Underwater Thruster Test Stand

Currently developing a comprehensive test apparatus to measure thrust output of underwater motors. Built from lab materials and 3D printed components, this system features real-time force measurement, web-based control interface, and automated data acquisition for ROV/AUV design optimization.

Python Raspberry Pi 3D Printing Load Sensors Web Interface ESC Control

Active Development

Project Overview

This underwater thruster test stand is an active development project designed to provide comprehensive testing capabilities for ROV and AUV thruster systems. Currently in active development, the project focuses on creating a robust, accessible testing platform using readily available lab materials and modern control systems.

The system is being built with a focus on modularity and ease of use, allowing researchers and engineers to quickly test different thruster configurations and generate accurate thrust-throttle curves for design optimization. The web-based interface ensures that anyone can connect to the device and control it without specialized software installation.

This project demonstrates practical engineering skills in mechanical design, electronics integration, software development, and data acquisition systems, all while working within resource constraints and utilizing available lab materials.

Technical Implementation

Mechanical Design

Frame Construction: Built from scrap DIN rail and aluminum tube sections
Lever Arm System: Pivoting mechanism for force transfer to load sensor
3D Printed Components: Custom adapters and brackets for thruster mounting
Modular Design: Easy thruster swapping and configuration changes

Sensing & Control

25kg Load Sensor: High-precision force measurement for thrust output
Blue Robotics Basic ESC: Electronic speed controller for thruster operation
Raspberry Pi: Central control unit and data processing
Real-time Data Acquisition: Continuous force monitoring and recording

Software & Interface

Python Backend: Control algorithms and data processing
Web Application: User-friendly interface for remote control
Network Connectivity: Direct computer connection for control access
Data Logging: Automated recording of thrust measurements

Development Approach

Rapid Prototyping: 3D printing for quick iteration and testing
Resource Optimization: Utilizing available lab materials and components
Modular Architecture: Easy to modify and expand functionality
Open Design: Accessible to other researchers and developers

Key Features

Real-time Force Measurement

25kg load sensor provides precise thrust measurements with real-time data acquisition and continuous monitoring capabilities.

Web-based Control

Intuitive web interface allows anyone to connect and control the test stand remotely without specialized software installation.

3D Printed Components

Custom adapters and brackets enable quick thruster mounting and configuration changes for testing different motor types.

Data Acquisition

Automated data logging and analysis capabilities for generating thrust-throttle curves and performance characterization.

Current Development Status

Hardware Assembly

Successfully constructed the mechanical frame using DIN rail and aluminum tubing, with 3D printed components for thruster mounting and lever arm pivoting.

Completed

Sensor Integration

Integrated 25kg load sensor with Raspberry Pi for force measurement and Blue Robotics ESC for thruster control.

Completed

Software Development

Currently developing Python control software and web interface for real-time thruster control and data acquisition.

In Progress

Testing & Calibration

Upcoming phase to validate force measurements, calibrate the system, and test with various thruster configurations.

Pending

Development Challenges & Solutions

Resource Constraints

Challenge: Working with limited lab materials and budget constraints while building a functional test stand.

Solution: Leveraged scrap DIN rail and aluminum tubing for the frame, designed 3D printed components for custom mounting solutions, and utilized existing lab equipment like the Blue Robotics ESC.

Precision Force Measurement

Challenge: Ensuring accurate force measurement with proper load transfer from thruster to sensor through the lever arm system.

Solution: Designed a precise lever arm mechanism with 3D printed brackets to ensure proper force transfer and minimize measurement errors from mechanical play or misalignment.

User Accessibility

Challenge: Creating an interface that allows anyone to use the test stand without specialized knowledge or software.

Solution: Developed a web-based interface that runs on the Raspberry Pi, allowing direct network connection and control through any web browser without additional software installation.

Future Development Plans

The thruster test stand is designed as a platform for continuous improvement and expansion. Future development phases will focus on enhancing measurement accuracy, expanding testing capabilities, and improving user experience.

Enhanced Data Analysis

Implement advanced data processing algorithms for real-time thrust curve generation, efficiency calculations, and performance comparison tools.

Automated Testing Sequences

Develop pre-programmed test routines for standardized thruster characterization and automated data collection protocols.

Multi-Thruster Testing

Expand the system to support testing of multiple thrusters simultaneously for ROV/AUV configuration optimization.

Environmental Simulation

Add capabilities for testing under different water conditions, temperatures, and pressure scenarios to better simulate real-world operating conditions.