Motor torque/amp = 0.91 in-oz/amp
Geared torque/amp = 2.17 in-oz/amp
At maximum current = 25 A
Geared torque = 0.91*25=22.75 in-oz
Ungeared torque = 2.17*25 = 54.25 in-oz
9
3.2 Propeller operating limitations
1) Noise Considerations
The prop tip speed should not exceed 600 to 650 feet per second (180 to 200 m/s)
to keep it within the noise limit (For a master airscrew nylon prop).6
Tip Speed = Vr (ft/s) = r = 0.00436*RPM*(Diameter in Inches)
Vr
RPM = (10)
0.00436 D
Lets Say we take limiting propeller tip speed as 600 ft/s

For 11X7 master-airscrew propeller, limiting RPM can be calculated
Limiting RPM = 600/(0.00436*11) =12510 rpm
2) Mechanical Considerations
One of the differences between wood and glass-filled nylon propellers is that
glass- filled nylon props have suggested RPM limits for mechanical considerations. This
varies according to Diameter of prop. For a Master Airscrew prop RPM limit
recommended by manufacturer is calculated as follows.6
RPM operating limit = 160,000/(Diameter in inches) (11)
For a 11X7 prop,
RPM operating limit = 160,000/11 = 14,545 rpm
Minimum of the above two operating limits will be taken into consideration that
is 12510 rpm.
10
4. Experiment to determine NO LOAD characteristics of Motor
The objective of this experiment was

1) To measure the armature resistance of the motor
2) To determine the No Load characteristics of the motor that is obtaining Back EMF vs
RPM and Mechanical losses vs RPM characteristics.
The above data will be used to predict the shaft power of DC motor.
4.1 Apparatus
DC Regulated power supply, DM 20 Multimeter, DC Motor, Optical tachometer.
4.2 Theory
Voltage eqn of Motor is given as2
V = Eb + I*Ra (12)
Multiplying (1) by I
V*I = I* Eb+ I2 *Ra (13)
Where, V*I = Input Power
I2 *Ra = Electrical losses in arma ture
I* Eb = Mechanical power developed
Hence eqn (13) can be interpreted as
Input power = Mechanical power developed + electrical losses in armature
Certain percentage of mechanical power developed is required for supplying iron

and friction losses in the motor and rest is available as output to drive the shaft of motor
Hence one can write eqn as
Input power = V*I= mechanical losses + Electrical losses + output (or net available
power at the shaft) (14)
Under no load conditions, torque applied at the shaft is zero hence output of
motor is zero. That is the total power supplied is used to overcome mechanical and
electrical losses only.
Output = 0 (under no load conditions) (15)
Relationship between speed and back emf of motor is given as2

Eb = N*/K (16)
When RPM is zero back emf is also zero (from (16)). So eqn (13) will become
Ra = V/I (17)
Using this Ra to calculate back emf for all values of current and voltage. This will enable
us to determine characteristic of mechanical losses Vs RPM using eqns (13), (14) and
(15).
For a constant flux motor back emf is directly proportional to speed of motor (from (16))
11
Hence, Eb RPM
This will provide linear relationship between back emf and RPM, which will be used to
evaluate back emf under loaded conditions and hence mechanical power developed.
Fig. 6: Experiment Set up
Image 3: No Load experiment set up
12
4.3 Set Up Description and Measurements:
Set up is arranged as shown in Fig. 6 and Image 3. Motor at no load is mounted
on rigid stand and connected to power supply. Voltmeter is connected to measure the
voltage across the motor. A white patch is marked on shaft of motor of measuring RPM
using Tachometer.
Before switching on power supply it is ensured that voltage and current knobs of
supply are at zero. Supply is switched on and voltage and current are increased gradually.
For measuring Ra, one has to ensure that motor shaft should not rotate and current is
brought in the range of 1 amp. After that voltage is measured in steps of 1 volt and
readings of current and RPM are noted down. This is done upto 10 volts. At the end of
experiment readings are taken again for measuring Ra.
Precautions:
1) Select the proper measurement range of voltmeter for accuracy in results. Select
smaller range (i.e. 200 mV or 2 V) for measuring Ra and higher range (20 V) for
measuring voltage across the motor.
2) While measuring Ra ensure that shaft of motor is not rotating. Circuit should
behave like a short circuit.
3) All electrical devices have transition time for warming up, so after changing any
parameter one should wait for sometime to stabilize readings that is steady state.
4) Measure armature resistance at the start and again at the end because of high
heating due to long run-time of motor there is enormous difference in both the
readings.
4.4 Observation:
I set of readings
Date: 28th July 2003
Experiment begins at: 11:21 Experiment Ends at: 12:24
Temperature at the start/end: 28.5/29 deg C
Pressure at the start/end: 995/996 mbar
Humidity at the start/end: 81/80 %
Armature Resistance Measurement (Ra):

(Measurements were taken when motor shaft was not rotating.)
Voltage across motor (V) Current Supplied (A)

Starting 0.075 1.0
End 0.215 2.0
Table 1: Armature resistance measurement
13
Obs. Voltage Across Current Supplied Speed (RPM)
no. Motor (V) (A)
1. 0.98 2.0 476
2. 2.03 2.5 1108
3. 3.01 2.8 1760
4. 4.01 3.7 2455
5. 5.0 4.3 3159
6. 6.0 4.5 3866
7. 7.0 4.8 4587
8. 8.01 5.0 5345
9. 9.01 5.2 6082
10. 10.0 5.2 6770
Table 2: Measuring Voltage, current and speed
During this experiment range of voltmeter selected was higher (20 V). Hence it
was decided to repeat the experiment for measuring Ra at lower voltage ranges.
Accordingly in the second set of readings, Ra was measured at all possible ranges of
voltmeter.
II set of readings
Date: 2/8/03
Experiment starts at: 11:02 am Ends at: 12.40 pm
Temp: 29 o C
Pressure: 1001 mbar
Humidity: 80%
Armature Resistance Measurement (Ra):

