RCbenchmark 1780 Series User manual
Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
Series 1780 Dynamometer
User Manual V2.2
Manual SKU#: PHAX
Image above shows the Series 1780 V2 coaxial version, with the optional no-solder board and two-axis ground railing system sold separately.
Copyright 2018 - Tyto Robotics Inc. Page 1/119
Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
Table of contents
Chapter 1: Introduction 6
1.1 Determine your configuration 7
1.2 Item checklists for your dynamometer 9
1.2.1 Series 1780 Dynamometer 25kgf-100A: Single-motor (SKU#:KHYER) 9
1.2.2 Series 1780 Dynamometer 40kgf-150A: Single-motor (SKU#:KTBKA) 9
1.2.3 Series 1780 Dynamometer 25kgf-100A: Basic coaxial (SKU#:KYQXD) 10
1.2.4 Series 1780 Dynamometer 40kgf-150A: Basic coaxial (SKU#:KDAPQ) 10
1.2.5 Series 1780 Dynamometer 25kgf-100A: Ultimate coaxial (SKU#:KCHQB) 11
1.2.6 Series 1780 Dynamometer 40kgf-150A: Ultimate coaxial (SKU#:KDRHP) 11
1.2.7 Accessories 12
Chapter 2: General safety rules 13
Chapter 3: Ground fixations and enclosure 16
3.1 Mounting options 17
3.1.2 Floor bolts 18
3.1.3 Plywood on the floor 19
3.1.4 Accessory: RCbenchmark railing system 19
3.1.4.1 Single-motor railing system: installation 21
3.1.4.2 One-axis railing system: installation and linear movement 24
3.1.4.3 Two-axis railing system: installation and linear movements 26
3.2 Design your own railing system 32
3.3 Accessory: RCbenchmark enclosure (available soon) 33
3.3.1 Additional safety aspects - specific to enclosure 33
3.3.2 What’s included in the enclosure 34
3.3.3 Enclosure installation steps 35
3.3.4 Integrate the ground railing system into the enclosure 42
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
3.4 Build you own enclosure 45
3.4.1 Design and build your own enclosure 45
3.4.2 Integrate the RCbenchmark railing system into your own cage 46
Chapter 4: Series 1780 Installation 47
4.1 Two-plate support and L brackets 48
4.1.1 What’s included and where to find the parts 49
4.1.2 Assembly of the support 50
4.1.3 Integrate the support into the railing system 56
4.2 Load measurement unit 58
4.2.1 Storage, calibration and warranty 58
4.2.2 What’s included 59
4.2.3 Mount load measurement unit to the support 60
4.2.4 Installation of the mechanical safety stop 64
4.2.5 Dismounting the load measurement unit from support 65
4.3. Motor, motor mount and optical RPM probe 66
4.3.1 What’s included 67
4.3.2 Install your motor onto the motor mount 68
4.3.3 Install the optical RPM probe on the motor mount 69
4.3.4 Install the motor mount assembly on the load measurement unit 72
4.4 Power and control console, ESC and no-solder board 75
4.4.1 What’s included and where to locate the components 76
4.4.2 Fixing the no-solder board on the support plate 78
4.4.3 Fixing the ESC on the support plate 80
4.4.4 Fixing the power and control console on the support plate 81
4.5 Main board 84
4.5.1 What’s included 85
4.5.2 How to install the main board on your structure 86
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
4.5.3 Install the main board on the RCbenchmark enclosure 87
4.6 Coaxial back-to-back special mount 89
4.6.1 What’s included 91
4.6.2 Placing the load measurement unit onto the special mount 92
4.6.3 Fixing the special mount assembly onto the support 95
4.6.4 Bonding of two load measurement units 96
Chapter 5: How to connect electrical components 101
5.1 Electrical safety rules 101
5.2 Motor power chain 101
5.2.1 Motor, no-solder board to ESC 101
5.2.2 ESC to power and control console 102
5.2.3 Power and control console to your power source 104
5.3 Sensor chain 105
5.3.1 Optical RPM probe and force sensor 105
5.3.2 Power sensor 106
5.3.3 Temperature probe 106
5.3.4 Air-speed probe 106
5.4 Control chain 106
5.4.1 Power and control console 106
5.5 Main board and PC 107
5.5.1 Indicator lights 107
5.5.2 Power and USB to your PC 108
5.5.3 Buzzer and safety cut-off switch 108
5.6 Cable management 108
Chapter 6: Two motors testing 110
6.1 Two motors face-to-face 110
6.2 Two motors face-to-face offset: partial overlapping 111
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
6.3 Two motors back-to-back (min: 100mm) 113
6.4 Single motor running for coaxial products 114
Chapter 7: Using the RCbenchmark software 115
7.1 Connecting to the tool 116
Chapter 8: Upgrade, warranty and technical support 117
8.1 Technical support 117
8.2 Upgrade your products 117
8.3 Product’s warranty 118
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
Chapter 1: Introduction
This is a user manual for the customers who purchased the Series 1780 Dynamometer V2, in
order to demonstrate all important information about preparing, assembling and using this
dynamometer. If you need the user manual for the original Series 1780 Dynamometer V1,
please contact us.
