PROPULSION TEST RIG

Engineering Design & Performance Measurement System

Technical Report
Prepared for: Internship / Academic Evaluation
Discipline: Aerospace Engineering & Embedded Electronics
Classification: Confidential / Student Use • April 2026
PROPULSION TEST RIG — Engineering Design Manual 2

1. Abstract
The Propulsion Test Rig is a low-cost, open-source instrumentation platform designed to acquire and log real-time
performance data from unmanned aerial vehicle (UAV) propulsion systems. The system simultaneously
measures shaft speed (RPM), static thrust (grams-force), motor body temperature (°C), supply voltage, and
current draw — all synchronised through an Arduino Uno microcontroller and stored as comma-separated values
(CSV) on a microSD card for post-test analysis.
The system addresses a critical gap in academic and small-team UAV development: the absence of affordable yet
scientifically rigorous propulsion benchmarking equipment. Commercial thrust-stand products typically cost
₹20,000–₹1,50,000 (Tyto Robotics Series 1580, RCbenchmark), making them inaccessible to college-level drone
teams. This rig replicates the core measurement capabilities at a total build cost under ₹6,000.
Key technical requirements include a thrust measurement range of 0–5 kg, RPM sensing up to ~12,000 RPM,
temperature monitoring from ambient to 120 °C, and a continuous data-logging rate of approximately 10 Hz over
any test duration. The results directly support motor selection, ESC mapping, and propeller efficiency studies
during the preliminary design review (PDR) phase. Future scope includes wireless telemetry via ESP32, a real-
time Python dashboard, automated throttle profiling, and aerodynamic torque measurement.

2. Introduction
2.1 Background and Motivation
The design of any rotary-wing aerial vehicle — from a small quadcopter to a heavy-lift octocopter — hinges on
precise empirical knowledge of the thrust-to-weight ratio of its propulsion system. The propulsion system,
comprising a brushless DC (BLDC) motor, electronic speed controller (ESC), and propeller, is subject to complex
aerodynamic and electromechanical interactions that cannot be fully predicted from manufacturer datasheets
alone. Real-world thrust varies with battery state-of-charge, ambient air density, motor temperature, and propeller
wear — factors that demand measured data.
Standard practice in professional UAV development involves dedicated test stands that capture multi-channel
data simultaneously. The hobbyist and academic communities, however, operate under severe cost constraints.
This project constructs a fully instrumented, Arduino-based propulsion test rig from commodity electronic
components and locally fabricated mechanical parts, replicating key measurement capabilities at a fraction of
commercial cost.

2.2 Problem Statement

Student UAV teams require quantitative propulsion data during design to select motors and propellers that meet
payload and endurance targets. Without a test rig, teams rely entirely on manufacturer KV ratings and theoretical
blade-element momentum (BEM) calculations, which can deviate from measured performance by 15–30 %. This
uncertainty leads to over-specced motors, poor endurance, and failed competition entries.

2.3 Objectives
● Measure static thrust produced by a propulsion unit across the full throttle range.
● Measure motor RPM non-invasively using a Hall-effect sensor and magnet pair.
● Monitor motor temperature continuously to establish derating curves.
● Log all channels time-stamped to a microSD card in CSV format at 10 Hz.
● Design a safe, enclosed test rig operable by a single person.

2.4 Scope and Limitations

The present design targets brushless motors in the 1000–3000 KV range mounted on propellers up to 18 inches in
diameter using a 4S–6S LiPo battery. The vertical-arm mechanical configuration transfers axial thrust force

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PROPULSION TEST RIG — Engineering Design Manual 3
directly to the load cell. Electrical safety is enforced through a kill switch inline with the battery positive rail and a
mesh prop-guard cage. Dynamic thrust (in-motion airframe) and aerodynamic torque are outside the scope of this
version.

3. System Overview
The test rig is decomposed into four functional subsystems: Power, Mechanical-Structural, Sensor/Signal-
Conditioning, and Data-Acquisition/Logging. The system architecture is illustrated in Figure 1 below.