(Measurements were taken when motor shaft was not rotating.)
Sr. No. Voltage (V) Current (A) Voltage Range used (V)
A) Before starting the experiment
1 0.0775 1 2 V D.C.
2 0.08 1 20 V D.C.
3 0.11 1 200 V D.C.
4 0.0835 1 200 mV D.C.
B) At the end of the experiment
1 0.188 2 2 V D.C.
2 0.235 2 20 V D.C.
3 0.22 1.9 200 V D.C.
Table 3: Armature resistance measurement
Readings obtained at 2 V DC were coming close to the values provided by

manufacturer. So it was decided to consider these values only.
14
Obs. no. Voltage Across Current Supplied Speed (RPM)
Motor (V) (A)
1. 1.0 1.85 525
2. 2.0 2.4 1135
3. 3.0 2.95 1788
4. 4.0 3.58 2458
5. 5.0 4.3 3160
6. 6.0 4.8 3882
7. 7.0 5.18 4623
8. 8.0 5.5 5350
9. 9.0 5.7 6088
10. 10.0 5.4 6800
11. 11.0 5.2 7525
Table 4: Measuring Voltage, current and speed
4.5 Calculations and Analysis
Estimating value of armature resistance

For I set of observations :
From eqn (17),
Ra = V/I
At the start of experiment: Ra = 0.075
At the end of experiment: Ra = 0.1075
Hence Ra 0.09125
For II set of observations :

From eqn (17),
Ra = V/I
We use the value of Ra as calculated from the 2 V D.C. range of the Multimeter. This
range has been selected due to the inherently small value of Ra estimated
At the start of experiment: Ra = V/I = 0.0775/1 = 0.0775.
At the end of experiment: Ra = V/I =0.188/2 = 0.094.
Hence Average Ra (0.0775 + 0.094)/2 = 0.08575.
Average Ra (from set 1 and 2) = 0.0885

[Note: Manufactures manual provide value of Ra = 0.069 (Appendix A)]
Using eqns 12, 13, 14 and 15 back emf, mechanical losses and electrical losses are
calculated in table 5.
15
Speed Input Power Back EMF Mechanical Losses Electrical Losses
(RPM) V*I (Watt) V- I*Ra (V) I* Eb (Watt) I^2*Ra (Watt)
476 1.96 0.803 1.606 0.354
1108 5.075 1.80875 4.521875 0.553125
1760 8.428 2.7622 7.73416 0.69384
2455 14.837 3.68255 13.625435 1.211565
3159 21.5 4.61945 19.863635 1.636365
3866 27 5.60175 25.207875 1.792125
4587 33.6 6.5752 31.56096 2.03904
5345 40.05 7.5675 37.8375 2.2125
6082 46.852 8.5498 44.45896 2.39304
6770 52 9.5398 49.60696 2.39304
525 1.85 0.836275 1.54710875 0.30289125
1135 4.8 1.7876 4.29024 0.50976
1788 8.85 2.738925 8.07982875 0.77017125
2458 14.32 3.68317 13.1857486 1.1342514
3160 21.5 4.61945 19.863635 1.636365
3882 28.8 5.5752 26.76096 2.03904
4623 36.26 6.54157 33.8853326 2.3746674
5350 44 7.51325 41.322875 2.677125
6088 51.3 8.49555 48.424635 2.875365
6800 54 9.5221 51.41934 2.58066
7525 57.2 10.5398 54.80696 2.39304
Table 5: Calculating Back EMF and Mechanical Losses at different RPM
16
The values of back emf are plotted against those of motor speeds for both the sets of
readings, on the same scale to yield an approximately straight line.
12
10
8
Back EMF (V)
0
0 1000 2000 3000 4000 5000 6000 7000 8000
Motor Speed (RPM)
Graph 1: Back EMF vs Motor Speed

60
50
40
Losses (Watt)
30
20
10
0
0 1000 2000 3000 4000 5000 6000 7000 8000
Speed (RPM)
Mechanical Losses Electrical Losses
Graph 2: Mechanical and Electrical Losses Vs RPM
17
4.6 Conclusions
1) Value of Ra = 0.0885 which is closer to the value provided in manufacturers
manual (Ra= 0.069).
2) Relationship between back emf and speed is determined as linear experimentally,
this matches with theoretical formula. Determined mathematically relationship can
be given as
Back emf = 0.001366*RPM + 0.2629 (18)
3) Mechanical losses (Iron and friction) are calculated at various speeds and
mathematical relationship between them is obtained
Mechanical Losses = -1.5446*E-10*(speed) 3 + 1.92*E-6*(speed) 2 + 1.5*E-3*(speed) +
0.372 (19)
(Matlab code for obtaining eqn (18) and (19) is given in Appendix C (1))
18
5. Experiment to predict the shaft power of DC motor
In this experiment, motor loaded with propeller is tested in wind tunnel at

different flow velocities. For a particular flow velocity, Power consumption is measured
at all RPM values. Using the back emf measured at NO Load conditions, Mechanical
power developed by motor is calculated. Shaft power is obtained by subtracting
mechanical losses from mechanical power. First this experiment was conducted with
11X7 propeller. Later this will be repeated with propeller of other sizes too.
5.1 Apparatus
Regulated DC Power Supply, Micro-Manometer, Pitot Static tube, Voltmeter,
Tachometer, Tunnel system with Regulated power supply, set up for mounting motor
inside the tunnel.
5.2 Theory
Relationship of Back EMF (Eb) with RPM was established in previous experiment. From
eqn (18)
Back emf = 0.001366*RPM + 0.2629 (18)
Mechanical Power developed = Mechanical Losses + Shaft power = Eb*I