The user manual of the Series 1780 is regularly updated. To ensure you have accurate
information and to ensure you have the latest version of the manual, we ask you to
download the latest PDF copy from our website:
https://rcbenchmark.gitlab.io/docs/en/
IMPORTANT!
We highly recommend that all operators who will be working with this machine carefully
read this user manual in its entirety, before carrying out any operation on the Series 1780.
Please notice that not following the instructions in this user manual may result in testing
errors, malfunction of the dynamometer, serious injuries, or death of the operator.
In this manual, any text following a # represents the RCbenchmark SKU# for this item. You
may refer to this number to order spare parts.
The Series 1780 dynamometer contains several major units: the load measurement units, the
power measurement unit, the main board, and the fixtures. Every box may contain one or
multiple bags of fasteners. Please keep them in the boxes until you need to use them.
All load measurement units, the 25kgf-12Nm version A side (#TRAK) & B side (#GDBA), and the
40kgf-18Nm version A side (#GYJT) & B side (#EPDY) are extremely sensitive to any external
forces. All the load measurement units come with a protective shell, within their own boxes.
Do not take it out until you need to mount it onto the support. And when you unmount the
load measurement unit from the support, please place it back into the protective casing. For
further information about how to store and keep a valid warranty on this unit, please refer to
section 4.2.1 of this manual.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
1.1 Determine your configuration
Currently, the Series 1780 Dynamometer offers the following configurations:
Series 1780 Dynamometer: Single-motor
25kgf-100A (#KHYER) and 40kgf-150A (#KTBKA)
●For characterizing one brushless motor
●Voltage, current, thrust, torque and RPM measurement
●Upgradable to any coaxial version (purchase necessary)
Series 1780 Dynamometer: Basic coaxial
25kgf-100A (#KYQXD) and 40kgf-150A (#KDAPQ)
●For characterizing one and two brushless motors
●Voltage, current, thrust, torque and RPM measurements for each motor
●Adjustable axial and radial distance (with railing system)
●Simultaneous control on both motors
●Individual and global data for the propulsion system
●Support the following setups:
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
Series 1780 Dynamometer: Ultimate coaxial
25kgf-100A (#KCHQB) and 40kgf-150A (#KDRHP)
●For characterizing two brushless motors
●Voltage, current, thrust, torque and RPM measurements for each motor
●Minimum axial distance for a back-to-back setup: 100mm
●Adjustable axial and radial distance (with railing system)
●Simultaneous control on both motors
●Individual and global data for the propulsion system
●Support the following setups:
Please verify your order and invoice about which configuration you purchased from us.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
1.2 Item checklists for your dynamometer
Before you use these checklists, please check which configuration you purchased from us. If
unsure please contact us.
