Skyfly electric aircraft prototype during electrical and control system integration testing

Electric aircraft electrical integration / control systems support

Skyfly Electric Aircraft Electrical and Control Integration Support

Electrical and control integration support for Skyfly’s electric aircraft development, helping battery, powertrain and main control systems communicate and operate together through remote testing, tethered hovering and early low-level flight testing.

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Vehicle
Skyfly electric aircraft prototype and full-scale test aircraft systems
Project
Electric aircraft electrical integration / control systems support

Project introduction

The objective

Support the development of a full-size electric aircraft platform, moving from system understanding and bench-level integration towards controlled testing and piloted operation.

The brief

Help make the battery system, electric powertrain and main controller work together, understand component communication, resolve software and hardware issues during testing and support the aircraft through staged test activity.

Engineering challenge

Problem, then system response

01 — Challenge
  • Integrating EV-style battery and powertrain systems into an aircraft environment
  • Making multiple complex systems communicate reliably
  • Supporting staged testing where safety and repeatability were critical
  • Debugging software and hardware issues during live prototype development
  • Working on a project where electrical reliability directly affected test safety

System architecture

Systems brought together

  1. 01High-voltage battery system
  2. 02Electric aircraft powertrain
  3. 03Main vehicle/aircraft controller
  4. 04Control communication links
  5. 05Remote test control setup
  6. 06Tethered test configuration
  7. 07Electrical safety and diagnostic workflow

Engineering & integration

Turning architecture into a vehicle

VASS scope
  • Investigated how full-scale aircraft components communicated and operated
  • Supported integration of battery and powertrain systems
  • Helped the main controller operate correctly with the rest of the aircraft
  • Supported electrical system debugging
  • Assisted with remote-control test operation
  • Supported tethered hover testing
  • Helped identify and resolve software and hardware issues during test phases
  • Supported transition towards early low-level flight testing and piloted testing

Commissioning & result

Development outcome

Outcome

The aircraft progressed through staged testing, including remote-control operation, tethered hovering and early low-level flight. The work helped prove the electrical and control system integration needed for the aircraft to continue into further development and testing.

For similar programmes

This project demonstrates VASS experience beyond road vehicles. The same skills used in EV conversions - battery integration, powertrain control, safety logic, CAN communication and fault finding - can also support high-value prototypes, specialist vehicles and electric mobility projects where reliability and staged testing are essential.

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