Shaft Power = Eb*I- Mechanical Losses (20)
Mechanical Losses are determined using eqn (19) which was established in no load
experiment.
Mechanical Losses = -1.5446*E-10*(speed)3 + 1.92*E-6*(speed)2 + 1.5*E-3*(speed) +
0.372 (19)
So shaft power is calculated using eqn (20). Once Shaft power is known we can estimate
value of Cp using eqn (8)
Equation 1
P
CP = (8)
n 3 D 5
J is calculated using eqn (6)
V
J = (6)
nD
Plot of Cp vs J is obtained for all flow velocities between 0 to 10 m/s.
Shaft power is estimated using eqn (20) at all va lues of RPM for a particular flow
velocities. In this way Plot of Shaft power vs RPM is obtained at all flow velocities.
This power vs rpm plot is cross plotted to obtain power vs velocity plot for different
values of RPM.
Voltage across motor was being measure at every step. So another plot of power vs
voltage is obtained for all flow velocities.
[Note: In this experiment it is assumed that flow velocity induced by DC motor is
negligible so we will talk in terms of wind tunnel velocity only]
19
5.3 Experime ntal Set-up and description
Experimental set-up is shown in (Image 4). Motor with a mount is rigidly

clamped on a stand and this stand is fixed on the base of tunnel in test-section. Height of
stand is such that propeller is at the center of tunnel. A white patch of paint is coated on
back side of each blade of propeller. This white patch is for the purpose of reflecting light
emanating from optical tachometer fixed at the back of propeller on stand for measuring
RPM of propeller. Motor is supplied current from a DC regulated power supply. A
voltmeter is connected across motor to measure the voltage. Flow velocity inside the
tunnel is controlled using Dimmer stat. A pitot static tube mounted at 78 cm from tunnel
inlet is connected to micro- manometer for measuring tunnel flow velocity.
Image 4: Set up inside the tunnel for predicting output power
20
5.4 Observations
First this experiment was conducted when there was no flow inside the tunnel.
Later on this experiment was repeated with V=2, 3 m/s. Observation and Calculation
tables for rest of the flow velocities are given in Appendix B.
Date : 04/08/03
Obs. Parameter At beginning of At end of the
No. the expt. experiment
1 Time 16:55 17:20
2 Temperature (C) 29 29
3 Pressure (mbar) 1003 1003
4 Relative Humidity 79% 80%
5 Voltage across motor at static
condition (for measuring Ra) (V) 0.104 0.175
6 Current through motor at static
condition (for measuring Ra) (A) 1.5 1.7
Table 6: Measuring Experiment Parameters
Flow Velocity=0 m/s with a 11X7 propeller

Obs. No. Voltage across DC Current through 2 Propeller Speed
motor DC Motor (RPM)
(V) (A)
1 1.0 2.1 1062
2 2.0 2.85 2250
3 3.0 3.9 3465
4 4.0 5.0 4750
5 5.0 6.25 5985
6 6.0 7.3 7008
7 7.0 9.0 8464
8 8.0 10.4 9650
9 9.0 11.85 10808
10 10.0 13.35 11900
11 11.0 14.8 12936
12 12.0 16.5 13938
Table 7: Observation table for power consumption and RPM
21
5.5 Calculation and Analysis
All the parameters as explained in section 5.2 theory are calculated and their plots
are obtained for all flow velocities.
(Note: Observation and Calculation tables for velocities other than 0 m/s are given in
Appendix B)
Voltage Motor Input Mechanical Back emf Shaft Efficiency Cp

across DC RPM Power Losses power of Motor
Motor
1 531 2.1 1.69 0.99 0.39 18.34 0.3053
2 1125 5.7 4.28 1.80 0.85 14.92 0.0709
3 1732.5 11.7 7.95 2.63 2.31 19.73 0.0527
4 2375 20 12.72 3.51 4.82 24.08 0.0427
5 2992.5 31.25 17.95 4.35 9.24 29.57 0.0409
6 3504 43.8 22.60 5.05 14.26 32.56 0.0393
7 4232 63 29.46 6.04 24.93 39.58 0.0390
8 4825 83.2 35.03 6.85 36.25 43.57 0.0383
9 5404 106.65 40.26 7.64 50.33 47.19 0.0378
10 5950 133.5 44.84 8.39 67.17 50.32 0.0378
11 6468 162.8 48.72 9.10 85.93 52.78 0.0377
12 6969 198 51.93 9.78 109.48 55.29 0.0384
Table 8: Calculating Cp and shaft power at zero flow velocity.
For obtaining correct plot of Cp Vs J, all those points which have values of J
greater than 0.8 were ignored because J is ratio of forward velocity to rotational velocity
at tip of prop. For a MAV in flight Values of RPM are much higher and therefore forward
velocity is much lesser than rotational velocity at the tip of prop. Also those first few
values of Cp which were obtained at very low power supply giving enormously high
values, were ignored.
22
Cp Vs J
0.06
0.05
0.04 V=2.25 m/s

V=3.19 m/s
Cp (power coefficient)
0.03 V = 3.9 m/s

V = 5.04 m/s
0.02 v = 6.36 m/s
V = 7.34 m/s
0.01 V = 8.11 m/s
V = 9.18 m/s
0.00 V = 9.63 m/s
0.00 0.20 0.40 0.60 0.80 1.00 1.20
-0.01
-0.02
J (advancd ratio)
Graph 3: Cp Vs J plot for velocities 2.25 to 9.63 m/s

Shaft Power Vs RPM
140.00
120.00
V = 0 m/s
100.00 V=2.25 m/s
V=3.19 m/s
80.00
V=3.90 m/s
Power Watts
V = 5.04 m/s
60.00
V = 6.36 m/s
40.00 V = 7.34 m/s

V = 8.11 m/s
20.00 V = 9.18 m/s
V = 9.63 m/s
0.00
0 1000 2000 3000 4000 5000 6000 7000 8000
-20.00
Motor Speed (RPM)
Graph 4: Shaft Power vs RPM at different flow velocities
Power vs RPM plot was crossploted using Matlab code (given in Appendix C)
to obtain power vs Velocity plot shown in Graph 5.
23
Power Vs Velocity
140
120
100
Power at RPM = 1000
Shaft Power (Watt)
80 Power at RPM=2000
Power at RPM=3000
Power at RPM=5000
Power at RPM = 7000
20
0
0 2 4 6 8 10 12
-20
Velocity (m/s)
Graph 5: Power vs Velocity at different RPM
Plots of Shaft Power v/s Voltage across motor for different observed forward
velocities
140
120 Obs velocity v = 0 m/s