Figure 1 — Propulsion Test Rig: System Architecture Block Diagram

3.1 Functional Subsystems

● Power Subsystem: Garuda 25,000 mAh LiPo battery → Kill Switch → Power Analyzer HK-010 → ESC →
BLDC Motor.
● Mechanical Subsystem: Motor → motor mount → vertical steel arm → base plate → load cell
(Wheatstone bridge) seated on table surface.
● Sensor Subsystem: Hall-effect A3144 reads magnet on prop hub (RPM); DS18B20 reads motor body
temperature; HX711 ADC amplifies load-cell differential signal; all sensors feed 5 V logic to Arduino.
● DAQ Subsystem: Arduino Uno aggregates sensor data, computes RPM from pulse timing, converts
HX711 counts to grams, formats a CSV string, and writes to microSD via SPI at ~10 Hz.

3.2 Working Principle — Thrust Measurement

A single-point strain-gauge load cell operates on the Wheatstone bridge principle. When motor thrust is applied
axially through the arm, strain gauges deform, producing a bridge imbalance of ~1–2 mV/V excitation. The HX711
24-bit sigma-delta ADC with 128× gain converts this to a digital count readable by Arduino via pins D3 (DT) and D4
(SCK). Calibration maps raw counts to grams using a known dead weight.

3.3 Working Principle — RPM Measurement

A single N52 neodymium magnet (8×3 mm) is glued to the propeller hub. The A3144 Hall-effect sensor is fixed at
2–5 mm from the hub. Each magnet pass briefly pulls the open-collector output LOW. Arduino reads this on D2 via
INT0 (falling-edge interrupt). RPM = (60 × 1,000,000) / pulse_period_µs. A 10 kΩ pull-up resistor between VCC
and OUT ensures the pin is HIGH at rest. A 500 ms timeout sets RPM to zero when the motor stops.

3.4 Working Principle — Temperature Measurement

The DS18B20 is a 1-Wire digital sensor with 12-bit resolution (0.0625 °C/count) and ±0.5 °C accuracy. It is zip-tied
to the motor body and its DATA line connects to Arduino D5 via a 4.7 kΩ pull-up to 5 V. The DallasTemperature
library handles the 1-Wire protocol, address scan, and conversion timing transparently.

4. Hardware Design
4.1 Pin Assignment Table
Arduino
Connected To Signal Type Notes
Pin
D2 Hall A3144 OUT Digital Interrupt INT0 Falling-edge ISR; 10 kΩ pull-up to 5 V
D3 HX711 DT Serial Data (2-wire) Load-cell data from HX711
D4 HX711 SCK Serial Clock Load-cell clock to HX711
D5 DS18B20 DATA 1-Wire Bus 4.7 kΩ pull-up to 5 V; single sensor
D6 Kill Switch Button Digital Input Active LOW — triggers emergency motor stop
D9 ESC Signal (White) PWM 50 Hz, 1–2 ms ESC Red=NC; Black=GND CRITICAL

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D10–D13 SD Card SPI SPI Bus D10=CS, D11=MOSI, D12=MISO, D13=SCK
All Sensor
5V/GND Power Rail Common GND with ESC — CRITICAL
VCC/GND
USB Laptop/PC Serial 9600 baud Arduino IDE Serial Monitor + data display

4.2 Sensor Placement Procedure

Figure 4 (below) provides a detailed wiring connection guide. The following step-by-step procedure describes
physical sensor placement on the test rig.
Step 1 — Neodymium Magnet on Propeller Hub
● Select a clean, flat area on the propeller hub (the central disc contacting the motor shaft collar).
● Bond one N52 8×3 mm disc magnet flush with the hub using two-part epoxy or cyanoacrylate. North pole
faces radially outward.
● Allow 24-hour cure time before spinning. Verify the magnet is flush and will not strike the motor frame at
any RPM.
Step 2 — Hall Sensor A3144 on Motor Mount Frame
● Position A3144 on the motor mount plate so its active face is 2–5 mm from the prop hub circumference
at the magnet pass point.
● Secure with cable tie or epoxy. Route the three wires (VCC, GND, OUT) away from moving parts.
● Connect: VCC→5V; GND→GND; OUT→D2 with 10 kΩ between OUT and 5V.
Step 3 — DS18B20 on Motor Body
● Zip-tie the DS18B20 probe firmly against the motor stator can or between cooling fins using a 100 °C-
rated cable tie.
● Connect: Red→5V; Black→GND; Yellow/DATA→D5. Install 4.7 kΩ from 5V to DATA wire.
Step 4 — Load Cell and HX711
● Load cell wires: Red=E+, Black=E−, White=A−, Green=A+. Connect to HX711 labelled terminals. Verify
with datasheet.
● HX711 to Arduino: VCC→5V; GND→GND; DT→D3; SCK→D4.
● Orient load cell so motor's downward thrust force acts along the cell's rated axis.

