UAVHE RW1-500APU

Overview

The RW1-500 is a complete hybrid power system that combines a rotary engine, high-efficiency generator, power electronics, and energy management unit in a single compact assembly.
It provides primary electrical power, distribution control, and battery management for multirotor UAV platforms operating in continuous or extended-range missions.
Lightweight and compact, the RW1-500 delivers up to 80 kW of continuous DC power with high fuel efficiency and low acoustic and thermal signatures.
The system operates fully autonomously, managing generation, distribution, and storage without external control input.

Design Features

The RW1-500 integrates a rotary engine and generator within a single housing and directly coupled shaft.
Thermal control is provided by an external dual-loop liquid cooling system with independent pumps and fans.
The ECU/PDU unit—available in liquid- or air-cooled configurations—contains the rectifier, power distribution electronics, control module, and integrated lithium starter battery.
This modular arrangement separates heat zones, simplifies installation, and provides stable, autonomous power regulation.

Core Features

– Integrated rotary engine and generator within a single housing.
– Cast-iron sleeve and end housings with aluminum structural casing for thermal stability and stiffness.
– Dual-loop liquid cooling system with independent pumps and ECU-controlled heat management.
– Forced-air cooling for generator stator and rotor.
– Exhaust enclosed in a cooled shroud; generator cooling air passes around the muffler and exits coaxially with exhaust gases, reducing infrared signature.
– ECU/PDU with rectifier, power distribution, control electronics, and integrated lithium starter battery.
– e-Supercharger providing throttle-less power control and altitude compensation.
– Generator rotor integrated as a dynamic counterbalance for vibration-free operation.
– Progressive combustion chamber geometry for efficient and stable burning.
– Premix/automix lubrication with internal fuel-based seal and bearing lubrication.
– Tungsten-carbide apex seals with DLC-coated slots and titanium springs.
– Redundant ignition system with four spark plugs per section.
– Full thermal and system diagnostics managed by ECU with autonomous regulation of pumps, fans, and e-supercharger.
– Low acoustic signature and zero vibration due to balanced architecture and multi-chamber silencer design.

Specifications

System Interfaces

The RW1-500 provides CAN bus, RJ45 TCP/IP, and Modbus RS-485 communication interfaces, compatible with most autopilot and power management protocols. Extended telemetry and analytics deliver real-time data on voltage, current, temperature, and overall system state.

The power section includes 16 independent 48 VDC ports, reconfigurable as 8 × 96 VDC or 4 × 144/192 VDC groups.
All ports use Surlok connectors and support software-defined voltage adjustment within 40–58 VDC, controllable during operation.

Each channel includes programmable limits for current and voltage, full protection against over-current and short-circuit, and complete telemetry feedback.
Maximum continuous current per port is 150 A.

The integrated battery management system supports up to 256 packs (12 S each) with bi-directional load ports, allowing controlled power flow between generator, batteries, and consumers under algorithm-based management.

Multiple RW-series modules can operate in parallel with hot-swap capability and automatic load balancing.

Designed in accordance with MIL-STD-810 and MIL-STD-461 environmental and electromagnetic standards.
Cold start to 95 % output achieved in under 75 s; hot restart (ECU active, engine off) — under 6 s.

Verified through full endurance and vibration testing under MIL-STD-810G profiles.

Configuration and Delivery Options

Each RW1-500 system can be configured to match customer integration requirements.
For prototype evaluation and development, UAVHE offers the Engineering Evaluation Demo Kit — a complete operational package including the production-grade engine-generator, ECU/PDU, fuel system (pumps, filters, lines, and pressure regulators), cooling system (radiators, pumps, and hoses), intake and exhaust assemblies, wiring harness, and control software for startup and testing.

Standard evaluation configuration price:
32 500 EUR, Ex-Works Barcelona.