Obs velocity v = 2.25 m/s
100
Shaft Power (Watt)
80 Obs velocity v = 3.90 m/s

60
obs velocity v = 6.36 m/s
20
obs velocity v = 9.18 m/s
0 2 4 6 8 10 12 14
-20
Voltage across motor (Volt)
Graph 6: Power Vs Voltage at different flow Velocities
24
6. Discussion and Further work
1) Upto this point sufficient technical information about the motor and different
propellers has been collected and this will serve as an exhaustive matter of reference for
further work in future.
2) Motors No load characteristics have been determined which helped in predicting
power generated at the shaft and obtaining other necessary plots.
3) A typical plot of Cp Vs J is shown in fig. 7 taken from reference no. 4
Fig7. Blade Performance Coefficients 4
The plot of Cp Vs J obtained in Graph 3 looks similar to that shown in Fig 7. Even
the maximum value of Cp in both the plot is coming closer to same value of 0.04. This
confirms the validity of prediction of shaft power using no load characteristics.
4) From the plot of Power vs RPM (Graph 4), the relationship between power and rpm is
coming cubic which again is in confirmation with physics.
5) Power Vs flow velocity plot (Graph 5) shows that shaft power required to rotate prop
will decrease as flow velocity increases this again confirms physics of system because
energy of flow will aid propeller to rotate hence lesser shaft power will be required.
Following Tasks will be completed in future to finish this exercise of power plant
measurement.
1) Uninstalled thrust measurement using load cell
2) Uninstalled toque measurement using torque sensors
3) Installed thrust and torque measurements
4) Repeating the whole exercise with different propeller-engine combinations
25
References
1. Anderson, J.D.,Introduction to Flight, Mc Graw Hill publishing company, Fourth
Edition, 2000, page no. 595-602.
2. Thareja, B.L., Introduction to electrical engineering, S. Chand company and
publisher limited, 1993
3. B B DALY, Woods Practical Guide to Fan Engineering, Woods of Colchester
Limited publisher.
4. Von mises, R., Theory of flight, Dover Inc., New York,1959
5. http://www.geocities.com/Yosemite/geyser/2126/flyinggadgets.html
6. http://www.masterairscrew.com/techbull.asp(Masterscrew propeller instruction
mannual)
7. http://www.astroflight.com (For DC motor instruction manual)
26
Appendix A
Cobalt 15 Geared Motor 7
Cobalt 15 Geared Mtr 2.4 to 1 ratio, 10 to 12 cells, 300W
Astro 15 Cobalt Geared Motor p/n 615G7
Model No. p/n 615G
Name 05 Geared
Gear Ratio 2.38 to 1
Armature Winding 7 turns
Armature Resistance 0.069 ohms
Magnet Type Sm Cobalt
Bearings Ball Bearings
Motor Speed 1488 rpm/volt
Geared Motor Speed 652 rpm/volt
Motor Torque/amp 0.91 in-oz /amp
Geared Torque 2.17 in-oz /amp
Voltage Range 8 to 12 volts
No Load Currrent 2 amps
Maximum Continuous Current 25 amps
Maximum Continuous Power 400 watts
Gear Motor Length 3.3 inches
Motor Diameter 1.3 inches
Motor Shaft Diameter 5/32 inch
Prop Shaft Diameter inch
Gear Motor Weight 9 oz
Expected Performance of Cobalt 15 Geared Motor7
27
Battery Prop Amps Watts Rpm
10 Nicads 11 x 7 14 amps 168 watts 6,400 rpm
Table 9: Motor specifications and expected performance mapping
Voltage Current Prop Watts RPM

10 5.4 No Load 54 6800
11 5.2 No Load 57.2 7525
10 13.35 11X7 (static flow) 133.5 5950
12 16.5 11X7 (static flow) 198 6969
Table 9A: Performance Results obtained in Lab
28
Appendix B
a) Flow velocity: 2.25 m/sec
Date: 05/08/03

No. the experiment experiment
1 Time 14:30 15:08
2 Temperature (C) 28.5 28.5

5 Voltage across motor at no
load (for measuring Ra) (V) 0.0875 1
6 Current through motor at no
load (for measuring Ra) (A) 0.1728 1.8
7 Wattmeter 1 (W) 16 16
10 P (mm of H 2 O) 0.3 0.3
11 Observed Velocity (m/sec) 1.9 2.0
12 Dimmer stat Voltage (V) 72 72
Table 10: Observations: Experiment paramters at V=2.25 m/s
29
Obs. No. Voltage across DC Current through 2 Propeller
motor DC Motor Speed
(V) (A) (RPM)
1 1.0 2.1 1072
2 2.0 2.9 2260
3 3.0 3.9 3450
4 4.0 5.1 4676
5 5.0 6.4 5940
6 6.0 7.75 7180
7 7.0 9.2 8380
8 8.0 10.6 9560
9 9.0 12.1 10700
10 10.0 13.6 11780
11 11.0 15.2 12800
12 12.0 17.0 13780
Table 11: Observations: Measuring power consumption and propeller speed
Voltage Propeller Mechanical Back EMF shaft Efficiency Cp J

across DC Speed(RPM) Losses power of Motor
motor
1 536 1.71 1.00 0.38 18.21 0.29 0.92

2 1130 4.30 1.81 0.93 16.11 0.08 0.44
3 1725 7.90 2.62 2.32 19.83 0.05 0.29
4 2338 12.42 3.46 5.20 25.51 0.05 0.21
5 2970 17.75 4.32 9.90 30.93 0.04 0.17
6 3590 23.40 5.17 16.64 35.79 0.04 0.14
7 4190 29.06 5.99 26.01 40.39 0.04 0.12
8 4780 34.62 6.79 37.38 44.08 0.04 0.10
9 5350 39.79 7.57 51.82 47.59 0.04 0.09
10 5890 44.36 8.31 68.64 50.47 0.04 0.08
11 6400 48.25 9.01 88.64 53.01 0.04 0.08
12 6890 51.47 9.67 113.00 55.39 0.04 0.07
Table 12: Calculation: Predicting shaft, Cp and J at V=2.25 m/s
30
b) Approach velocity: 3.19 m/sec.
Date: 05/08/03

No. the exp. experiment
1 Time 15:20 16:00
5 Voltage across motor at no load
(for measuring Ra) (V) 0.1404 0.292
6 Current through motor at no load
(for measur ing Ra) (A) 1.6 1.8
7 Wattmeter 1 (W) 24.2 24.2
8 Wattmeter 2 (W) 22.1 22.1
10 P (mm of H 2 O) 0.6 0.6
12 Dimmerstat Voltage (V) 90 90
Table 13: Observation: Measuring Experimental Parameters at V=3.19 m/s