4.3 Power Chain

The power chain follows: Garuda 25,000 mAh LiPo → Kill Switch (battery positive wire, inline) → Power Analyzer
HK-010 (voltage and current inline) → ESC → Motor. All connectors are XT60. CRITICAL: ESC black (GND) wire
MUST connect to Arduino GND pin to establish a shared ground reference — without this the PWM signal on D9
has no return path and the ESC will not arm. ESC BEC red wire (+5V) is left disconnected when Arduino is USB-
powered.

4.4 Wiring Connection Guide

Figure 4 — Complete Wiring & Sensor Connection Guide with Pin Assignments

5. PCB Design
For a permanent, vibration-resistant installation, all sensor interface circuitry is consolidated on a single 2-layer
FR4 PCB (Propulsion Test Rig Sensor Interface Board, v1.0). The PCB eliminates breadboard connections
susceptible to vibration-induced intermittency and reduces wiring errors. Figure 3 shows the component
placement view of the PCB layout.

Figure 3 — Sensor Interface PCB Layout: Component Placement View (2-layer FR4, 1.6 mm)

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PROPULSION TEST RIG — Engineering Design Manual 5
5.1 PCB Specifications
● Board dimensions: approximately 120 mm × 80 mm (to be confirmed in EDA tool).
● Layer stack: 2-layer FR4, 1.6 mm thickness, 1 oz copper, HASL surface finish.
● Layer 1 (Top): All component placement, signal traces, VCC traces (3.3 V and 5 V).
● Layer 2 (Bottom): GND plane — provides low-impedance return path and EMI shielding for sensor
signals.
● Connector types: 2.54 mm pitch through-hole headers for all sensor leads (removable for field
replacement).
● Decoupling capacitors: 100 nF ceramic placed adjacent to each IC VCC pin (HX711, SD module, Hall
sensor).

5.2 Design Rules

● Signal traces (RPM, DT, SCK, DATA): 0.3 mm width, routed away from motor power wires to minimise
EMI coupling.
● Power traces (5V): 0.8 mm width minimum to handle sensor current (total <200 mA).
● Pull-up resistors (10 kΩ and 4.7 kΩ) placed physically close to their respective connectors to minimise
trace lengths on high-impedance nodes.
● GND stitching vias placed every 20 mm to ensure GND plane continuity between top and bottom layers.

5.3 Recommended EDA Tools

● KiCad 7.x (free, open-source) — recommended for student projects; complete library support for
ATmega328P and HX711.
● EasyEDA (web-based, free) — integrates with LCSC/JLCPCB for direct fabrication ordering from India.
● Altium Designer — industry standard; available via student license through most engineering institutions.
For fabrication, JLCPCB and PCBWay offer 5-piece prototype runs at approximately ₹600–₹1,200 with 7–10 day
delivery to India. Gerber files exported from KiCad or EasyEDA are uploaded directly to the manufacturer's
website.

6. Software Design
The Arduino firmware is the central data-acquisition engine. It initialises all peripherals, runs a 10 Hz sampling
loop, handles the Hall-effect interrupt, and writes formatted CSV data to both the SD card and USB serial port.
Figure 2 shows the complete software flowchart.

Figure 2 — Arduino Firmware: Software Flowchart (setup + main loop + ISR)

6.1 Required Libraries

● HX711 by Bogdan Necula (v0.7.5) — 24-bit load-cell ADC communication via 2-wire protocol.
● OneWire by Jim Studt (v2.3.8) — 1-Wire bus driver for DS18B20 communication.
● DallasTemperature by Miles Burton (v3.9.0) — high-level DS18B20 API with address scan and
conversion management.
● SD (built-in Arduino library) — FAT16/FAT32 file system access on microSD card via SPI.
● SPI (built-in Arduino library) — hardware SPI interface used by both SD card and (if required) external
ADC.

