Method for the assembly and installation of an instrumental diagnostic complex for a hybrid power plant of a light aircraft

The features of assembling an instrumental diagnostic complex for a light aircraft hybrid power unit (HPU), based on a reciprocating internal combustion engine and an electric motor, are considered. A method for integrating the instrumental diagnostic complex during the nodebynode assembly of the HPU for monitoring its condition during operation is presented. The key diagnostic parameters of the internal combustion engine and the electric motor are analyzed; sensors and hardware components are selected taking into account stringent operational requirements; an architecture for placement is designed, and a stepbystep technological sequence of assembly is developed, including additional operations (welding, drilling) for installing the sensors. During the study, a comparative analysis is conducted of the manufacturability of the proposed unitbyunit installation and an alternative option for installing the instrumental diagnostic complex on an already assembled HPU. A dimensionless manufacturability coefficient is proposed; its calculations show the advantage of unitbyunit assembly and installation in smallscale production (up to 12 assemblies): in this case, the coefficient for one diagnostic complex is 0.83, compared to 0.61 for assembly and installation on an assembled HPU. This is achieved by eliminating the operations related to the manufacture and use of special tooling. The results obtained demonstrate that the proposed method makes it possible to improve production adaptability, reduce labor costs, and simplify the installation process; it can be recommended for use in smallscale production and in assembling prototype GSU samples. The prospect of creating an instrumental diagnostic complex with an increased share of highintegration microsystem sensors to improve the accuracy and reliability of diagnostics is demonstrated.