(V) (A)
1 1.0 2.0 1093
2 2.0 2.6 2270
3 3.0 3.6 3485
4 4.0 4.9 4720
5 5.0 6.5 6000
6 6.0 7.9 7250
7 7.0 9.3 8430
8 8.0 10.9 9610
9 9.0 12.35 10740
10 10.0 14.1 11850
11 11.0 15.85 12900
12 12.0 17.7 13880
Table 14: Observation: Measuring Power Consumption at V=3.19 m/s
31
Voltage prop Mechanic Back Shaft Efficiency Cp J
Across speed al Losses EMF power of Motor
the Motor
1 546.5 1.74 1.01 0.28 13.76 0.20 1.27
2 1135 4.33 1.81 0.38 7.38 0.03 0.61
3 1742.5 8.01 2.64 1.50 13.90 0.03 0.40
4 2360 12.60 3.49 4.48 22.88 0.04 0.29
5 3000 18.02 4.36 10.33 31.78 0.05 0.23
6 3625 23.73 5.21 17.47 36.85 0.04 0.19
7 4215 29.30 6.02 26.69 41.00 0.04 0.16
8 4805 34.85 6.83 39.56 45.37 0.04 0.14
9 5370 39.96 7.60 53.87 48.47 0.04 0.13
10 5925 44.64 8.36 73.19 51.90 0.04 0.12
11 6450 48.60 9.07 95.22 54.61 0.04 0.11
12 6940 51.77 9.74 120.68 56.82 0.04 0.10
Table 15: Calculations: Shaft power, Cp and J at V=3.19 m/s
c) Flow velocity: 3.9 m/sec.

Date: 05/08/03

1 Time 16:35 17:02
(for measuring Ra) (A) 1.8 1.8
7 Wattmeter 1 (W) 33.5 34
10 P (mm of H 2 O) 0.9 0.9
Table 16: Observations: Measuring experimental parameters
32
(V) (A)
1 1.0 2.05 1082
2 2.0 2.5 2300
3 3.0 3.6 3520
4 4.0 5.1 4762
5 5.0 6.65 6000
6 6.0 8.0 7240
7 7.0 9.5 8440
8 8.0 10.9 9600
9 9.0 12.25 10700
10 10.0 13.9 11800
11 11.0 15.5 12800
12 12.0 17.85 13840
Table 17: Observations: Measuring Power Consumption and prop RPM
Voltage
Across prop Mechanic Back Shaft Efficiency
Cp J
DC Motor speed al Losses EMF power of Motor
1 541 1.72 1.00 0.33 16.07 0.2467 1.57

2 1150 4.41 1.83 0.17 3.48 0.0136 0.74
3 1760 8.13 2.67 1.47 13.59 0.0319 0.48
4 2381 12.77 3.52 5.16 25.30 0.0453 0.36
5 3000 18.02 4.36 10.98 33.03 0.0482 0.28
6 3620 23.68 5.21 17.98 37.46 0.0450 0.24
7 4220 29.35 6.03 27.91 41.98 0.0441 0.20
8 4800 34.80 6.82 39.53 45.34 0.0424 0.18
9 5350 39.79 7.57 52.96 48.03 0.0410 0.16
10 5900 44.44 8.32 71.24 51.25 0.0411 0.14
11 6400 48.25 9.01 91.34 53.57 0.0413 0.13
12 6920 51.65 9.72 121.78 56.85 0.0436 0.12
Table 18: Calculation: Shaft power, Cp and J at V=3.90 m/s
33
d) Approach velocity: 5.04 m/sec.
Date: 06/08/03

1 Time 11:20 11:49
2 Temperature (C) 28 C 28 C
7 Wattmeter 1 (W) 43 42.5
8 Wattmeter 2 (W) 41 40.5
10 P (mm of H 2 O) 1.5 1.5
11 Observed Velocity (m/sec) 5 5
Table 19: Observation: Measuring Experimental Parameters

(V) (A) (RPM)
1 1.0 2.15 1072
2 2.0 2.7 2328
3 3.0 3.6 3560
4 4.0 4.95 4786
5 5.0 6.6 6010
6 6.0 8.0 7250
7 7.0 9.45 8480
8 8.0 10.95 9630
9 9.0 12.5 10740
10 10.0 14.15 11830
11 11.0 15.8 12900
12 12.0 17.6 13880
Table 20: Observations: Measuring power consumption and RPM at V=5.04 m/s
34
Voltage Prop Mechanic Back Shaft Efficiency Cp J
across DC speed al Losses EMF power of Motor
motor
1 536 1.71 1.00 0.43 20.10 0.33 2.05

2 1164 4.48 1.85 0.52 9.59 0.04 0.95
3 1780 8.27 2.69 1.43 13.23 0.03 0.62
4 2393 12.86 3.53 4.62 23.32 0.04 0.46
5 3005 18.06 4.37 10.77 32.62 0.05 0.37
6 3625 23.73 5.21 17.99 37.48 0.04 0.30
7 4240 29.54 6.05 27.68 41.85 0.04 0.26
8 4815 34.94 6.84 39.96 45.62 0.04 0.23
9 5370 39.96 7.60 55.01 48.90 0.04 0.20
10 5915 44.56 8.34 73.49 51.94 0.04 0.19
11 6450 48.60 9.07 94.76 54.52 0.04 0.17
12 6940 51.77 9.74 119.71 56.68 0.04 0.16
e) Flow Velocity = 6.36 m/s

Date: 08/08/03
1 Time 15:33 16:04
10 P (mm of H 2 O) 2.4 2.4
Table 22: Observations: Measuring Experimental parameters
35
(V) (A) (RPM)
1 1.0 2.45 1024
2 2.0 2.95 2264
3 3.0 3.7 3510
4 4.0 4.8 4730
5 5.0 6.2 5940
6 6.0 7.95 7140
7 7.0 9.5 8350
8 8.0 10.95 9540
9 9.0 12.5 10700
10 10.0 14 11800
11 11.0 15.7 12840
12 12.0 17.5 13800
Table 23: Observations: Measuring Power consumption and prop RPM
Current Prop Mechanic Back shaft Efficiency Cp J

through speed al Losses EMF power of Motor
DC Motor
2.45 512 1.63 0.96 0.73 29.87 0.64 2.71
2.95 1132 4.32 1.81 1.02 17.32 0.08 1.23
3.7 1755 8.10 2.66 1.74 15.71 0.04 0.79
4.8 2365 12.64 3.49 4.13 21.51 0.04 0.59
6.2 2970 17.75 4.32 9.03 29.14 0.04 0.47
7.95 3570 23.22 5.14 17.64 36.99 0.05 0.39
9.5 4175 28.92 5.97 27.76 41.74 0.05 0.33
10.95 4770 34.52 6.78 39.70 45.32 0.04 0.29
12.5 5350 39.79 7.57 54.85 48.75 0.04 0.26
14 5900 44.44 8.32 72.07 51.48 0.04 0.24
15.7 6420 48.39 9.03 93.42 54.10 0.04 0.22
17.5 6900 51.53 9.69 118.02 56.20 0.04 0.20
Table 24: Calculations: Shaft power, Cp and J at V= 6.36 m/s
36
f) Flow Velocity = 7.34 m/s
Date: 08/08/03

