Custom engine-control electronics for unmanned aircraft

The Custom UAV ECU is a custom engine-control electronic for unmanned aircraft from Performance Electronics with professional grade and dual-use market. Performance Electronics offers custom engine-control electronics for unmanned aircraft, a service that provides engine control units (ECUs) matched to the engine and airframe of a UAV. The company, based in Cincinnati, Ohio, designs and produces electronic control units for unmanned vehicles of all types, and supplies OEM customers who sell the hardware under their own brand.

The custom work is based on the PE4-UV engine management system, a compact ECU developed for small engines in unmanned vehicles. UAV versions use hardware and firmware modules related to those of the company's automotive controllers and a similar PC-based tuning software, and they are configured for the specific application. The system can control every aspect of a small engine, and the company can provide complete PE4 integration projects with existing or new engine designs and airframes.

The input and output set listed for the PE4-UV is four dedicated thermocouple inputs, seven analog sensor inputs (0 to 5 V), two switched inputs and four configurable outputs that work as on/off or PWM. The standard models include a CAN bus, two injector drivers, two ignition coil drivers and inputs for throttle position, manifold absolute pressure and intake air temperature, while the number of thermocouple inputs, stepper motor drivers and digital outputs varies by model. Where an application needs more thermocouples or other special inputs, a daughterboard is available.

For vehicle integration, the specific UAV features are customer-specified connectors, including military-specification connectors as an option, a 12 V or 28 V supply, data logging for up to 40 hours, a CAN bus and password protection. The hardware and software are modular and adaptable, in standard or custom designs.

The ECU also supports fuel-flow measurement, developed because UAV customers need an accurate estimate of fuel consumption to calculate remaining flight time. An engine-control unit with this function is used in internal combustion engines for unmanned aircraft, and Performance Electronics control hardware has been used with a multi-fuel UAV engine.

Typical applications are gasoline and heavy-fuel piston engines and other small internal combustion engines on fixed-wing and rotary-wing unmanned aircraft, where the engine controller must be adapted to the engine, the sensors, the power supply and the data link of the airframe. The service covers a project from concept to production.