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B320 FlyCore Integration Case Study

Power Hardware and Power Supply Architecture

This airframe uses a smart battery power architecture. In addition to the standard positive and negative power connectors, it has a PX4 MAVLink CAN protocol interface (rather th…

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This airframe uses a smart-battery power architecture. In addition to the standard positive and negative power connectors, it has a PX4 MAVLink CAN protocol interface (rather than using a conventional current-sensor solution). It can connect to the power distribution board for CAN forwarding (or the battery can connect directly to the flight controller), allowing the current battery level to be displayed after the flight controller parses the data. It is recommended to use a regulated DC power supply with current limiting and short-circuit protection, monitor the current for abnormalities, and ensure that none of the wiring arrangements causes a short circuit.

Non-Negotiable Physical Constraints

Do not disassemble the flight controller module

Treat the entire module (including the internal IMU and vibration-isolation structure) as a single unit. The factory calibration is based on this structure. Any disassembly will invalidate the calibration and cause positioning divergence; in severe cases, attitude control may be lost.

Do not change the extrinsic parameters of the sensor-fusion module

The relative mounting positions and angles of the vision and radar sensors are factory-calibrated extrinsic parameters. The mechanical connection between them must likewise never be disassembled, loosened, or repositioned.

Rigidly secure the flight controller

When transferring the complete flight controller module to a new airframe, ensure that the mounting surface is flat, use vibration-isolating mounting, and do not introduce additional high-frequency vibration.

Do not obstruct the vision sensor or radar

No part of the airframe, cables, payload, or any other component may intrude into the field of view (FOV) of the vision camera or radar.

Power Topology and Components

The power path must be split into two branches, with propulsion power clearly separated from equipment power:

Power-on/off instructions:

The power source is a 6S smart battery. It connects to a power switch module located beneath the lower shell at the rear of the aircraft. After connecting the power source, press the button to turn the system on; press it again to turn the system off. The power module has two output branches. One branch goes to a 60 V—18 V step-down module, which supplies the flight controller and onboard computer with 18 V at 5 A. The other branch goes to the ESC power input and mainly supplies propulsion power to the UAV airframe.

The green box indicates the location of the power button The aircraft nose direction and power-button location

Propulsion power input (first branch)

Battery requirement: 6S voltage platform.

Connection method: Connect the positive and negative battery terminals directly to the power input of the ESC.

Key component: Connect an electrolytic capacitor matched to the ESC in parallel across the positive and negative pads of the ESC power input. It absorbs voltage spikes generated while the ESC is operating, filters, regulates, and smooths the power supply, and protects the entire system.

Equipment power input (second branch)

Connection method: At the battery input, split out a positive and negative branch and connect it to the input of an 18 V step-down module.

Output: The 18 V output of the step-down module powers both the flight controller and the onboard computer. Ensure that both can reliably receive 18 V.

CAN protocol of the power module

Do not overlook this: It is the only channel for returning voltage, current, and battery-level information. If a standard BEC without the CAN protocol is used, the flight controller will be unable to determine the remaining battery level, creating a risk of an aircraft crash due to sudden power loss.

Correct wiring: A power module that supports the CAN protocol must be used. The protocol is MAVLink; connect its CAN_H and CAN_L wires to the flight controller's CAN bus network.