1 Time 16:15 16:41
10 P (mm of H 2 O) 3.2 3.2
Table 25: Observations: Measuring Experimental Parameters

(V) (A)
1 1.0 2.1 1084
2 2.0 2.5 2326
3 3.0 3.1 3600
4 4.0 4.4 4840
5 5.0 6.15 6080
6 6.0 7.75 7285
7 7.0 9.45 8480
8 8.0 11.0 9650
9 9.0 12.5 10740
10 10.0 14.15 11840
11 11.0 16.0 12890
12 12.0 17.9 13880
Table 26: Observations: Measuring power consumption and prop RPM
37
Voltage prop Mechanica Back EMF shaft Efficiency Cp J
across DC speed l Losses power of Motor
motor
1 542 1.73 1.00 0.38 18.04 0.28 2.95
2 1163 4.48 1.85 0.15 2.99 0.01 1.38
3 1800 8.41 2.72 0.03 0.31 0.00 0.89
4 2420 13.08 3.57 2.62 14.88 0.02 0.66
5 3040 18.37 4.42 8.78 28.56 0.04 0.53
6 3642.5 23.89 5.24 16.71 35.93 0.04 0.44
7 4240 29.54 6.05 27.68 41.85 0.04 0.38
8 4825 35.03 6.85 40.36 45.86 0.04 0.33
9 5370 39.96 7.60 55.01 48.90 0.04 0.30
10 5920 44.60 8.35 73.55 51.98 0.04 0.27
11 6445 48.56 9.07 96.50 54.83 0.04 0.25
12 6940 51.77 9.74 122.63 57.09 0.04 0.23
Table 27: Calculations: Shaft Power, Cp and J at V = 7.34 m/s
g) Flow Velocity = 8.11

Date: 08/08/03

1 Time 16:48 17:22
10 P (mm of H 2 O) 3.9 3.9
38
(V) (A)
1 1.0 2.0 1104
2 2.0 2.55 2368
3 3.0 2.95 3650
4 4.0 4.15 4910
5 5.0 5.95 6130
6 6.0 7.7 7350
7 7.0 9.3 8520
8 8.0 10.9 9650
9 9.0 12.6 10800
10 10.0 14.3 11880
11 11.0 16.2 12920
12 12.0 18.0 13880
Table 29: Observations: Measuring power consumption and RPM
Voltage prop ML Back shaft Efficiency Cp J

across speed EMF powe r of Motor
DC motor
1 552 1.76 1.02 0.27 13.56 0.19 3.20

2 1184 4.59 1.88 0.20 3.96 0.01 1.49
3 1825 8.58 2.76 -0.45 -5.11 -0.01 0.97
4 2455 13.37 3.62 1.64 9.89 0.01 0.72
5 3065 18.60 4.45 7.88 26.49 0.03 0.58
6 3675 24.20 5.28 16.48 35.67 0.04 0.48
7 4260 29.73 6.08 26.84 41.23 0.04 0.42
8 4825 35.03 6.85 39.67 45.50 0.04 0.37
9 5400 40.23 7.64 56.03 49.41 0.04 0.33
10 5940 44.76 8.38 75.03 52.47 0.04 0.30
11 6460 48.67 9.09 98.54 55.30 0.04 0.27
12 6940 51.77 9.74 123.61 57.23 0.04 0.25
Table 30: Calculations: Shaft Power, Cp and J at V= 8.11 m/s
39
h) Flow Velocity = 9.18 m/s
Date: 08/08/03

1 Time 17:32 17:55
10 P (mm of H 2 O) 5.0 5.0

(V) (A) (RPM)
1 1.0 2.1 1113
2 2.0 2.7 2396
3 3.0 3.1 3715
4 4.0 4.0 5005
5 5.0 5.7 6255
6 6.0 7.4 7423
7 7.0 9.1 8608
8 8.0 10.9 9720
9 9.0 12.45 10830
10 10.0 13.95 11930
11 11.0 15.8 12980
12 12.0 17.85 13900
Table 32: Observations: Measuring Power Consumption and prop RPM
40
Voltage Prop Mechanica Back EMF shaft Efficiency Cp J
across DC speed l Losses power of Motor
motor
1 556.5 1.78 1.02 0.37 17.62 0.25 3.60

2 1198 4.67 1.90 0.46 8.51 0.03 1.67
3 1857.5 8.81 2.80 -0.13 -1.39 0.00 1.08
4 2502.5 13.76 3.68 0.97 6.06 0.01 0.80
5 3127.5 19.16 4.54 6.69 23.49 0.03 0.64
6 3711.5 24.54 5.33 14.92 33.61 0.03 0.54
7 4304 30.14 6.14 25.75 40.43 0.04 0.47
8 4860 35.36 6.90 39.87 45.72 0.04 0.41
9 5415 40.36 7.66 55.01 49.09 0.04 0.37
10 5965 44.96 8.41 72.38 51.88 0.04 0.34
11 6490 48.88 9.13 95.35 54.86 0.04 0.31
12 6950 51.82 9.76 122.33 57.11 0.04 0.29
i) Flow Velocity = 9.63 m/s