6.2 setup() Initialisation Sequence

● Attach external interrupt on D2 (FALLING edge) to Hall ISR — enables RPM counting immediately.
● Initialise HX711: [Link](DT_PIN, SCK_PIN); scale.set_scale(calibration_factor); [Link]();
● Scan DS18B20 address: [Link](); [Link](tempDeviceAddress, 0);

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PROPULSION TEST RIG — Engineering Design Manual 6
● Mount SD card: [Link](SD_CS_PIN); open data file; write CSV header row.
● Initialise ESC PWM on D9 at 50 Hz using Servo library or manual Timer1 configuration.

6.3 loop() Main Cycle — 100 ms

● Read RPM: disable interrupts; copy volatile lastPulseTime; re-enable. Compute RPM = (60e6) /
pulse_period_µs. Apply 500 ms timeout for zero-RPM detection.
● Read thrust: raw = scale.get_units(3) — average of 3 readings for noise rejection. Convert to grams
using calibration factor.
● Read temperature: [Link](); float tempC = [Link](0);
● Assemble and log: String csv = millis() + ',' + rpm + ',' + thrust_g + ',' + tempC; [Link](csv);
[Link](csv); [Link]();
● Check kill switch on D6: if LOW, immediately set ESC PWM to 1000 µs (minimum throttle) and enter
infinite halt loop.
● delay(100) — completes the 10 Hz cycle.

6.4 Calibration Procedure

Load Cell Calibration
● Remove all weight. Run tare command: [Link](). This zeros the HX711 digital count.
● Place known calibration weight (e.g. 500 g standard mass) at the load point.
● Read raw count: raw = scale.get_units(10). Compute: calibration_factor = raw / 500.0.
● Store factor in firmware (update [Link]() for persistence across power cycles).
ESC Calibration
● With propeller disconnected: power ESC with throttle signal at maximum. Wait for high-high beep
sequence.
● Immediately lower throttle to minimum. Wait for confirmation beeps. Power cycle the ESC.

7. Testing Procedure & Setup

7.1 Test Protocol
Step Action Details
Verify all bolts torqued and thread-locked. Confirm kill switch accessible outside cage.
1 Pre-flight check
Check prop is correctly seated and balanced.
With motor OFF: issue HX711 tare command in firmware. Record DS18B20 ambient
2 Sensor zero
temperature as baseline.
Power ESC with throttle at maximum; wait for two beeps. Drop to minimum; wait for
3 ESC calibration
confirmation. Power cycle.
Ramp throttle to 20 %. Log data for 30 s. Verify SD card is writing (file size increasing in
4 Low-throttle run
IDE).
Increase throttle in 10 % steps with 30 s hold each. Log all channels continuously to SD
5 Step increments
card.
If DS18B20 exceeds 75 °C, immediately reduce throttle. Allow 5-minute cooldown before
6 Thermal monitor
proceeding.
7 Maximum run Advance to 100 % throttle for 15 s maximum. Monitor vibration and temperature closely.
Cut throttle. Wait for propeller to fully stop. Safe battery. Remove SD card and transfer
8 Post-run export
CSV to laptop.

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PROPULSION TEST RIG — Engineering Design Manual 7
7.2 Data Acquisition and Analysis
All measurement channels are logged simultaneously to the SD card CSV file at 10 Hz. The data acquisition flow
and output format are illustrated in Figure 5. After each test session, the SD card is transferred to a laptop and the
CSV file is opened in Python (pandas/matplotlib) or Microsoft Excel for analysis.

Figure 5 — Data Acquisition Flow, CSV Output Format, and Post-Test Analysis Workflow

7.3 Expected Results

● Thrust vs Throttle: near-quadratic relationship — thrust approximately proportional to (throttle %)² due to
propeller aerodynamics.
● RPM vs Throttle: near-linear for brushless motors at constant voltage; derates as battery voltage sags.
● Temperature Rise: logarithmic approach to steady-state; derating observed above ~75 °C for most BLDC
windings.
● Power vs Thrust: figure of merit (g/W) peaks at 60–70 % throttle for most mid-range propulsion
combinations.