1.2.1 Series 1780 Dynamometer 25kgf-100A: Single-motor (SKU#:KHYER)
Please check the following items are in the carton:
●Load measurement unit 25kgf-12Nm: A side (SKU#: TRAK) x1
●Mono main board V2 (SKU#: RHGQ) x1
●Main board power adapter (SKU#: PGAC) x1
●Power & control console 100A: A side (SKU#: AQJT) x1
●Fixture brackets and fasteners box (SKU#: XJEA) x1
●Support plates in wrap (SKU#: YREP) x1
●Motor mount V2 (SKU#: ETHR) x1
●Hand tools kit V2 (SKU#: DBHQ) x1
●General user manual (SKU#: PHAX) x1
●Mechanical safety stop (SKU#: UTPF) x1
1.2.2 Series 1780 Dynamometer 40kgf-150A: Single-motor (SKU#:KTBKA)
Please check the following items are in the carton:
●Load measurement unit 40kgf-18Nm: A side (SKU#: GYJT) x1
●Mono main board V2 (SKU#: RHGQ) x1
●Main board power adapter (SKU#: PGAC) x1
●Power & control console 150A: A side (SKU#: RBEP) x1
●Fixture brackets and fasteners box (SKU#: XJEA) x1
●Support plates in wrap (SKU#: YREP) x1
●Motor mount V2 (SKU#: ETHR) x1
●Hand tools kit V2 (SKU#: DBHQ) x1
●General user manual (SKU#: PHAX) x1
●Mechanical safety stop (SKU#: UTPF) x1
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
1.2.3 Series 1780 Dynamometer 25kgf-100A: Basic coaxial (SKU#:KYQXD)
Please check the following items are in the carton:
●Load measurement unit 25kgf-12Nm: A side (SKU#: TRAK) x1
●Load measurement unit 25kgf-12Nm: B side (SKU#: GDBA) x1
●Dual main board V2 (SKU#: GPDE) x1
●Main board power adapter (SKU#: PGAC) x1
●Power & control console 100A: A side (SKU#: AQJT) x1
●Power & control console 100A: B side (SKU#: YGKE) x1
●Fixture brackets and fasteners box (SKU#: XJEA) x2
●Support plates in wrap (SKU#: YREP) x2
●Motor mount V2 (SKU#: ETHR) x2
●Hand tools kit V2 (SKU#: DBHQ) x1
●General user manual (SKU#: PHAX) x1
●Mechanical safety stop (SKU#: UTPF) x2
1.2.4 Series 1780 Dynamometer 40kgf-150A: Basic coaxial (SKU#:KDAPQ)
Please check the following items are in the carton:
●Load measurement unit 40kgf-18Nm: A side (SKU#: GYJT) x1
●Load measurement unit 40kgf-18Nm: B side (SKU#: EPDY) x1
●Dual main board V2 (SKU#: GPDE) x1
●Main board power adapter (SKU#: PGAC) x1
●Power & control console 150A: A side (SKU#: RBEP) x1
●Power & control console 150A: B side (SKU#: GAPD) x1
●Fixture brackets and fasteners box (SKU#: XJEA) x2
●Support plates in wrap (SKU#: YREP) x2
●Motor mount V2 (SKU#: ETHR) x2
●Hand tools kit V2 (SKU#: DBHQ) x1
●General user manual (SKU#: PHAX) x1
●Mechanical safety stop (SKU#: UTPF) x2
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
1.2.5 Series 1780 Dynamometer 25kgf-100A: Ultimate coaxial
(SKU#:KCHQB)
Please check the following items are in the carton:
●Load measurement unit 25kgf-12Nm: A side (SKU#: TRAK) x1
●Load measurement unit 25kgf-12Nm: B side (SKU#: GDBA) x1
●Coaxial Back-to-back Special Mounting (SKU#: JCTX) x1
●Dual main board V2 (SKU#: GPDE) x1
●Main board power adapter (SKU#: PGAC) x1
●Power & control console 100A: A side (SKU#: AQJT) x1
●Power & control console 100A: B side (SKU#: YGKE) x1
●Fixture brackets and fasteners box (SKU#: XJEA) x2
●Support plates in wrap (SKU#: YREP) x2
●Motor mount V2 (SKU#: ETHR) x2
●Hand tools kit V2 (SKU#: DBHQ) x1
●General user manual (SKU#: PHAX) x1
●Mechanical safety stop (SKU#: UTPF) x2
1.2.6 Series 1780 Dynamometer 40kgf-150A: Ultimate coaxial
(SKU#:KDRHP)
Please check the following items are in the carton:
●Load measurement unit 40kgf-18Nm: A side (SKU#: GYJT) x1
●Load measurement unit 40kgf-18Nm: B side (SKU#: EPDY) x1
●Coaxial Back-to-back Special Mounting (SKU#: JCTX) x1
●Dual main board V2 (SKU#: GPDE) x1
●Main board power adapter (SKU#: PGAC) x1
●Power & control console 150A: A side (SKU#: RBEP) x1
●Power & control console 150A: B side (SKU#: GAPD) x1
●Fixture brackets and fasteners box (SKU#: XJEA) x2
●Support plates in wrap (SKU#: YREP) x2
●Motor mount V2 (SKU#: ETHR) x2
●Hand tools kit V2 (SKU#: DBHQ) x1
●General user manual (SKU#: PHAX) x1
●Mechanical safety stop (SKU#: UTPF) x2
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
1.2.7 Accessories
If you purchased any of these accessories, you can find them in the carton that comes with
your Series 1780 Dynamometer (any configuration):
●Series 1780 temperature probe (SKU#: JTKB)
●Series 1780 no-solder board V2 (SKU#: HABT)
●Series 1780 air-speed probe (SKU#: BJPK)
●Series 1780 XLCH motor mount (SKU#: LXMF)
If you purchased any railing systems or enclosures, most of the items will come in a separate
carton. However, the fasteners and the fixture plates for the ground railing systems may be
within the same carton of your Series 1780 Dynamometer. Please follow the detailed checklist
in Chapter 3 in order to locate these items.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
Chapter 2: General safety rules
Always put safety first! It is your responsibility!