Date: 08/08/03
Obs. Parameter At beginning of the At end of the

No. expt. experiment
1 Time 18:05 18:32
4 Relative Humidity 87 87
10 P (mm of H 2 O) 5.6 5.4
Table 34: Observations: Measuring Experimental parameters
41
(V) (A)
1 1.0 2.1 1110
2 2.0 2.65 2386
3 3.0 3.15 3734
4 4.0 3.85 5040
5 5.0 5.55 6280
6 6.0 7.3 7460
7 7.0 9.0 8590
8 8.0 10.75 9735
9 9.0 12.45 10840
10 10.0 14.2 11940
11 11.0 16.0 12940
12 12.0 17.85 13900
Table 35: Observations: Measuring Shaft power and prop RPM
Voltage Prop Mechanic Back shaft Efficiency Cp J

across DC speed al Losses EMF power of Motor
motor
1 555 1.70 1.02 0.44 21.10 0.31 3.79
2 1193 4.55 1.89 0.47 8.82 0.03 1.76
3 1867 8.74 2.81 0.13 1.34 0.00 1.13
4 2520 13.70 3.71 0.57 3.70 0.00 0.83
5 3140 19.00 4.55 6.27 22.58 0.02 0.67
6 3730 24.38 5.36 14.73 33.64 0.03 0.56
7 4295 29.67 6.13 25.50 40.47 0.04 0.49
8 4867.5 35.00 6.91 39.30 45.70 0.04 0.43
9 5420 39.96 7.67 55.49 49.52 0.04 0.39
10 5970 44.56 8.42 74.98 52.80 0.04 0.35
11 6470 48.33 9.10 97.29 55.28 0.04 0.32
12 6950 51.46 9.76 122.69 57.28 0.04 0.30
Table 36: Calculations : Shaft power, Cp and J at V = 9.36 m/s
42
Appendix C
1) Matlab Code to determine relationship of back emf and Mechanical Losses with
RPM under no load conditions.
speed1 =[476 1108 1760 2455 3159 3866 4587 5345 6082 6770];
speed2 =[525 1135 1788 2458 3160 3882 4623 5350 6088 6800 7525];
speed = [speed1 speed2];
backemf1= [0.803 1.80875 2.7622 3.68255 4.61945 5.60175 6.5752 7.5675
8.5498 9.5398];
backemf2= [0.836275 1.7876 2.738925 3.68317 4.61945 5.5752 6.54157
7.51325 8.49555 9.5221 10.5398];
backemf= [backemf1 backemf2];
ML1= [1.606 4.521875 7.73416 13.625435 19.863635 25.207875 31.56096
37.8375 44.45896 49.60696];
ML2= [1.54710875 4.29024 8.07982875 13.1857486 19.863635 26.76096
33.8853326 41.322875 48.424635 51.41934 54.80696];
ML = [ML1 ML2];
P = polyfit(speed,backemf,1);
Q = polyfit(speed,ML,3);
R= polyval(Q,531)
2) Matlab Code to cross-plot Power vs RPM curve to Power vs Velocity curve
X2 = [531 1125 1732.5 2375 2992.5 3504 4232 4825 5404 5950 6468 6969];
Y2 = [0.385111588 0.850707533 2.308882603 4.815833598 9.241422298
14.25909031 24.93418906 36.24712091 50.32770609 67.17436772 85.92821245
109.4773216];
Q2 = polyfit(X2,Y2,3);
V = [0 2.253405806 3.186797052 3.903013345 5.044668012 6.357179464
7.340638549 8.105871243 9.180387233 9.630880586];
P1(1) = polyval(Q2,1000);
P2(1) = polyval(Q2,2000);
P3(1) = polyval(Q2,3000);
P4(1) = polyval(Q2,4000);
p5(1)=polyval(Q2,5000);
p6(1)=polyval(Q2,6000);
p7(1)=polyval(Q2,7000);
X3 = [536 1130 1725 2338 2970 3590 4190 4780 5350 5890 6400 6890];
Y3 = [0.382332824 0.934243871 2.319673572 5.204451707 9.896384323
16.64102897 26.01313759 37.38389699 51.82038098 68.63875297 88.63544116
112.9996123];
P1(2) = polyval(Q3,1000);
P2(2) = polyval(Q3,2000);
P3(2) = polyval(Q3,3000);
P4(2) = polyval(Q3,4000);
p5(2) = polyval(Q3,5000);
p6(2)=polyval(Q3,6000);
p7(2)=polyval(Q3,7000);
X4 = [546.5 1135 1742.5 2360 3000 3625 4215 4805 5370 5925 6450 6940];
Y4 = [0.275283258 0.383734785 1.501352333 4.484856496 10.32920163
17.46675351 26.69245408 39.56170078 53.87458043 73.18566327 95.21765389
120.6842461];
43
P1(3) = polyval(Q4,1000);
P2(3) = polyval(Q4,2000);
P3(3) = polyval(Q4,3000);
P4(3) = polyval(Q4,4000);
p5(3) = polyval(Q4,5000);
p6(3)= polyval(Q4,6000);
p7(3)=polyval(Q4,7000);
X5 = [541 1150 1760 2381 3000 3620 4220 4800 5350 5900 6400 6920];
Y5 = [0.329375074 0.174241137 1.468123359 5.160188944 10.98333663
17.98033014 27.91407678 39.53365284 52.95603098 71.24057809 91.33703116
121.775865];
P1(4) = polyval(Q5,1000);
P2(4) = polyval(Q5,2000);
P3(4) = polyval(Q5,3000);
P4(4) = polyval(Q5,4000);
p5(4) = polyval(Q5,5000);
p6(4)= polyval(Q5,6000);
p7(4)=polyval(Q5,7000);
X6 = [536 1164 1780 2393 3005 3625 4240 4815 5370 5915 6450 6940];
Y6 = [0.432086624 0.517976713 1.429317758 4.617532275 10.76601841
17.98821851 27.68137638 39.95985194 55.01432843 73.49043 94.76397389
119.7099521];
P1(5) = polyval(Q6,1000);
P2(5) = polyval(Q6,2000);
P3(5) = polyval(Q6,3000);
P4(5) = polyval(Q6,4000);
p5(5)=polyval(Q6,5000);
p6(5)=polyval(Q6,6000);
p7(5)=polyval(Q6,7000);
X7 = [512 1132 1755 2365 2970 3570 4175 4770 5350 5900 6420 6900];
Y7 = [0.731707824 1.022106421 1.743709729 4.128969468 9.032400323
17.64377849 27.75658069 39.70461438 54.84878098 72.07280809 93.42486765
118.0161655];
P1(6) = polyval(Q7,1000);
P2(6) = polyval(Q7,2000);
P3(6) = polyval(Q7,3000);
P4(6) = polyval(Q7,4000);
p5(6)=polyval(Q7,5000);
p6(6)=polyval(Q7,6000);
p7(6)=polyval(Q7,7000);
X8 = [542 1163 1800 2420 3040 3642.5 4240 4825 5370 5920 6445 6940];
Y8 = [0.378887851 0.14932772 0.028784322 2.619389143 8.78337784
16.70609438 27.68137638 40.35943091 55.01432843 73.54693736 96.50455452
122.6328341];
P1(7) = polyval(Q8,1000);
P2(7) = polyval(Q8,2000);
P3(7) = polyval(Q8,3000);
P4(7) = polyval(Q8,4000);
p5(7) = polyval(Q8,5000);
p6(7) = polyval(Q8,6000);
p7(7) = polyval(Q8,7000);
X9 = [552 1184 1825 2455 3065 3675 4260 4825 5400 5940 6460 6940];
44
Y9 = [0.271185775 0.202108448 -0.452495632 1.641359588 7.880408753
16.48156982 26.83777208 39.67404591 56.02743129 75.0299195 98.54458474
123.6071281];
P1(8) = polyval(Q9,1000);
P2(8) = polyval(Q9,2000);
P3(8) = polyval(Q9,3000);
P4(8) = polyval(Q9,4000);
p5(8) = polyval(Q9,5000);
p6(8) = polyval(Q9,6000);
p7(8)= polyval(Q9,7000);
X10 = [556.5 1198 1857.5 2502.5 3127.5 3711.5 4304 4860 5415 5965 6490
6950];
Y10 = [0.370066198 0.459808671 -0.129400758 0.96955156 6.694276971
14.92318331 25.75163058 39.87125821 55.00548826 72.37514697 95.34809061
122.3309858];
P1(9) = polyval(Q10,1000);
P2(9) = polyval(Q10,2000);
P3(9) = polyval(Q10,3000);
P4(9) = polyval(Q10,4000);
p5(9) = polyval(Q10,5000);
p6(9) = polyval(Q10,6000);
p7(9)=polyval(Q10,7000);
X11 = [555 1193 1867 2520 3140 3730 4295 4867.5 5420 5970 6470 6950];
Y11 = [0.443173975 0.467513133 0.126215662 0.569752071 6.266828005
14.73285352 25.49611604 39.30041543 55.49041635 74.97559798 97.28896479
122.6923657];
P1(10) = polyval(Q11,1000);
P2(10) = polyval(Q11,2000);
P3(10) = polyval(Q11,3000);
P4(10) = polyval(Q11,4000);
p5(10) = polyval(Q11,5000);
p6(10) = polyval(Q11,6000);
p7(10)=polyval(Q11,7000);
RPM1 = [V;P1]';
RPM2 = [V;P2]';
RPM3 = [V;P3]';
RPM4 = [V;P4]';
RPM5 = [V;p5]';
RPM6 = [V;p6]';
RPM7 = [V;p7]';
45