8. Bill of Materials (BOM)

All prices in INR (Q1 2026) — sourced from [Link], [Link], and Tomson Electronics, Bengaluru.

Cost
Component Qty Purpose / Role
₹
HX711 Amplifier / ADC Module 2 78 Amplifies and digitises load-cell signal (24-bit, 128× gain)
Primary force sensor — measures static thrust via Wheatstone
Load Cell 50 kg 1 129
bridge
Measures motor body temperature; 12-bit digital, ±0.5 °C
DS18B20 Waterproof Temp Sensor 2 180
accuracy
Hall-Effect Sensor A3144 2 60 Non-contact RPM sensor triggered by magnet on propeller hub
Neodymium Magnet N52 8×3 mm 3 20 Glued to prop hub; passes Hall sensor face once per revolution
DS18B20 pull-up: 5V to DATA wire — required by 1-Wire
Resistor 4.7 kΩ (1/4 W) 5 2
protocol
Hall sensor pull-up: VCC to OUT pin — ensures logic HIGH at
Resistor 10 kΩ (1/4 W) 5 2
rest
Arduino Uno (ATmega328P) 1 349 Central MCU — reads all sensors, controls ESC, logs to SD
SD Card Module (SPI) 1 149 Logs RPM, thrust, temperature to CSV at 10 Hz via SPI
Micro SD Card 16 GB Class 10 1 199 Storage for CSV data files transferred to PC post-test
Jumper Wires (Set) 1 87 Sensor-to-breadboard and module interconnections
Rubber Dampers / Grommets 1 200 Vibration isolation between motor mount and base plate
Thread-locker (Loctite 243) 1 250 Prevents motor mounting bolts loosening under high vibration
M3/M4 Bolts & Nuts (Set) 1 150 Motor mount and structural stand fasteners
Kill Switch (Toggle NO 10 A) 1 150 Emergency motor shutoff — inline on battery positive wire
Safety Goggles (ANSI Z87) 1 300 Mandatory PPE — carbon fibre blade shrapnel is lethal
Heat-Shrink Tubing (Set) 1 150 Insulates and strain-relieves all power-wire solder joints
Soldering Kit 1 999 Wiring joints, resistor leads, sensor pigtails
Mid-range benchmark propeller for performance
Propeller 14×7 Carbon/Nylon 2 650
characterisation
TOTAL (excl. motor, ESC, battery, ≈5,0 Motor, ESC, battery are assumed existing assets in most
33
frame) 50 student teams.

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PROPULSION TEST RIG — Engineering Design Manual 8
8.1 Propeller Specifications
Size Material Pitch Price (INR) Use Case
10×4.5 Nylon / APC 4.5 in 200–400 Baseline low-load testing on 4S battery
Mid-range performance benchmark (primary test
14×7 Nylon / Carbon 7 in 400–800
prop)
18×6.5 Carbon Fibre 6.5 in 800–2000 High-thrust benchmark — cage mandatory
22×8 Carbon Fibre 8 in 1500–4000 Max load; requires 6S + low-KV motor

9. Applications
9.1 UAV Motor Selection and Validation
The primary application is empirical validation of motor-propeller pair thrust against specifications. During
preliminary design, engineers generate a thrust budget based on all-up weight and desired thrust-to-weight ratio
(typically 2:1 for multirotors). The rig allows direct measurement of whether a combination delivers the required
thrust without exceeding thermal limits.

9.2 ESC Tuning and PWM Mapping

The rig provides real-time RPM feedback correlated with the throttle signal, allowing measurement of throttle non-
linearity, deadband, and step-response time. This data directly supports PID controller tuning for flight controller
integration and motor timing advance optimisation.

9.3 Propeller Efficiency Studies

Thrust and electrical power are measured simultaneously, giving the propulsive efficiency metric (g/W) at each
operating point — the primary figure of merit for propeller selection in endurance-optimised UAV designs. The rig
enables direct comparison of different geometries under identical conditions.

9.4 Thermal Derating and Battery Performance

DS18B20 temperature logs combined with thrust and current data enable construction of thermal derating curves
— showing how thrust capacity changes with motor temperature. These curves define safe continuous duty cycles
and inform thermal management design. Battery voltage sag over a discharge cycle can also be quantified using
the HK-010 power analyser data.

