50V 250A dc power supply

A Case Study: 50V 250A DC Power Supply in Drone Propeller Power-On Test

Discover how a custom 50V 250A, 12.5kW DC power supply solved critical testing challenges for an industrial drone manufacturer. Learn the key specs for reliable drone propeller power-on tests.

Introduction: The Critical Role of Precision Power in Drone Testing

In the rapid evolution of drone technology, rigorous testing is the cornerstone of reliability and performance. One of the most demanding procedures is the propeller power-on test, a vital validation step that simulates real-world flight electrical stresses on the ground. This case study get in research to how a customized DC power supply provided the robust, precise, and intelligent solution to drone prop power-on test.

drone prop power-on test

Part 1: The Testing Challenge

A comprehensive power-on test must accurately replicate the dynamic electrical environment of actual flight to validate motor efficiency, thrust performance, thermal management, and system durability under stress.

Key challenges include:

  • Instantaneous High-Current Demand: Simulating the massive inrush current during propeller startup and the sudden surges during rapid acceleration.
  • Precision Voltage & Current Regulation: Enabling accurate measurement of power consumption and efficiency.
  • Critical Ripple and Noise Suppression: Providing ultra-clean DC power to prevent electrical noise from interfering with sensitive Flight Controller (FC) and Electronic Speed Controller (ESC) feedback signals.
  • Continuous Full-Load Endurance: Reliably sustaining high power output for prolonged durability and thermal runaway tests.

Part 2: Decoding the Specs – Essential DC Power Supply Parameters

To meet these challenges head-on, the DC power supply (or rectifier) must be engineered with specific, high-performance parameters. The 50V/250A unit deployed in this case was defined by several critical specifications.

Precise and Wide-Ranging Output

The 0-50V continuously adjustable voltage and 0-250A adjustable current output. The 12.5kW power provides essential headroom for testing peak performance without clipping.

Exceptional Output Quality & Dynamic Response

  • Low Ripple & Noise (<1%): A “clean” DC output is non-negotiable. High-frequency noise can corrupt sensor data and cause erratic ESC behavior. Our solution maintained ripple well below this threshold.
  • Fast Dynamic Response Time (Millisecond-level): The power supply must react almost instantaneously to the motor’s rapidly changing load.

Comprehensive Protection & Control Intelligence

  • Protections: Over-Voltage (OVP), Over-Current (OCP), Over-Temperature (OTP), and Short-Circuit (SCP) protections are mandatory for safeguarding both the test equipment and the valuable unit under test.
  • Control Modes: Automatic changeoverbetween Constant Voltage (CV) and Constant Current (CC) modes is essential for simulating different load conditions.
  • Programmable: Remote control interfaces (e.g., LAN, CAN, RS485) are crucial for integration into automated test benches, allowing for the execution of complex, repeatable test sequences.

Part 3: Our Customized Solution – Engineered for the Task

We moved beyond offering a standard catalog product to deliver a tailored turnkey solution. Our engineering team designed this power system in four units parallel, each module is able to run independently. If one module power supply in failure, but the others can operate normally.

HighPrecision

Utilizing an advanced DSP control technology, we suppressed output voltage ripple less than 1% at full load, voltage resolution 1mV and current resolution 1mA

Robust Cooling for Reliability

To tackle the thermal challenge of continuous operation, we optimized the internal thermal layout and airflow design. This guaranteed stable, full-power output even in ambient temperatures up to 45°C.

Intelligent Control for Automation

We equipped the unit with dual CAN bus and Ethernet (LAN) interfaces. This allowed the engineers to seamlessly integrate the supply into their test software, programming complex tasks.

Part 4: Measurable Results – Transforming Test Capabilities

The deployment of this customized DC power system led to significant, measurable improvements in the client’s R&D process.

Increased Test Efficiency

Automated, programmable testing replaced hours of manual adjustments.

Expanded Test Coverage & Enhanced Safety

With confidence in the power supply’s robust peak capability and protections, the team could safely execute previously stress tests, such as simulating emergency accelerate or abrupt stops. This approach helped identify potential design margins early in the development cycle.

Reduced Total Cost of Testing

One high-integration, modular units saved valuable lab space, and minimized costly downtime caused by equipment failure or limitation.

Conclusion: The Foundation of Innovation

In the demanding field of drone development, the test equipment is as pivotal as the design itself. A high-performance, tailor-made DC power supply does more than just deliver energy—it acts as the foundational pillar for validation, quality assurance, and breakthrough innovation. By providing a precise, reliable, and intelligent dc rectifier, it empowers engineers to build drones that are safer, more powerful, and capable of achieving the extraordinary.