It is extremely important to stay alert and to know how each item works. Read this part for
yourself, and make sure all your colleagues who will be potentially working on the Series
1780 have carefully read this guide before using the dynamometer.
This part will not cover details about how to assemble the Series 1780 Dynamometer, neither
about how to connect the electrical components. For these operations, please refer to their
proper chapters within this manual. However, you should still read through this chapter
before moving on to the next steps.
The following instructions apply on both operating and maintenance personnel and must be
followed during all phases of operations, service, testing and repair of this instrument.
To ensure safety, please follow these instructions:
1. Before construction make sure all your tools are in good condition and don’t need to
be replaced. Learn the tools application, limitations, and possible hazards.
2. Inspect all fasteners before every experiment and as often as possible.
3. Make sure to use properly rated cables for the power.
4. Do not use power tools in the presence of flammable liquids or gases.
5. Always keep your work area clean, do not work on surfaces that are dirty with oil.
Small metal chips may be blown up and hit the propeller by accident. Clean your
testing room before every test.
6. Respect the Murphy’s law. If you think something might go wrong, it will.
7. Make sure you are dressed for safety. The load cell parts may be sharp, wear gloves
all along the assembly. Do not wear jewelry or inappropriate clothing when operating
the tool.
8. Do not let children around the Series 1780 dynamometer.
9. Never force the tool to do a job for which it was not designed or outside its
specifications. Using the tool outside of its official specifications will void the
warranty and is at your own risk.
10. Do not use or assemble the tool alone.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
11. Do not substitute parts or modify the instrument.
12. Always disconnect the power source before making adjustments, changing parts,
cleaning or working on the tool.
13. Do not store anything near or above the tool, especially in function.
14. Always keep your tools clean, in good working order.
15. Do not operate the tool if you are under the influence of drugs, alcohol, or medication
that may affect your ability to properly use the tool.
16. Do not open and touch the electrical circuits inside the enclosures (No-solder Board,
Power & control control, Main board, Force sensor circuit). Do not change or modify
the electrical circuit.
17. Respect the working conditions concerning the power, voltage and current of the
motors that you use on the Series 1780 Dynamometer.
18. Make sure you are running all your tests in a safe space. You should have some
protection. Such as an enclosure or a safety cage, in order to shield and protect when
the propeller breaks apart on its spinning surface.
19. The safety cage or the enclosure should be suitably rated for containing a propeller
failure. It should also protect in case the Series 1780 comes apart (loose screw or
mechanical failure).
20. Make sure nobody is in the room or near the propeller in function.
21. Wait for the propeller to stop spinning before accessing the testing area.
22. Make sure all the parts have time to cool down after any test. The motor, ESC,
batteries and wires may be hot. Please keep a fire extinguisher available in the
proximity.
23. Make sure a protective surface is between you and the propeller in function. Wear
protective glasses at all times while in the same room.
24. For the installation of the components in the Series 1780, please always refer to the
proper chapter in this manual. Always use the given fasteners, following their proper
instructions to make sure the proper fasteners are used and are well tightened.
Confirm the structure’s rigidity every time before any tests.
25. Unbalanced propellers and extreme vibrations can lead to fatigue failure of some
aluminum components and/or the load cells. Please ensure the unit is completely
enclosed in the safety area and inspect all parts before performing a test.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
26. Note that unbalanced propellers may cause resonances and powerful vibrations. It
may result in structure failure, and can endanger someone. If you find your structure
vibrating due to resonances, stop the test as soon as possible.
27. If you are using your own built fixtures, make sure they are rigid enough to support
your loads.
28. Ground railing systems and the enclosures must be fixed on the ground properly.
They cannot be left free on the ground.
29. Do not approach the Series 1780 before cutting off the power
30. If using ground rails, after each adjustment of position, ensure the fasteners between
the fixture plate and the rail are properly tightened.
31. Never forget about the lock washers, they are important to resist high vibration from
the propulsion system.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
Chapter 3: Ground fixations and enclosure
IMPORTANT!
You should prepare the ground fixtures before assembling the Series 1780 Dynamometer.
