Unmanned Systems Technology 003 | UAV Solutions Talon 120 | Cable harnesses | Austro Engine AE50R and AE300 | Autonomous mining | AUVSI 2015 show report | Transponders | Space systems

53 Austro Engine AE50R rotary and AE300 I4 | Dossier hours is feasible. As a UAV it has been successfully tested at 33,000 ft, requiring only 40% of take-off power to cruise at that altitude. A future development will be a two-stage turbocharging system, specifically designed for flying at higher altitude. The current single- stage system will be retained for altitudes of up to 33,000 ft, since the more complex and heavier system is not necessary for such operation, and that covers most routine missions. Where the two-stage system is specified, it will be run as a single stage at lower altitude – closing one stage is seen as preferable to having two wastegates both partially open. As it is, in the AE50R and the AE300, Austro Engine already has ‘low’ and ‘high’ power engines that are ideal for a wide variety of uses in the world of unmanned aerial systems. Unmanned Systems Technology | Summer 2015 The AE50R tends to be used in unmanned rotor craft and as optional power in gliders, whereas the AE300 tends to be used for fixed-wing UAVs Austro Engine is an independent company and also part of the Diamond Group, which also embraces companies producing complete aircraft and offering advanced composite manufacturing services. At the moment Austro Engine employs 85 in its purpose-designed 7600 sq m facility. The chief executive of Austro Engine is Juergen Heinrich, with Markus Rippa as chief technical officer and Peter Lietz the chief operating officer. The AE50R accounts for about 25% of total output, and tends to be used in unmanned rotor craft and as optional power in (manned) gliders, whereas the AE300 tends to be used for fixed-wing UAVs and light aircraft. Currently in development are the AE200, a three-cylinder alternative to the AE300, and the AE330, which is a more powerful, 180 bhp evolution of the AE300, using a slightly modified turbocharger. The running logged so far indicates that there is no risk inherent in that power increase. Also in development is the AE80R, a development from the AE50R, a new single-rotor design that will exploit “a different design approach” according to Lietz. Manufacture of most of the AE50R’s mechanical engine components is outsourced, with the assembly done in-house. At Austro Engine, all engines are hand-built and all – both new and overhauled – are dyno tested for 100 minutes before dispatch. The test system includes a carry cart and quick release couplings to get the engines in and out of the cell with the least delay. Austro Engine has four AVL-equipped dyno cells, all fundamentally the same but with one configured specifically for rotary engine work, and another (with additional test equipment) for r&d work; they can all can be programmed automatically. There is a diesel and an avgas supply available to each cell, although the fact that one is rotary-dedicated avoids the need to purge the supply lines after fuel changes. In addition to its engine test cells, Austro Engine has a propeller test cell, where an entire aero powertrain can be run (in push or pull configuration). This cell can be climatically controlled, and in many respects resembles a small wind tunnel, although it is not designed to be used as such. Since quality control is particularly important for aero engines, Austro Engine has an extensive inspection laboratory, which includes a Zeiss CMM, and a materials laboratory where testing such as hardness and roughness can be carried out. Destructive testing can also be conducted, and there are Magnaflux and die- penetrant testing facilities as well. Engine harnesses are produced in-house using techniques including laser cable cutting and auto crimping; the harnesses are bespoke to particular aircraft, and each harness is checked before use. The company also produces an interface box that connects the flight control computer to the engine control system. Austro Engine The AE300 is based on a proven automotive I4 turbodiesel