Kailash Propeller Test

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Kailash Propeller Test

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Propeller Characterization

Practical Training Report Submitted by

Center for Aerospace System and Design Engineering

Selecting correct combination of engine and propeller is very crucial step in

2. Theory and background

4. Experiment to determine NO LOAD characteristics of Motor

5. Experiment to predict the shaft power of DC motor

6. Discussion and Further work

Because of Simplicity, efficiency and cost effectiveness, propeller based IC

Image 1: Wind Tunnel for experimentation on MAV

Similar to wings propellers are made up of airfoil sections designed to generate an

Fig 1: Crossection of a three bladed propeller1

Fig. 2: Varying pitch angle along the span of propeller1

Fig 3: Resultant local velocity seen by a section of propeller1

Fig 4: Lift and drag force on an airfoil of a propeller1

T = L cos - D sin (3)

Fig. 5: Measuring Pitch of a propeller4

3.1 DC Motor Operating Limitation

1) Voltage, Current and Power Limitations

2) RPM and Torque Limitations

Lets Say we take limiting propeller tip speed as 600 ft/s

Limiting RPM = 600/(0.00436*11) =12510 rpm

The objective of this experiment was

Certain percentage of mechanical power developed is required for supplying iron

Output = 0 (under no load conditions) (15)

Relationship between speed and back emf of motor is given as2

Fig. 6: Experiment Set up

Image 3: No Load experiment set up

Armature Resistance Measurement (Ra):

Voltage across motor (V) Current Supplied (A)

Armature Resistance Measurement (Ra):

Readings obtained at 2 V DC were coming close to the values provided by

4.5 Calculations and Analysis

Estimating value of armature resistance

For II set of observations :

Average Ra (from set 1 and 2) = 0.0885

Graph 1: Back EMF vs Motor Speed

Mechanical Losses Electrical Losses

Graph 2: Mechanical and Electrical Losses Vs RPM

In this experiment, motor loaded with propeller is tested in wind tunnel at

Mechanical Power developed = Mechanical Losses + Shaft power = Eb*I

Experimental set-up is shown in (Image 4). Motor with a mount is rigidly

Image 4: Set up inside the tunnel for predicting output power

Flow Velocity=0 m/s with a 11X7 propeller

Voltage Motor Input Mechanical Back emf Shaft Efficiency Cp

0.04 V=2.25 m/s

0.03 V = 3.9 m/s

Graph 3: Cp Vs J plot for velocities 2.25 to 9.63 m/s

40.00 V = 7.34 m/s

Graph 4: Shaft Power vs RPM at different flow velocities

Graph 5: Power vs Velocity at different RPM

120 Obs velocity v = 0 m/s

80 Obs velocity v = 3.90 m/s

Graph 6: Power Vs Voltage at different flow Velocities

Fig7. Blade Performance Coefficients 4

Model No. p/n 615G

Gear Ratio 2.38 to 1

Armature Winding 7 turns

Armature Resistance 0.069 ohms

Magnet Type Sm Cobalt

Bearings Ball Bearings

Motor Speed 1488 rpm/volt

Geared Motor Speed 652 rpm/volt

Motor Torque/amp 0.91 in-oz /amp