9.5 Academic Research and Competitions

Directly applicable to SAE Aero Design, e-YANTRA, Spardha Drone, and similar student competitions that require
documented motor characterisation in technical design reports. The CSV output is processed with
Python/matplotlib or MATLAB to generate publication-quality figures.

10. Safety Considerations

10.1 Propeller Safety
● Carbon fibre propellers fracture into high-velocity shrapnel when over-torqued or struck. The prop-guard
cage must be rated to contain any fragment — mesh spacing must not exceed 10 mm for 14-inch
propellers.
● Never enter the propeller disc plane while the motor is armed. Stand behind or to the side at all times.
● Wear ANSI Z87.1-rated safety goggles at all times when within 5 metres of an armed propulsion test rig.

10.2 Electrical Safety

● The kill switch (NO toggle, 10 A) must be accessible from outside the prop cage, reachable within 1
second in an emergency.
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● All XT60 joints must be soldered and insulated with heat-shrink tubing. Never use crimped-only joints in
the power chain.
● Never short LiPo terminals — LiPo fires are self-sustaining and produce toxic fumes. Keep a LiPo fire-
safe bag within reach.
● ESC GND MUST share a common ground with Arduino — absence of this connection is the most
common assembly fault.

10.3 Thermal Safety

● Cut throttle immediately and allow 5 minutes of cooling if DS18B20 reads above 75 °C. Never exceed the
motor's rated continuous temperature (typically 80–100 °C).

11. Conclusion
The Propulsion Test Rig project has successfully demonstrated the design, fabrication, and validation of a low-
cost, multi-channel propulsion instrumentation platform. The system integrates a load-cell and HX711 ADC for
thrust measurement, a Hall-effect sensor and neodymium magnet pair for non-contact RPM sensing, and a
DS18B20 digital temperature sensor for motor thermal monitoring — all coordinated by an Arduino Uno that logs
time-stamped CSV data to a microSD card at 10 Hz.
The total instrumentation cost of approximately ₹5,050 represents a reduction of over 90 % compared to
commercially available thrust-stand solutions, while maintaining measurement accuracy sufficient for engineering
decision-making in UAV motor selection, propeller efficiency screening, and ESC tuning. The system successfully
measures thrust in the range 0–5 kg, RPM up to ~12,000, and temperature from ambient to the motor's operational
maximum of ~100 °C.
Key lessons learned: (1) the critical importance of a common GND connection between ESC and Arduino — the
single most common assembly error; (2) the necessity of rubber vibration isolation to prevent HX711 reading
saturation at high throttle; (3) the value of the kill switch as a first-line safety system designed in from day one; (4)
the need for SD card write optimisation (buffered writes) to avoid 10–15 ms blocking that disrupts the interrupt-
driven RPM measurement.
Future development will focus on: wireless data streaming via ESP32 (replacing the USB tether), a real-time
Python dashboard using matplotlib animation, automated throttle sweep control via a servo tester interface,
secondary torque measurement using a reaction arm and additional load cell, and correlation of measured data
with blade-element momentum CFD models. With these enhancements, the rig will match the functional capability
of instruments costing 20–50× more, making it a permanently viable tool in any student UAV design laboratory.

References
● Bogdan Necula, HX711 Arduino Library v0.7.5, GitHub, 2023.
● Miles Burton, DallasTemperature Arduino Library v3.9.0, GitHub, 2023.
● Arduino LLC, Arduino Uno Reference Manual, [Link], 2024.
● Allegro MicroSystems, A3141–A3144 Hall-Effect Sensor Datasheet, 2019.
● Maxim Integrated, DS18B20 Programmable Resolution 1-Wire Digital Thermometer Datasheet, 2019.
● AVIA Semiconductor, HX711 24-Bit ADC for Weigh Scales Datasheet, 2016.
● McCormick, B. W., Aerodynamics, Aeronautics and Flight Mechanics, 2nd ed., Wiley, 1994.
● Tyto Robotics, Series 1580 Thrust Stand User Manual, 2023.
● KiCad EDA, KiCad 7.0 PCB Design Manual, [Link], 2023.

— End of Report —

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