This applies both for your own mounting methods, or if using our ground railing system.
The Series 1780 Dynamometer offers an option to purchase the ground railing system and the
enclosure as accessories with your Series 1780 Dynamometer order. If you wish to add this to
your dynamometer, please visit our online store or contact us at [email protected]
The ground rails assist you to fix the whole Series 1780 Dynamometer on the ground. For the
customers who purchased the Series 1780 single-motor configuration, these rails function as
a fixture jig. For the customers who purchased the Series 1780 coaxial configurations, these
rails will allow 1-axis or 2-axis linear movements, in order to adjust the axial and/or radial
distances between two propellers.
The Series 1780 enclosures contain several T-slotted beams. It provides ground fixing and
some protections for the Series 1780. You may need to add the metal meshes and the
Plexiglas accordingly. Currently, we cannot fully guarantee the safety as the mesh was not
designed to fully stop the debris from flying out of the enclosure. No matter if you have this
type of enclosure or not, any personnel should never stay near the spinning propellers,
especially on their rotation surfaces.
You can also build your own ground fixtures, enclosures or safety cages for the Series 1780.
We will present some ideas and examples about how to build these in the following sections.
Always remember, you are responsible for the safety of using the Series 1780 Dynamometer.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
3.1 Mounting options
IMPORTANT!
Using no fixture, or leaving the Series 1780 improperly secured may cause permanent damage
to the load measurement unit, or cause damage to your facility, or even cause casualties.
Check the safety guide for more information.
In this section, we will present several possibilities to fix the Series 1780 on the ground. You
have several methods at your disposal, depending on your available resources and
depending on the components you purchased (railing system and/or enclosure).
The base of the Series 1780 is made of two corner brackets, which together form the following
hole pattern:
Fig. 3.1: Hole pattern for fixing the Series 1780 to a structure. All annotations in mm. Four holes available for M8 or
5/16” bolt, X distance at 114.3 mm, Y distance at 38.1 mm.
If you purchased any of our railing system accessories, you will also have a fixture base plate
(#KGTP) as shown in Fig. 3.2. Even if you don’t use the railing system, you may find this fixture
plate helpful in attaching your Series 1780 to your own structure.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
Fig. 3.2: Fixture base plate (#KGTP): adapter to place and hold the S1780 on the rails. This part comes with the
railing system accessory, or can be purchased separately.
In summary here are some available mounting options:
●RCbenchmark railing system without enclosure
●RCbenchmark railing system with enclosure
●Directly bolted to the floor
●Bolted to your own structure
●Bolted to Plywood and weights
3.1.2 Floor bolts
If you have not purchased our railing system, please follow the instructions in this section
(floor bolts) or the next section (floor plywood) to fix your Series 1780 on the floor. In order
to use floor bolts, you must drill the floor or have a structure available.
When drilling holes in the ground, please use caution and follow the instructions from the
bolts suppliers to properly insert adapters and the bolt cover inside the concrete. We
recommend to have a technician in civil engineering to examine your building’s security and
to assist you for the installation of the floor bolts. You should also get the approval from
your building manager.
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
3.1.3 Plywood on the floor
If your facility does not allow to drill into the concrete flooring, you may use a large piece of
plywood and place heavy weights in each corner of the plywood, along with rubber pads to
increase friction between the plywood and the floor. There is a high bending moment at the
base of the tool, make sure to use washers and a sufficiently thick plywood to handle it.
Using the fixture plate shown in Fig. 3.2 may help in securing the tool (separate purchase
required). The screw heads can easily break through the plywood under heavy load. It is your
responsibility to make the base of your structure suitable for supporting the Series 1780.
3.1.4 Accessory: RCbenchmark railing system
If you have purchased one of our Series 1780 ground railing systems, this section will present
you how to securely install the rails and the fixture plate.
We currently offer three configurations of railing system:
●Single-motor ground railing system shown in Fig. 3.3 (SKU#: KADXH)
●One-axis ground railing system shown in Fig. 3.4 (SKU#: KBHED)
●Two-axis ground railing system shown in Fig. 3.5 (SKU#: KBJRA)
Fig. 3.3: Single-motor railing system (SKU#: KADXH)
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Series 1780 Dynamometer User Manual V2.2
Document ID: J3LDP2
Publish date: 2019-03-25
Fig. 3.4: One-axis railing system
Fig. 3.5: The two-axis ground railing system (SKU#: KBJRA) with the Series 1780 coaxial version installed on the
rails. Allows adjusting the radial offset to perform partial propeller overlapping tests.
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Table of contents
